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.
© 2022 Stellar Industries, Inc.
Rev 2
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 PN: 118498
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
NOTICE
Cold Weather Performance
Although clear data on cold weather performance from every steel manufacturer
is not available for all types and thicknesses of steel, Stellar Industries is
confident that the weldments on our products will operate to 100% of their
intended purpose to temperatures down to -40° F / C.
It is recommended it Stellar manufactured equipment needs to be used in
temperatures below -40° F / C, the operator should pull the unit into a
climate-controlled area and allow the weldments to warm up to and then maintain
a temperature above this level.
P65 Warning / Serial Tag Location / Cold Weather

Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498 | Page iii
Table of Contents
Introduction ............................................................................................................................................................. iv
Chapter 1 - Specications ...........................................................................................................................1
Model 8630 Specications ........................................................................................................................................2
Capacity Chart - Decal PN 118550 ...........................................................................................................................3
Dimensional Drawing 1 .............................................................................................................................................4
Dimensional Drawing 2 .............................................................................................................................................5
Chapter 2 - Installation.................................................................................................................................7
General Installation ...................................................................................................................................................8
Installer Notice .......................................................................................................................................................8
Torque Data Chart .................................................................................................................................................9
Installation Overview............................................................................................................................................10
Installation Overview............................................................................................................................................11
Control Kit - PN 118530 ..........................................................................................................................................12
Control Kit - PN 118530 - Parts List ........................................................................................................................13
Electrical Circuit Grounding ....................................................................................................................................14
Valve Bank - PN 125254.........................................................................................................................................16
Valve Bank - PN 125254 Parts List.........................................................................................................................17
Alternate Valve Bank - PN 44530............................................................................................................................18
Alternate Valve Bank - PN 44530 Parts List............................................................................................................19
Hydraulic Kit - PN 107780.......................................................................................................................................20
Hydraulic Kit - PN 107780 Parts List.......................................................................................................................21
Hydraulic Installation...............................................................................................................................................22
Winch Case Drain Installation.................................................................................................................................23
Hydraulic System ....................................................................................................................................................24
Face Seal/O-Ring Size Chart..................................................................................................................................24
Stability Procedure..................................................................................................................................................25
Crane Load Level Indicator.....................................................................................................................................26
Decal Placement - PN 118504................................................................................................................................27
Chapter 3 - Assembly Drawings................................................................................................................29
Base Assembly - PN 50364 ....................................................................................................................................30
Base Assembly - PN 50364 Parts List ....................................................................................................................31
Gear Bearing - PN 47869 .......................................................................................................................................32
Gear Bearing - PN 47869 Parts Llst .......................................................................................................................33
Mast Assembly - PN 131787...................................................................................................................................34
Mast Assembly - PN 131787 Parts List...................................................................................................................35
Winch - PN 107774.................................................................................................................................................36
Winch - PN 107774 Parts List.................................................................................................................................37
Main Boom Assembly - PN 118509.........................................................................................................................38
Main Boom Assembly - PN 118509 Parts List.........................................................................................................39
Extension Boom Assembly - PN 106804 ................................................................................................................40
Extension Boom Assembly - PN 106804 Parts List ................................................................................................41
Extension Boom Assembly - PN 106804 Parts List ................................................................................................42
Main Cylinder Assembly - PN 114688.....................................................................................................................44
Main Cylinder Assembly - PN 114688 Parts List.....................................................................................................45
Extension Cylinder Assembly - PN 103416 ............................................................................................................46
Extension Cylinder Assembly - PN 103416 Parts List ............................................................................................47
Snatch Block Assembly - PN 56266 .......................................................................................................................48
Snatch Block Assembly - PN 56266 Parts List .......................................................................................................49
Wireless Remote Replacement Parts .....................................................................................................................50
Wireless Remote Replacement Parts List ..............................................................................................................51

Page iv | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
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 Heavy 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.
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 PN: 118498 | Page 1
Chapter 1 - Specications
Chapter Contents
Model 8630 Specications ......................................................................................................... 2
Capacity Chart - Decal PN 118550 ............................................................................................ 3
Dimensional Drawing 1 .............................................................................................................. 4
Dimensional Drawing 2 .............................................................................................................. 5

Page 2 | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
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)
NOTES:
* CRANE RATING IN BOOST MODE. NORMAL CRANE RITING IS 45,000 FT-LB (6.2 TM).
** MAXIMUM CAPACITIES IN BOOST MODE.
Model 8630 Specications

Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498 | Page 3
Capacity Chart - Decal PN 118550

Page 4 | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
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

Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498 | Page 5
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

Page 6 | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
This Page Left Intentionally Blank.

Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498 | Page 7
Chapter 2 - Installation
Chapter Contents
General Installation ...................................................................................................................................................8
Installer Notice ..........................................................................................................................................................8
Torque Data Chart.....................................................................................................................................................9
Installation Overview...............................................................................................................................................10
Installation Overview...............................................................................................................................................11
Control Kit - PN 118530 ..........................................................................................................................................12
Control Kit - PN 118530 - Parts List ........................................................................................................................13
Electrical Circuit Grounding ....................................................................................................................................14
Valve Bank - PN 125254.........................................................................................................................................16
Valve Bank - PN 125254 Parts List.........................................................................................................................17
Alternate Valve Bank - PN 44530............................................................................................................................18
Alternate Valve Bank - PN 44530 Parts List............................................................................................................19
Hydraulic Kit - PN 107780.......................................................................................................................................20
Hydraulic Kit - PN 107780 Parts List.......................................................................................................................21
Hydraulic Installation...............................................................................................................................................22
Winch Case Drain Installation.................................................................................................................................23
Hydraulic System ....................................................................................................................................................24
Face Seal/O-Ring Size Chart..................................................................................................................................24
Stability Procedure..................................................................................................................................................25
Crane Load Level Indicator.....................................................................................................................................26
Decal Placement - PN 118504................................................................................................................................27

Page 8 | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
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®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 Tra󰀩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.
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.

Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498 | Page 9
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 a󰀨ect 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 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

Page 10 | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
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 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 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

Stellar® 8630 Telescopic Crane Owner’s Manual PN 118498 | Page 11
Installation Overview
2
1
FRONT
Motor
Hole Mounting Detail
Ø1.063
7.38
14.75
7.38
14.75
Ø6.00
4 Places
ITEM PART DESCRIPTION QTY
1 5199 CAP SCR 1.00X8X3.00 HHGR8 ZY 4
2 6538 WASHER 1.00 SAE FLAT YELLOW GR8 4

Page 12 | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
Control Kit - PN 118530
NOTICE
Any modication to the crane control sys-
tem (electrical and/or hydraulic) must be
approved by Stellar.
E
F
A
C
D
B
FB
D
ECA
A
B
PD1
PD2
CRANE PWR
CTRL OUTPUT
GROUND
START/STOP
OPTION 2
DV OUTPUT
2 1
12
AB
BA
A
B
TRANSMITTER
CPRSR ON/OFF
SPEED CTRL
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
EXTENSION SENSOR
& INCLINOMETER
8
3
6
DOCKING STATION
#1 / BLK SUPPLY (-)
#2 / RED SUPPLY (+) 12V/24V
#3 / GRN ALARM DISABLE GND INPUT
WHT OPTION OUTPUT
PIGTAIL
13
A2B
SWITCH 10
CORD REEL
9
BUTT CONNECT
GREEN (A)
RED (B)
REMOTE
TETHER
ROT
ROT
PROPORTIONAL
CW CCW
VALV E
MAIN
DOWN
EXT.
RETRACT
MAIN
UP
EXTEND
WINCH
DOWN
WINCH
UP
EXT

Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498 | Page 13
Control Kit - PN 118530 - Parts List
PN 118530
ITEM PART DESCRIPTION QTY
01 113550 RADIO CTRL ASM 4 FCTN CDTPRO G6RC PG 1
02 113569 RECEIVER CDTPRO G6RC 2.4GHZ 14P 1
03 113568 TRANSMITTER 4 FCTN MECH CDTPRO G6RC PG 1
04 113571 CTRL MODULE MECH CRANE CDTPRO G6 REF
05 113580 WIRE HRNS MECH CRANE CDTPRO G6 451 REF
06 113551 DOCKING STATION RADIO TRANS CDTPRO REF
07 108268 TRANSDUCER PRESSURE 0-5000PSI #4 SAE DT 2REF
08 110460 ENCODER BOOM VECTOR 6M CANOPEN 1
09 123760 CORD REEL 29FT 4 WIRE SEALED 1
10 35105 SWITCH LIMIT (NO) ROLLER LVR LT BRKT E1161 1
11 89152 TETHER CABLE 10M M-F M12 SCANRECO REF
12 119851 TAG QUICK START CDTPRO TX REF
13 124587 PIGTAIL ASM 14IN 2P WP SHRD 1

Page 14 | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
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
exibility.
• Be sure to grind the frame rail around the hole to ensure a proper ground connection.
• Frame rail thickness may require additional at 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 PN: 118498 | Page 15
This Page Left Intentionally Blank.

Page 16 | Stellar®8630 Telescopic Crane Owner’s Manual PN: 118498
HYDRAULIC SCHEMATIC
3
1
5
3
3
4
2
5
6
Valve Bank - PN 125254