stellar labs 10630 User manual

Model 10630
Telescopic 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.
© 2014 Stellar Industries, Inc. Last Revision: 09/27/16
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
®
TM

Page ii | Stellar®10630 Telescopic Crane Owner’s Manual
Model 10630 Manual Revisions
Date of Revsion Section Revised Description of Revision
3/23/15 Chapter 3:
Assembly Drawings
New Base, Gear Bearing, Mast
Assemblies.
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®10630 Telescopic Crane Owner’s Manual | Page iii
Table of Contents
Introduction ........................................................................................ iv
Chapter 1 - Specications.....................................................................1
Model 10630 Specications ...............................................................1
Capacity Chart - Decal PN 71859 ....................................................2
Dimensional Drawing 1 .......................................................................3
Dimensional Drawing 2 .......................................................................4
Chapter 2 - Installation ..........................................................................5
General Installation .............................................................................5
Installer Notice ...................................................................................5
Torque Data Chart ............................................................................6
Installation Overview ........................................................................7
Control Kit - PN 72782 .........................................................................8
Control Kit (Non-Boost) - PN 73213 ....................................................9
Hydraulic Kit - PN 72758 ....................................................................10
Valve Bank - PN 52265 ......................................................................11
Hydraulic Installation.........................................................................12
Winch Case Drain Installation ..........................................................13
Hydraulic System ...............................................................................14
Face Seal/O-Ring Size Chart ...........................................................15
Stability Procedure ............................................................................16
Decal Placement - PN 71857 ...........................................................18
Chapter 3 - Assembly Drawings .........................................................19
Base Assembly - PN 71166 ................................................................19
Gear Bearing - PN 71041 ..................................................................20
Mast Assembly - PN 72796 ................................................................21
Winch - PN 57918 ..............................................................................22
Main Boom Assembly - PN 72609 ....................................................23
Extension Boom Assembly - PN 70808 .............................................24
Main Cylinder Assembly - PN 71162 ................................................25
Extension Cylinder Assembly - PN 71455 .........................................26
Cable & Hook Assembly - PN 55898 ...............................................27
CDT™ Radio Transmitter Assembly - PN 56647 ...............................28

Page iv | Stellar®10630 Telescopic 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 General Light Duty 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®10630 Telescopic Crane Owner’s Manual | Page 1
Model 10630 Crane
Specifications Sheet
Page: 1 of 4
Crane Rating*:
70,800 ft-lb (9.79 TM)
Standard Boom Length:
13' 4" (4.06 m) from CL of Crane
Boom Extension:
Hydraulic 100" (254 cm)
Hydraulic 100" (254 cm)
Maximum Horizontal Reach:
30' (9.14 m) from CL of Crane
Maximum Vertical Lift:
31' 9" (9.68 m) from Crane Base
Stowed Height (Crane Only):
37.75" (95.5 cm)
Required Mounting Space:
20" x 21" (50.8 cm x 53.3 cm)
Approximate Crane Weight:
Controls:
Radio control standard for all functions.
Wire Rope:
7/16" (1.11 cm) 6X19 IWRC-DGXXIP X 120' (36.58 m)
Boom Elevation:
-10º to +80º
Line Pull Speed:
60 ft/min (18.29 m/min)
Max. Single Part Line:
5,000 lbs (2,265 kg)
Max. Double Part Line:
10,000 lbs (4,535 kg)
Rotation (Worm Gear):
400º Power
Lifting Capacity**:
10,000 lbs @ 7' (4,535 kg @ 2.13 m)
2,360 lbs @ 30' (1,070 kg @ 9.14 m)
Power Supply:
2,580 lbs (1,170 kg)
10630 Standard
1st Stage:
2nd Stage:
PTO & Pump:
8 gpm @ 3,000 psi
(30.3
lpm @ 207 bar)
Winch Specifications
*Crane
rating in Boost Mode. Normal crane rating is 60,000 ft-lbs (8.30 TM).
**Maximum capacities in Boost Mode.
Chapter 1 - Specications
Model 10630 Specications

Page 2 | Stellar®10630 Telescopic Crane Owner’s Manual
Model 10630 Crane
Specifications Sheet
Page: 2 of 4
Crane Rating*:
Standard Boom Length:
Boom Extension:
Maximum Horizontal Reach:
Maximum Vertical Lift:
Stowed Height (Crane Only):
Required Mounting Space:
Approximate Crane Weight:
Controls:
Wire Rope:
Boom Elevation:
Line Pull Speed:
Max. Single Part Line:
Max. Double Part Line:
Rotation (Worm Gear):
Lifting Capacity**:
Power Supply:
1st Stage:
2nd Stage:
Winch Specifications
PN 71859 - Rev A
0’
2.4 m1.8 m1.2 m0.6 m
2’ 4’ 6’ 8’
3.1 m
10’
3.7 m
12’
4.3 m
14’
4.9 m
16’
5.5 m
18’
6.1 m
20’
6.7 m
22’
7.3 m
24’
7.9 m
26’
8.5 m
28’
13’4”
4.06 m
21’8”
6.60 m
30’
9.14 m
-10º
80º
0º
15º
30º
45º
60º
2.4 m
1.8 m
6’
8’
3.1 m
10’
3.7 m
12’
4.3 m
14’
4.9 m
16’
5.5 m
18’
6.1 m
20’
6.7 m
22’
7.3 m
24’
7.9 m
26’
8.5 m
28’
9.8 m
32’
10.4 m
34’
9.1 m
30’
10000 lbs
4535 kg
10000 lbs
4535 kg
10000 lbs
4535 kg
9000 lbs
4080 kg
6365 lbs
2885 kg
5195 lbs
2355 kg
4500 lbs
2040 kg
2765 lbs
1250 kg
2000 lbs
905 kg
4000 lbs
1810 kg
2825 lbs
1280 kg
2305 lbs
1045 kg
2070 lbs
935 kg
2865 lbs
1295 kg
3195 lbs
1445 kg
3915 lbs
1775 kg
5535 lbs
2510 kg
10000 lbs
4533 kg
7510 lbs
3405 kg
6130 lbs
2780 kg
5310 lbs
2405 kg
4570 lbs
2070 kg
5390 lbs
2445 kg
2810 lbs
1275 kg
3315 lbs
1505 kg
2030 lbs
920 kg
2395 lbs
1085 kg
3265 lbs
1480 kg
2360 lbs
1070 kg
3380 lbs
1530 kg
2440 lbs
1105 kg
3770 lbs
1710 kg
2725 lbs
1235 kg
4620 lbs
2095 kg
3335 lbs
1510 kg
6530 lbs
2960 kg
4720 lbs
2140 kg
4655 lbs
2110 kg
5495 lbs
2490 kg
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
Maximum 1 - part line capacity is
5000 lbs (2270 kg). For greater
loads, use 2 - part line.
Boost
(If Equipped)
Standard
Capacity Chart - Decal PN 71859

Stellar®10630 Telescopic Crane Owner’s Manual | Page 3
Model 10630 Crane
Specifications Sheet
Page: 3 of 4
Crane Rating*:
Standard Boom Length:
Boom Extension:
Maximum Horizontal Reach:
Maximum Vertical Lift:
Stowed Height (Crane Only):
Required Mounting Space:
Approximate Crane Weight:
Controls:
Wire Rope:
Boom Elevation:
Line Pull Speed:
Max. Single Part Line:
Max. Double Part Line:
Rotation (Worm Gear):
Lifting Capacity**:
Power Supply:
1st Stage:
2nd Stage:
Winch Specifications
31'10"
9.70m
23'8"
7.21m
15'5"
4.70m
3'5"
1.04m
0.54m
1'9"
6'4"
1.93m
13'3"
4.04m 21'7"
6.58m 29'11"
9.12m
1.47m
4'10"
1'1"
0.33m
Dimensional Drawing 1

Page 4 | Stellar®10630 Telescopic Crane Owner’s Manual
Model 10630 Crane
Specifications Sheet
Page: 4 of 4
Crane Rating*:
Standard Boom Length:
Boom Extension:
Maximum Horizontal Reach:
Maximum Vertical Lift:
Stowed Height (Crane Only):
Required Mounting Space:
Approximate Crane Weight:
Controls:
Wire Rope:
Boom Elevation:
Line Pull Speed:
Max. Single Part Line:
Max. Double Part Line:
Rotation (Worm Gear):
Lifting Capacity**:
Power Supply:
1st Stage:
2nd Stage:
Winch Specifications
13'-3"
[ 4.03m ]
12.19in
0.31m
52.73in
1.34m
20.29in
0.52m
42.00in
1.07m
24.54in
0.62m
CG
0.98m
38.57in
14'-11"
[ 4.54m ]
Dimensional Drawing 2

Stellar®10630 Telescopic Crane Owner’s Manual | Page 5
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 10630
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

Page 6 | Stellar®10630 Telescopic 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. If special
lubricants of high stress ability,
such as Never-Seez compound
graphite and oil, molybdenum
disulphite, colloidal copper or white lead are applied, multiply 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.
• 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

Stellar®10630 Telescopic Crane Owner’s Manual | Page 7
1. Determine that the mounting location for the 10630 crane is at least 20” x 21” (50.8 x 50.8
cm).
2. Use the detail below to drill 1.06” diameter holes into the mounting plate. Run tap on the
threads of the base to be sure they are clean.
3. Use a crane or lifting device capable of lifting the weight of the Stellar® crane. The
Stellar® 10630 weighs approximately 2975 lbs (1350 kg). Note: cranes are shipped
with rotation positioned at 200 degrees of 400 degree system. This will allow for easy
installation of the crane and permanent connection of all hydraulic and electrical
components prior to repositioning into the crane saddle.
4. Connect straps or chain from the lifting device to the lifting rings on the Stellar 10630.
5. Use six (6) 3” x 1” #8 bolts and six (6) #8 at washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the Stellar 10630 just above the crane compartment and
start the bolts. Have someone assist in leveling the crane. Note: the rotation motor
should be to the door side of crane compartment and the boom should be extended
back over the rear bumper.
9. Secure the crane using the mounting hardware provided. Note: longer or shorter cap
screws may be required – recommended thread engagement into crane base is 1.75” –
use grade 8, zinc plated cap screws only.
10. Torque the cap screws to 680 ft-lbs.
11. Remove supporting crane.
12. Hook-up hydraulics and electrical using the schematics provided in this chapter.
Installation Overview
1
2
NOTE:
STABILITY DECAL P/N 16881
IS PART OF THIS KIT
2.38
6.88
7.38
7.38
6.00
.YTQNOITPIRCSEDTRAPMETI
15199 CAP SCR 1.00X8X3.00 HHGR8 ZY 6
26538 WASHER 1.00 SAE FLAT YELLOW GR86
FrontMotor
14.75
PN 13539
13.75
14.75
1.063
6 Places

Page 8 | Stellar®10630 Telescopic Crane Owner’s Manual
RECEIVER - RADIO (PART OF 1)
RADIO CONTROLLER ASSEMBLY
WIRE HARNESS 12621/12628 LMI TRANSMITTER - RADIO (PART OF 1)
PD1
PD2
ROTROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH
DOWN
WINCH
UP
AB
MAIN CYL
MANIFOLD
PD1
PD2
BASE END
ROD END
B
AB
AB
AB
AB
A
ABABABAB
INCLINOMETER
4
2
3
A2B
SWITCH
CORD REEL
FB
D ECA
POWER
PWR UNIT SIGNAL
GROUND
ENG START
ENG STOP
CPRSR ON/OFF
SPEED CTRL
PWR ON DEMAND MODE
SPEED CTRL
ON / OFF MODE
8
6
7
5
TRANSDUCER PRESSURE 5000 PSI CORD REEL ASM 28/30 FT CRANE SWITCH LIMIT E1161-B9111-6C INCLINOMETER 60 DEG PENNY AND GILES
CABLE BACKUP HETRONIC G2 (PART OF 1)
PN 72782
Control Kit - PN 72782

Stellar®10630 Telescopic Crane Owner’s Manual | Page 9
RECEIVER - RADIO (PART OF 1)
RADIO CONTROLLER ASSEMBLY
WIRE HARNESS 12621/12628 LMI TRANSMITTER - RADIO (PART OF 1)
PD1
PD2
ROTROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH
DOWN
WINCH
UP
AB
MAIN CYL
MANIFOLD
PD1
PD2
BASE END
ROD END
B
AB
AB
AB
AB
A
ABABABAB
INCLINOMETER
4
2
3
A2B
SWITCH
CORD REEL
FB
D
ECA
POWER
PWR UNIT SIGNAL
GROUND
ENG START
ENG STOP
CPRSR ON/OFF
SPEED CTRL
PWR ON DEMAND MODE
SPEED CTRL
ON / OFF MODE
8
6
7
5
TRANSDUCER PRESSURE 5000 PSI
CORD REEL ASM 28/30 FT CRANE SWITCH LIMIT E1161-B9111-6C INCLINOMETER 60 DEG PENNY AND GILES
CABLE BACKUP HETRONIC G2 (PART OF 1)
PN 73213
Control Kit (Non-Boost) - PN 73213

Page 10 | Stellar®10630 Telescopic Crane Owner’s Manual
NOTE: USE 12" OF HOSE PROTECTOR
P/N 17288 OVER THE 3 WINCH HOSES
NOTE: USE 32" OF HOSE PROTECTOR
P/N 17288 OVER THE ROTATION HOSES
PN 72758
Hydraulic Kit - PN 72758

Stellar®10630 Telescopic Crane Owner’s Manual | Page 11
HYDRAULIC SCHEMATIC
4
1
3
3
3
2
NOTE: PN's 24960 & 25371 DO NOT INCLUDE COIL PN 44532
4
44
44
44
4
3
EUQROTYTQNOITPIRCSEDTRAPMETI
125367 RELIEF VALVE 24685/24690 137 FT LBS
25368 SEAL KIT 25367
224960 VALVE FLW CTRL PRP/JP04C3150N 0-8120-22 FT LBS
25369 SEAL KIT 24960/25381
325371 VALVE SOLND 3 POS 4 WAY TAND G04571 425 FT LBS
25373SEAL KIT 25371/25372
444532 COIL 12VDC DUETSCH CAP012H 93FT LBS
PN 52265
Valve Bank - PN 52265

Page 12 | Stellar®10630 Telescopic Crane Owner’s Manual
1. After mounting, locate the pressure and return
lines. Note: Pressure line is 3/8” hose; Winch
Case Drain Line is 3/8” hose; Return line is 1/2”
hose. Hoses are terminated using swivel fittings.
2. Install hydraulic lines per diagram below. See
next page for Case Drain Installation. Note:
Stabilizer valve supplies oil to crane using the
Power Beyond feature.
3. Install hydraulic reservoir with return filter. Attach
pump pressure line to valve, return link to tank.
4. Fill system with hydraulic oil (See Stellar®
Lubrication Recommendations for fluid details).
(Blue)
Stabilizer Functions
Stabilizer Functions
Typical Stabilizer Valve
with Power Beyond Capabilities
Follow the instructions presented
on this page. Failure to follow
these instructions may result in
death or serious injury.
WARNING
Hydraulic Installation

Stellar®10630 Telescopic Crane Owner’s Manual | Page 13
Installing the winch case drain
1. The winch case drain must run directly to the reservoir to ensure no back pressure in the line.
2. Use 3/8” hydraulic hose and fittings rated for a minimum of 300 psi.
3.
4. Attach one end of the winch case drain to 3/8 swivel fitting located in step 3.
5. Route the winch case drain hose directly to the reservoir.
6. Connect the second end of the winch case drain to unshared fitting on the top of the reservoir as
shown in Fig 2.
Fig.1 Fig. 2
Locate the winch case drain line at the bottom of the crane base as shown in Fig. 1 (Blue Hose).
Note: Both the main pressure and winch case drane line use a 3/8” swivel fitting. Verify the winch
case drain is attached to the hose that is connected to the winch motor.
(Blue)
Follow the instructions presented
on this page. Failure to follow
these instructions may result in
death or serious injury.
WARNING
Winch Case Drain Installation

Page 14 | Stellar®10630 Telescopic Crane Owner’s Manual
Hydraulic System

Stellar®10630 Telescopic Crane 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
#161”
3/4”
5/8”
1/2”
3/8”
1/4”
D1250
B
A
Face Seal/O-Ring Size Chart

Page 16 | Stellar®10630 Telescopic Crane Owner’s Manual
Denition of Stability for the Stellar Telescopic Crane Products:
A truck is stable until the load cannot be lifted off the ground with the winch, without
tipping over the truck. Every Stellar crane installed must be tested for stability to determine
the actual load capacity of the nal truck package. The actual test data must be
recorded and supplied with the truck at the time of in-service and should be kept with
the truck at all times. The following procedure will test the truck package for stability and
will provide a stability capacity chart. The load limit information shown on the stability
capacity chart is formulated on 85% tipping.
Set Up:
1. Locate the truck on a test course in position for loading and engage travel brakes.
2. Set stabilizers so that they make contact with rm, level footing.
3. Operate the crane under partial load to assure operator prociency and proper
machine function.
4. Put the radio into Stability Test Mode:
A. Push the bottom four switches up and hold until all lights come on (approximately
5 seconds.)
B. At this point,the crane will have enough capacity to handle the weight for the
stability test.
C. The radio will timeout of stability mode after 30 minutes or when the E-Stop button
is pushed.
Note: The radio can only be put into stability mode ve times. After that, the radio would
have to be returned to Stellar to be reprogrammed to allow additional stability testing. All
other radio functions will work properly even if stability mode is not available.
Stability Procedure