stellar labs Small OTR 2200 User manual

Small OTR
Service Cranes
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 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 ii | Stellar®Small OTR Service Crane Owner’s Manual
Small OTR Crane Manual Revisions
Date of Revision 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]
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.
WARNING

Stellar®Small 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
Chapter 3 - Troubleshooting...................................................................................................... 17
Manual Operation.................................................................................................................. 23

Page iv | Stellar®Small 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 specific 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®Small OTR Service Crane Owner’s Manual | Page 1
Chapter 1 - Operation
General Operation
Pre-Operation Inspection
Safety should be the number one thought on every operator’s mind. Three factors should
exist for safe operation: a qualified operator, well-maintained equipment, and the proper
use of this equipment.
This chapter contains information regarding the safety and operation of Stellar® Small 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 qualifications specified in
ANSI B30.5 - Chapter 5-3 Operation. Trainees or untrained persons shall be under the direct
supervision of qualified 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-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, inspect the crane for all of the following:
• Vehicle for standard checks such as proper tire inflation and fluid 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
WARNING

Page 2 | Stellar®Small 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 specific
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, 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 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 figured
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 and calculating
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
WARNING

Stellar®Small 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
Once the PTO is engaged, 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.
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 positioned on stable, flat 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
WARNING

Page 4 | Stellar®Small 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).
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 toggle (See Radio Remote Control
page for details). The remote control units for these models operate the crane functions
proportionally by using the trigger to control the oil flow entering the control valve when
a specific toggle is activated. The more you engage the trigger, 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 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.
• 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.
• Make certain that the stabilizers are positioned on flat, 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.
WARNING
Step 5: Operate the crane

Stellar®Small OTR Service Crane Owner’s Manual | Page 5
• 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 fixed 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
WARNING
WARNING
Step 5: Operate the crane (Cont.)

Page 6 | Stellar®Small 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.
Retract outriggers using the control levers or switches marked ‘outrigger’.
WARNING
Step 10: Leave the worksite
Step 6: Stow the crane
When the job is complete, use the correct toggles to bring the crane gently down onto the
crane rest.