stellar labs 8630 User manual

Model 8630
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 Notification.
© 2021 Stellar Industries, Inc. PN 118498
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®8630 Telescopic Crane Owner’s Manual
Model 8630 Manual Revisions
Date of Revision Section Revised Description of Revision
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®8630 Telescopic Crane Owner’s Manual | Page iii
Table of Contents
Introduction ............................................................................................................................................iv
Chapter 1 - Specifications......................................................................................................................... 1
Model 8630 Specifications .................................................................................................................... 1
Capacity Chart - Decal PN 118550...................................................................................................... 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
CDT Control Kit - PN 118531 .................................................................................................................. 8
CDTpro Control Kit - PN 118530............................................................................................................. 9
Electrical Circuit Grounding................................................................................................................ 10
Hydraulic Kit - PN 107780 ..................................................................................................................... 11
Valve Bank - PN 44530 ......................................................................................................................... 12
Hydraulic Installation............................................................................................................................ 13
Winch Case Drain Installation............................................................................................................. 14
Hydraulic System .................................................................................................................................. 15
Face Seal/O-Ring Size Chart............................................................................................................... 16
Stability Procedure ............................................................................................................................... 17
Crane Load Level Indicator................................................................................................................ 18
Decal Placement - PN 118504............................................................................................................ 19
Chapter 3 - Assembly Drawings ............................................................................................................. 20
Base Assembly - PN 50364 ................................................................................................................... 20
Gear Bearing - PN 47869 ..................................................................................................................... 21
Mast Assembly - PN 106541................................................................................................................. 22
Winch - PN 107774................................................................................................................................ 23
Main Boom Assembly - PN 118509 ..................................................................................................... 24
Extension Boom Assembly - PN 106804.............................................................................................. 25
Extension Boom Material List - PN 106804.......................................................................................... 26
Main Cylinder Assembly - PN 114688 ................................................................................................. 27
Extension Cylinder Assembly - PN 103416.......................................................................................... 28
Snatch Block Assembly - PN 56266..................................................................................................... 29
Chapter 4 - Replacement Parts .............................................................................................................. 31

Page iv | Stellar®8630 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®8630 Telescopic Crane Owner’s Manual | Page 1
Chapter 1 - Specifications
Model 8630 Specifications
Crane Rating*: 53,100 ft-lbs (7.3 TM)
Standard Boom Length: 13’ 0” (3.96 m) from CL of Crane
Boom Extension: 1st Stage: Hydraulic 100” (254 cm)
2nd Stage: Hydraulic 100” (254 cm)
Maximum Horizontal Reach: 29’ 8” (9.04 m) from CL of Crane
Maximum Vertical Lift: 31’ 6” (9.6 m) from Crane Base
Stowed Height (Crane Only): 38.6” (98 cm)
Required Mounting Space: 20” x 21” (50.8 cm x 53.3 cm)
Approximate Crane Weight: 8630 HSS Standard: 1735 lbs (787 kg)
Controls: Radio control standard for all functions.
Wire Rope: 3/8” (0.95 cm)6X31 IWRC-DGXIP X 120’ (36.58 m)
Boom Elevation: -10º to +80º
Winch Specifications
Line Pull Speed: 60 ft/min (18.29 m/min)
Max. Single Part Line: 4,300 lbs (1,950 kg)
Max. Double Part Line: 8,600 lbs (3,900 kg)
Rotation (Worm Gear): 400º Power
Lifting Capacity**: 8,600 lbs @ 6’2” (3,900 kg @ 1.88 m)
1,770 lbs @ 30’ (803 kg @ 9.14 m)
Power Supply: PTO & Pump: 8 gpm @ 3,000 psi
(30.3 lpm @ 207 bar)
*Crane rating in Boost Mode. Normal crane rating is 45,000 ft-lbs (6.2 TM).
**Maximum capacities in Boost Mode.

Page 2 | Stellar®8630 Telescopic Crane Owner’s Manual
Capacity Chart - Decal PN 118550

Stellar®8630 Telescopic Crane Owner’s Manual | Page 3
29'-8"
9.04m
21'-4"
6.50m
13'-0"
3.96m
4'-8"
1.43m
9.60m
31'-6"
4.60m
15'-1"
6'-2"
1.87m
3'-3"
0.99m
23'-4"
7.10m
Dimensional Drawing 1

Page 4 | Stellar®8630 Telescopic Crane Owner’s Manual
13'-0"
3.96m
43.50in
1.10m
19.25in
0.49m
43in
1.1m
CG
0.32m
0.98m
12.50in
14'-10"
4.51m
38.60in
19.60in
0.50m
21.75in
0.55m
Dimensional Drawing 2

Stellar®8630 Telescopic Crane Owner’s Manual | Page 5
Installer Notice
According to Federal Law (49 cfr part 571), each final-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 final completion, or a date between those two dates.
This requirement shall, however, be superseded by any conflicting 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
Traffic 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 8630 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.
NOTICE
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
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.

Page 6 | Stellar®8630 Telescopic Crane Owner’s Manual
When using the torque data in the chart, the following rules should be observed:
• Bolt manufacturer’s particular specifications 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 specified 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 in the table.
• 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
specific 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®8630 Telescopic Crane Owner’s Manual | Page 7
1. Determine that the mounting location for the 8630 is at least 18” x 20” (45.7 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 8630 HSS
weighs approximately 1715 lbs (778 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 8630.
5. Use four (4) 1” x 3” #8 bolts and four (4) #8 flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the 8630 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.
Installation Overview
2
1
FRONT
Motor
Hole Mounting Detail
Ø1.063
7.38
14.75
7.38
14.75
Ø6.00
4 Places
65382
ITEM NO. PART NO.
15199
QTY.
WASHER 1.00 SAE FLAT YELLOW GR8
CAP SCR 1.00X8X3.00 HHGR8 ZY
DESCRIPTION
4
4

Page 8 | Stellar®8630 Telescopic Crane Owner’s Manual
E
F
A
C
D
B
FB
D
ECA
A
B
PD1
PD2
REMOTE
TETHER
CPRSR ON/OFF
SPEED CTRL
CRANE PWR
CTRL OUTPUT
GROUND
START/STOP
OPTION 2
DV OUTPUT
21
12
E LINK
CAN BUS
CTRL PWR JUMPER
REMOTE TETHER
MAIN CYL
MANIFOLD
PD1
PD2
BASE
END
ROD
END
7
4
CONTROLLER
ID DECAL
2
RECEIVER
GROUND
GROUND
GROUND
CRANE PWR
OPTION 2
OPTION 1
DV OUTPUT
CTRL OUTPUT
5
ROT
ROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXT.
RETRACT
MAIN
UP
EXTEND
WINCH
DOWN
WINCH
UP
EXT
AB
A2B
SWITCH
CORD REEL
9
10
EXTENSION SENSOR
& INCLINOMETER
8
RECEIVER G6RC 2.4GHZ 14P (PART OF 1)
RADIO CTRL ASM 4 FCTN CDT G6 PG
TRANSMITTER 4 FCTN MECH G6RC PG (PART OF 1)
DOCKING STATION RADIO TRANS G6
SWITCH LIMIT (NO) ROLLER LVR LT BRKT E1161
CORD REEL ASM 15/20/21 FT CRANE
ENCODER BOOM VECTOR 6M CANOPEN
TRANSDUCER PRESSURE 0-5000PSI #4 SAE DT
CTRLMODULEMECHCRANEG6
WIREHRNSMECHCRANECDTPLUSG6451RETRO
TETHER CABLE 10M M-F M12 SCANRECO
CORD REEL ASM 28/30 FT CRANE
TAG TRANSMITTER SCANRECO
TRANSMITTER
3
6
DOCKING STATION
#1 / BLK SUPPLY (-)
#2 / RED SUPPLY (+) 12V/24V
#3 / GRN ALARM DISABLE GND INPUT
WHT OPTION OUTPUT
CDT Control Kit - PN 118531
NOTICE
Any modification to the crane control
system (electrical and/or hydraulic)
must be approved by Stellar.

Stellar®8630 Telescopic Crane Owner’s Manual | Page 9
E
F
A
C
D
B
FB
D
ECA
A
B
PD1
PD2
REMOTE
TETHER
CPRSR ON/OFF
SPEED CTRL
CRANE PWR
CTRL OUTPUT
GROUND
START/STOP
OPTION 2
DV OUTPUT
21
12
E LINK
CAN BUS
CTRL PWR JUMPER
REMOTE TETHER
MAIN CYL
MANIFOLD
PD1
PD2
BASE
END
ROD
END
7
4
CONTROLLER
ID DECAL
2
RECEIVER
GROUND
GROUND
GROUND
CRANE PWR
OPTION 2
OPTION 1
DV OUTPUT
CTRL OUTPUT
5
ROT
ROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXT.
RETRACT
MAIN
UP
EXTEND
WINCH
DOWN
WINCH
UP
EXT
AB
A2B
SWITCH
CORD REEL
9
10
EXTENSION SENSOR
& INCLINOMETER
8
RECEIVER G6RC 2.4GHZ 14P (PART OF 1)
RADIO CTRL ASM 4 FCTN CDT PLUS G6RC PG
TRANSMITTER 4 FCTN MECH G6RC PG (PART OF 1)
DOCKING STATION RADIO TRANS G6
SWITCH LIMIT (NO) ROLLER LVR LT BRKT E1161
CORD REEL ASM 15/20/21 FT CRANE
ENCODER BOOM VECTOR 6M CANOPEN
TRANSDUCER PRESSURE 0-5000PSI #4 SAE DT
CTRLMODULEMECHCRANEG6
WIREHRNSMECHCRANECDTPLUSG6451RETRO
TETHER CABLE 10M M-F M12 SCANRECO
CORD REEL ASM 28/30 FT CRANE
TAG TRANSMITTER SCANRECO
TRANSMITTER
3
6
DOCKING STATION
#1 / BLK SUPPLY (-)
#2 / RED SUPPLY (+) 12V/24V
#3 / GRN ALARM DISABLE GND INPUT
WHT OPTION OUTPUT
CDTpro Control Kit - PN 118530
NOTICE
Any modification to the crane control
system (electrical and/or hydraulic)
must be approved by Stellar.

Page 10 | Stellar®8630 Telescopic Crane Owner’s Manual
Electrical Circuit Grounding
When installing the crane, always locate a good source for grounding the circuit. A majority of
electrical failures are due to poor grounding. Poor grounding can cause intermittent operation of
the equipment, electrical component failures and cause the equipment to not operate at all.
Chassis manufacturers usually will have a ground strap which ties into the truck frame from the
battery, but it is always a good idea to check each individual model to verify where the ground is
located. Never use the mechanic body as a ground source. Make sure the electrical grounds are
routed to either the chassis frame rail or the chassis’s main grounding source.
Stellar provides a stud (PN 40992) for grounding the crane to the chassis frame rail:
• Hole size: 21/64”
• The hole location should allow for the shortest length of ground wire while keeping enough
slack for flexibility.
• Be sure to grind the frame rail around the hole to ensure a proper ground connection.
• Frame rail thickness may require additional flat washers (as shown).
• Use an electrical coating on hardware to prevent corrosion.
Inside Frame Rail Outside Frame Rail
WARNING
Drill the hole to the frame rail in accordance with the chassis body
builder’s guide.

Stellar®8630 Telescopic Crane Owner’s Manual | Page 11
Hydraulic Kit - PN 107780
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
HARDWARE KIT: 118872
PN 107780

Page 12 | Stellar®8630 Telescopic Crane Owner’s Manual
PN 44530
125367 1RELIEF VALVE 24685/24690
25369 SEAL KIT 24960/25381
224960 1VALVE FLW CTRL PRP/JP04C3150N 0-8
25368 SEAL KIT 25367
325371 3VALVE SOLND 3 POS 4 WAY TAND G04571
425372 1VALVE SOLND 3 POS 4 WAY OPEN G04591
25373 SEAL KIT 25371/25372
544532 9
37 FT LBS
20-22 FT LBS
25 FT LBS
25 FT LBS
3 FT LBSCOIL 12VDC DUETSCH CAP012H
ITEM PART No. QTY.DESCRIPTION TORQUE
NOTE: PN's 24960 & 25371 DO NOT INCLUDE COIL PN 44532
5
3
1
4
5
5
3
2
HYDRAULIC SCHEMATIC
Valve Bank - PN 44530

Stellar®8630 Telescopic Crane Owner’s Manual | Page 13
1. After mounting, locate the pressure and return
lines. Note: Pressure line is 3/8” hose; Winch
Case Drain Line is 1/4” 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
1/2” Line 1/4” Line
3/8” Line
Hydraulic Installation

Page 14 | Stellar®8630 Telescopic Crane Owner’s Manual
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 1/4” hydraulic hose and fittings rated for a minimum of 300 psi.
3.
4. Attach one end of the winch case drain to 1/4” 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: 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
1/2” Line 1/4” Line
3/8” Line
Winch Case Drain Installation

Stellar®8630 Telescopic Crane Owner’s Manual | Page 15
Hydraulic System

Page 16 | Stellar®8630 Telescopic Crane Owner’s Manual
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