stellar labs 23000 User manual

Model 23000
Articulating Crane
Owner’s Manual
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Subject to Change without Notication.
© 2022 Stellar Industries, Inc.
Rev 6
PN 90307
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®23000 Articulating Crane Owner’s Manual
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
Serial Tag Location / P65 Warning

Stellar®23000 Articulating Crane Owner’s Manual | Page iii
Table of Contents
Introduction z ............................................................................................................................................................ iv
Chapter 1 - Specications.......................................................................................................................................... 1
Model 23000 Specications ......................................................................................................................................2
Capacity Chart - Decal PN 128331 ...........................................................................................................................3
Chapter 2 - Installation ............................................................................................................................................... 5
General Installation ...................................................................................................................................................6
Installer Notice .......................................................................................................................................................6
Torque Data Chart .................................................................................................................................................7
Installation Overview ..............................................................................................................................................8
Mounting Kit Drawing .............................................................................................................................................8
Hydraulic Installation .................................................................................................................................................9
Hydraulic Pressure Settings ....................................................................................................................................10
Face Seal/O-Ring Size Chart ..................................................................................................................................10
Hydraulic Kit - PN 128728 .......................................................................................................................................12
Hydraulic Kit - PN 128728 Parts List .......................................................................................................................13
Hydraulic Kit - PN 128728 Parts List .......................................................................................................................14
Control Kit (900 MHz Version) - PN 127357 ...........................................................................................................16
Control Kit (900 MHz Version) - PN 127357 Parts List ...........................................................................................17
Grease Kit - PN 103070 ..........................................................................................................................................18
Grease Kit - PN 103070 Parts List ..........................................................................................................................19
Decal Placement 23000 .........................................................................................................................................20
Decal Placement 23000 Parts List .........................................................................................................................21
Chapter 3 - Assembly Drawings .............................................................................................................................. 23
Base Assembly - PN 127259 ..................................................................................................................................24
Base Assembly - PN 127259 Parts List ..................................................................................................................25
Bearing Assembly - PN 18471 ................................................................................................................................26
Gear Box - PN 60505 ..............................................................................................................................................27
Valve Bank - PN 42802 ...........................................................................................................................................28
Valve Bank - PN 42802 ...........................................................................................................................................29
Mast Assembly - PN 100730 ...................................................................................................................................30
Mast Assembly - PN 100730 Parts List ...................................................................................................................31
Main Cylinder Assembly - PN 101532 ....................................................................................................................32
Main Cylinder Assembly - PN 101532 Parts List ....................................................................................................33
Main Boom Assembly - PN 100724 ........................................................................................................................34
Main Boom Assembly - PN 100724 Parts List ........................................................................................................35
Outer Cylinder Assembly - PN 61245 .....................................................................................................................36
Outer Cylinder Assembly - PN 61245 Parts List .....................................................................................................37
Extension Boom Assembly - PN 128248 ................................................................................................................38
Extension Boom Assembly - PN 128248 Parts List ................................................................................................39
Extension Cylinder Assembly- PN 128719 .............................................................................................................40
Extension Cylinder Assembly- PN 128719 Parts List .............................................................................................41
Stabilizer Assembly- PN 40453 ...............................................................................................................................42
Stabilizer Assembly- PN 40453 Parts List ...............................................................................................................43
Stabilizer Cylinder Assembly- PN 40456 ................................................................................................................44
Stabilizer Cylinder Assembly- PN 40456 Parts List ................................................................................................45
Reservoir Assembly - PN 86356 .............................................................................................................................46
Reservoir Assembly - PN 86356 Parts List .............................................................................................................47
Optional 15 Ton Hook Kit - PN 55139 .....................................................................................................................48
Optional 15 Ton Hook Kit - Parts List ......................................................................................................................49
Radio Transmitter - PN 89149/93084 .....................................................................................................................50
Chapter 4 - Replacement Parts ............................................................................................................................... 51
Replacement Parts .................................................................................................................................................52
Replacement Parts - Continued ...........................................................................................................................53

Page iv | Stellar®23000 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®23000 Articulating Crane Owner’s Manual | Page 1
Chapter 1 - Specications
CHAPTER CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
128331 CAPACITY CHART ..................................................................................................................................... 3

Page 2 | Stellar®23000 Articulating Crane Owner’s Manual
Crane Rating: 230,000 ft-lbs ( 31.8 ton meters)
Standard Boom Length: 13’ 4” (4.06m) from CL of Crane
Boom Extension: Hydraulic 37” (0.94 m)
Maximum Horizontal Reach: 16’ 5” (5.0 m) from CL of Crane
Maximum Vertical Lift: 20’ 8” (6.29m)
(From Base)
Cylinder Specications: Inner Lift Cylinder: 8” (20.3 cm) bore with integral pilot
operated counterbalance valves
Outer Lift Cylinder: 6.5” (16.5 cm) bore with integral pilot
operated counterbalance valves
Extension Cylinder: 5” (12.7 cm) bore with integral pilot
operated counterbalance valves
Rotation: 315 degree power
(planetary gear with pinion)
Lifting Capacities: 14,000 lbs @ 16’5” (6350 kg @ 5.m)
Power Supply Required: PTO & Pump - 16 gpm @ 4,400 psi
(60 lpm @ 304 bar)
Controls: Fully Proportional Paddle Controls for all functions.
Stowed Height: 116” (295 cm)
(Above Truck Frame)
Mounting Space Required: 48” (121.9 cm)
Chassis RBM (Recommended): 2,760,000 in-lb
Approximate Shipping Weight: 11,500 lbs (5,220 kg)
Model 23000 Specications

Stellar®23000 Articulating Crane Owner’s Manual | Page 3
128831
Capacity Chart - Decal PN 128331

Page 4 | Stellar®23000 Articulating Crane Owner’s Manual
THIS PAGE LEFT INTENTIONALLY BLANK

Stellar®23000 Articulating Crane Owner’s Manual | Page 5
Chapter 2 - Installation
CHAPTER CONTENTS
GENERAL INSTALLATION .................................................................................................................... .................6
INSTALLER NOTICE ............................................................................................................................................... 6
TORQUE DATA CHART ........................................................................................................................................... 7
INSTALLATION OVERVIEW .................................................................................................................................... 8
MOUNTING DRAWING ........................................................................................................................................... 8
HYDRAULIC INSTALLATION .................................................................................................................................. 9
HYDRAULIC PRESSURE SETTINGS .................................................................................................................. 10
FACE SEAL / O-RING SIZE CHART ..................................................................................................................... 10
HYDRAULIC KIT (128728) .................................................................................................................................... 12
CONTROL KIT .......................................................................................................................................................16
GREASE KIT (103070) ..........................................................................................................................................18
DECAL PLACEMENT (105542) .............................................................................................................................20

Page 6 | Stellar®23000 Articulating Crane Owner’s Manual
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.
General Installation
This chapter is designed to serve as a general guide for the installation of a Stellar 23000 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 [phone].
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

Stellar®23000 Articulating Crane Owner’s Manual | Page 7
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

Page 8 | Stellar®23000 Articulating Crane Owner’s Manual
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 500-550 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 preferably 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.
PN 16659
ITEM PART DESCRIPTION QTY
1 8054 MTG BLOCK 15000 4
2 11677 PLATE MOUNTING 23000 4
3 14498 TIE DOWN ROD 8
4 9180 WASHER 1.25 SAE FLAT YELLOW GR8 16
5 8834 NUT 1.25-7 HHGR8 TOP LOCKING 8
6 8978 NUT 1.25-7 HHGR8 16
7 8202 FRAME SUPPORT 15000 CRANE 4
Installation Overview
Mounting Kit Drawing

Stellar®23000 Articulating Crane Owner’s Manual | Page 9
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 hydralic hose. The hose should be
installed so any bend is with this curvature.
WARNING
WARNING
WARNING
NOTICE

Page 10 | Stellar®23000 Articulating Crane Owner’s Manual
Hydraulic Pressure Settings
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
#161”
3/4”
5/8”
1/2”
3/8”
1/4”
D1250
B
A
Face Seal/O-Ring Size Chart
Function Flow Extend Retract
Inner 10.6 4400 2200
Outer 10.6 4400 2200
Extension 10.6 4400 4400
Rotation 3.9 2200 2200
TM Rot 6.6 2200 2200
TM Pad Rot 6.6 2500 2500
TM Clamp 6.6 4200 4200
Pressure (PSI)
Main Relief 4600 PSI

Stellar®23000 Articulating Crane Owner’s Manual | Page 11
THIS PAGE LEFT INTENTIONALLY BLANK

Page 12 | Stellar®23000 Articulating Crane Owner’s Manual
82,42
04 04 04 04 04 04 04
34
34
34
44,34
82,42 82,42 82,42 82,42 82,42
9
3
73,42 73,42 73,42 73,42 73,42
93
72
22
52 11
818181361
612
2 61 61 3 81 81 81
878 7
8 7 8 7
3
1
21
24
24
24 24
15 15
24
24
74
74
24
2
4
32 83
74 74
54,4
2
5
4,42
33,84
43,84
2
3,
0
3
13,03
2
3,
0
3
13,03
63,94
53,92
OT
01
9
82,42 82,42 82,42 82,42 82,42 82,42
51
64 64
41
41
60
60
60
60
71
71
50
50
30
30
70
70
8
0
8
0
70
70
80
80
20
20
05
14
02
62
12
44
TM CLAMP OPEN
TM CLAMP CLOSED
TM PAD ROTATION CCW
TM ROTATION CCW
TM ROTATION CW
TM PAD ROTATION CW
ROTATION CCW
ROTATION CW
EXT RETRACT
EXT EXTEND
EXTENSION
O.R. CS
O.R. CS
RETRACT
RETRACT
EXTEND
EXTEND
DOWN
OUT
OUTER RETRACT
INNER EXTEND
OUTER
INNER RETRACT
INNER EXTEND
ROTATION
INNER
RETRACT
EXTEND
O.R SS O.R SS
OUT
RETRACT
EXTEND
DOWN
HIGH
PRESSURE
FILTER
FROM
PUMP
RETURN TO 1 / 4”
RSRVR FTG
RETURN
TO TANK
Hydraulic Kit - PN 128728

Stellar®23000 Articulating Crane Owner’s Manual | Page 13
Hydraulic Kit - PN 128728 Parts List
PN 128728
ITEM PART DESCRIPTION QTY
1128729 HOSE KIT 23000 V4 (INCL:2-21) 1
269750 HOSE-HYD 0.38 X 62 2REF
369751 HOSE-HYD 0.38 X 29 2REF
497596 HOSE-HYD 0.38 X 36 2REF
597598 HOSE-HYD 0.38 X 28 2REF
675928 HOSE-HYD 0.38 X 54 4REF
711674 HOSE-HYD 0.38 X 102 4REF
816493 HOSE-HYD 0.38 X 84 4REF
969752 HOSE-HYD 0.75 X 35 1REF
10 70772 HOSE-HYD 0.50 X 33 1REF
11 9104 HOSE-HYD 0.75 X 72 1REF
12 70774 HOSE-HYD 0.50 X 24 1REF
13 39895 HOSE-HYD 0.25 X 108 1REF
14 75927 HOSE-HYD 0.25 X 54 2REF
15 55677 HOSE-HYD 0.25 X 12 1REF
16 98234 HOSE-HYD 0.38 X 112 4REF
17 24405 HOSE-HYD 0.38 X 70 2REF
18 98235 HOSE-HYD 0.25 X 112 6REF
19 97597 HOSE-HYD 0.25 X 36 6REF
20 127263 HOSE-HYD 0.25 X 12 1REF
21 52614 HOSE-HYD 0.25 X 31 1REF
22 14354 FTG 12-10 MFS-MAORB 90 1
23 55394 SWTICH PRESS OVERLD CD=11C-5500R/WD 1
24 C1111 FTG 10-6 MORB-FORB STRAIGHT REDUCER 19
25 D0525 FTG 12-12-12 MFS-FFSS-MFS RUN TEE 1
TSAMFOWEIVPOT
ETALPDAEHKLUB
NIAMFOWEIVPOT
SEBUTTROPMOOB
DNETXELYCTXE
TCARTERLYCTXE
WCTORDAPMT
WCCTORDAPMT
ESOLCPMALCMT
NEPOPMALCMT
WCTORMT
WCCTORMT
91
81
81 91
81 91
61 71
61 4
81 91
61 4
61 71
81 91
81 91
DNETXELYCTXE
TCARTERLYCTXE
WCCTORDAPMT
WCTORDAPMT
ESOLCPMALCMT
NEPOPMALCMT
WCTORMT
WCCTORMT
TCARTERLYCRETUO
DNETXELYCRETUO
EVLAVMORFSESOH
DAEHKLUBOTKNAB
LYCTXE/SRELPUOCMTOT
6
6
5
5
41
41
6
6
NI63
NI43
NI04 NI62
NI62
USE SPIRAL HOSE WRAP OVER HOSES
FROM BULKHEAD PLATE TO PROT TUBES,
AND FROM PORT TUBES TO FUNCTIONS.
(GROUPED AS SHOWN)

Stellar®23000 Articulating Crane Owner’s Manual | Page 14
PN 128728
ITEM PART DESCRIPTION QTY
26 37179 FTG 8-10-8 MFS-MOAB-MFS TEE 1
27 D1435 FTG 12-10 MFS-MORB STRAIGHT 1
28 25361 FTG 6-6 MFS-MAORB 90 LONG 12
29 39780 GUAGE OIL LF 2.5 0-6000 CBM SAE 1
30 47405 FTG 6-6 MORB-MFS BULKHEAD STRAIGHT 4
31 13554 QUICK CPLR FFH04-38-SAE-F 2
32 13555 QUICK CPLR FFH04-38-SAE-M 2
33 13557 QUICK CPLR FFN06-12SAE-M 1
34 13556 QUICK CPLR FFN06-12SAE-F 1
35 44521 FTG 5-4 MORB-FORB STRAIGHT REDUCER 1
36 52820 FTG 4-5 MFS-MAORB 90 1
37 C0338 FTG 6-6 MFS-MAORB 90 5
38 3861 FTG 6-6 MAORB-FORB 90 1
39 0882 FTG 6 FFS CAP 2
40 D1302 FTG 6-10 MFS-MAORB 90 7
41 C4922 FTG 4-6 MFS-MORB STRAIGHT 1
42 C1854 FTG 6-8 MFS-MORB STRAIGHT 8
43 C1180 FTG 8-12 MFS-MORB STRAIGHT 4
44 C2376 FTG 8-8 MFS-FFSS 90 2
45 D1193 FTG 6-6 MFS-MAORB 45 2
46 C1198 FTG 4-4 MFS-MAORB 90 2
47 0279 FTG 6-6 MFS-MORB STRAIGHT 4
48 47406 FTG 8-8 MORB-MFS BULKHEAD STRAIGHT 2
49 23421 FTG 4-4-4 MFS-FFSS-MFS RUN TEE 1
50 D1190 FTG 4-6 MFS-MAORB 45 1
51 7343 FTG 6-8 MFS-MAORB 45 2
Hydraulic Kit - PN 128728 Parts List

Stellar®23000 Articulating Crane Owner’s Manual | Page 15
THIS PAGE LEFT INTENTIONALLY BLANK

Page 16 | Stellar®23000 Articulating Crane Owner’s Manual
Control Kit (900 MHz Version) - PN 127357