4.04.001 Stellar Crane 12630

This Policy is under development.

Purpose

The purpose of this procedure is to establish the minimum requirements for maintaining the Stellar model 12630 crane for use on Flogistix Crane Trailers.

This Policy is effective for all Stellar 12630 model cranes used on Flogistix Crane Trailers that are being used at Flogistix Field Locations, Manufacturing locations, or Customer locations for maintaining Flogistix equipment and being used only by Flogistix trained employees.

• Before operating the equipment (Stellar model 12630 Crane),

• Make sure all regular maintenance has been performed.

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

• • Check Vehicle or Crane Trailer for standard checks such as proper tire inflation and that trailer inspection has been completed before continuing use of trailer

  • 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.

  • Crane hook and make sure safety latch is operation on hook

  • Loose parts, damage to structures or weld of base where crane is mounted to crane trailer.

  • Anti-two block switch for proper function.

  • Wire rope for broken wires, extensive wear, distortion, and heat damage. •

  • All safety guards for proper installation.

  • Auxiliary crane battery (If used) for adequate charge. Maintenance for auxiliary battery recharge instructions.

  • 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.

General Maintenance guidelines:

Position the Crane where it will be out of the way of other operations or vehicles in the area.

Lower the boom fully or stow in the cradle to prevent uncontrolled movement

Place all controls in the off position and secure operating features from inadvertent motion, Follow all Flogistix directed Lockout/Tag Out procedures

Before any service or repair is performed, disengage the hydraulic power source and shut off power source to crane

Allow system to cool before performing any maintenance

///before performing maintenance on electrical components, disconnect the power source.

Before performing any maintenance on hydraulic components, relieve hydraulic pressure from all hydraulic circuits. Move control levers repeatedly through their operating positions to relive all pressures

Do Not disconnect hydraulic hoses while there is still pressure in those components.

Stellar model 12630 Crane Maintenance

Refer to the below example on the recommended maintenance schedule for the Stellar 12630 Crane.

Hydraulic Oil/Filter Maintenance

Stellar Industries recommends the first filter change to occur after the first 250 hours of service. The second, and every subsequent change, should occur after every 1,000 hours of service. By following these guidelines, the hydraulic oil should last up to 6,500 hours. Note: These recommendations are based on normal working parameters. If operating in less than favorable conditions excessive dust, moisture, etc. Be sure to check the filter gauge often for filter change notice. Important:

Washing Crane

Prior to washing the Stellar crane, all electrical components must be covered to prevent any water from being injected into plastic housing. Avoid any direct water pressure to any of the electrical components.

PTO and Pump Maintenance

Every six months, remove the hydraulic pump from the PTO and lubricate splines using Stellar PN 20885. Failure to lubricate splines will cause damage to the PTO and hydraulic pump

Extension Boom Maintenance

While operating the crane, extend and retract the extension booms.

If the extension weldments are noisy during operation, it is necessary to lubricate the booms. Stellar® Model Cranes feature a metal coating which will require an aerosol lubricant. Stellar® Industries recommends aerosol style lubricant Stellar® PN 44512.

Rotation Gear Bearing Maintenance

Rotation Gear Bearing Worm End Play & Backlash

Stellar® Telescopic Cranes have an integral base and worm drive rotation system.

Backlash is the shortest distance between non-driving tooth surfaces in mating gears. Measure backlash using a feeler gauge at or near the pitch diameter and tangent to the gear.

Locate High Tooth

To set both Worm End Play and Backlash, first locate the high tooth on the gear. This spot is marked by the manufacturer with light blue paint. If the paint mark cannot be found, use a dial indicator with a magnetic base and a round steel pin large enough to contact the bearing near the pitch line of the bearing tooth to locate the high tooth:

Step 1: Set the indicator base on the face of the bearing race with no teeth.

Step 2: Place the pin between two of the teeth.

Step 3: Set the indicator probe on the pin and adjust the dial to zero.

Step 4: Rotate the bearing, checking every third tooth until you find the highest indicator reading.

Step 5: Check three teeth in both directions in this area to determine the highest tooth. The amount of run-out varies depending on the diameter of the bearing.

Step 6: Once you find the high tooth, mark it for future reference.

Set Worm End Play

Step 1: Locate the high tooth on the gear (See above)

Step 2: Screw a bolt into the threaded hole nearest the high tooth. Screw additional bolts into threaded holes at 90º from the high tooth.

Step 3: Mount a magnetic base with an indictor attached on top of the worm housing and at the opposite end from the motor mount.

Step 4: Adjust the indicator to read from the end of the worm shaft. Set the indicator to 0.

Step 5: Using two of the bolts as handles, rotate the outer race back and forth. Read the total indicator movement. This measurement is the end play of the worm. The specification for end play is +0.000/-0.004” (+0.000/-0.1016mm). If end play does not meet this specification, remove the bearing retainer and add or remove shims from the unit. Repeat this procedure until the end play meets specification.

Set Gear Bearing Backlash

Step 1: Locate the high tooth on the gear (See above)

Step 2: Rotate the bearing until the high tooth is engaged with the worm. Loosen the three bearing retaining allen head bolts just enough to be able to move the bearing toward or away from the worm. Screw a bolt into the threaded hole in the bearing nearest the worm.

Step 3: Set the magnetic indicator base on the worm housing with the indicator probe against the bolt. Set the indicator dial to zero.

Step 4: Move the bearing back and forth. Watch the indicator dial and adjust the bearing in or out of the worm until the total indicator movement is 0.005” (0.127 mm). Notice: Be sure to deduct any end play in the worm from the indicator reading.

Step 5: Rotate the bearing 180º. Recheck the backlash. The total backlash should be 0.005” to 0.012” (0.127 to 0.3048 mm).

Step 6: After setting the backlash, torque the bearing retaining allen head bolts while watching the indicator dial so the correct backlash setting is maintained. Use the Torque Data Chart and Rotation Gear Bearing Thread Tightening Procedure for specifications.

Recommended Lubrication types

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all Stellar 12630 cranes that are currently being by Flogistix personnel and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees using Flogistix portable cranes should be properly trained in the proper use and lifting technics and have attended the required Crane and Rigging training through Flogistix EHSS.

Employees should be aware that units could contain flammable and toxic gasses. Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes.

Environmental spill of compressor oil and production fluids

Safety

All Personal Protective Equipment (PPE) for Field Mechanical duties apply for this procedure. Flogistix EHSS Manual, Section 8, Procedure 8.3 Personal Protective Equipment (PPE)

Four Gas Monitor, if nipple is being replaced in the field which is outlined in the Flogistix EHSS Manual, Section 8, Procedure 8.3 Personal Protective Equipment (PPE)

This procedure applies to all Stellar 12630 crane units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to any Customers safety practices.

Disposal of fluids

Flogistix Service Technicians performing maintenance on the Stellar 12630 will properly dispose of any used oil from the crane according to Flogistix policy. Disposal of any fluids will be done at an approved or designed waste location.

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• Emergency and First Aid procedures

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing Preventative Maintenance shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out LOTO items to properly perform LOTO procedure according to Flogistix policy

Approvals:

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: