stellar labs 9621 User manual

Model 9621
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.
© 2016 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®9621 Telescopic Crane Owner’s Manual
Model 9621 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®9621 Telescopic Crane Owner’s Manual | Page iii
Table of Contents
Introduction ........................................................................................ iv
Chapter 1 - Specications.....................................................................1
Model 9621 Specications .................................................................1
Capacity Chart - Decal PN 72810 ....................................................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 73260 .........................................................................8
Control Kit (Non-Boost) - PN 73367 ....................................................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 72802 ...........................................................18
Chapter 3 - Assembly Drawings .........................................................19
Base Assembly - PN 71166 ................................................................19
Gear Bearing - PN 71041 ..................................................................20
Mast Assembly - PN 72799 ................................................................21
Winch - PN 57917 ..............................................................................22
Main Boom Assembly - PN 72762 ....................................................23
Extension Boom Assembly - PN 71578 .............................................24
Main Cylinder Assembly - PN 72610 ................................................25
Extension Cylinder Assembly - PN 28859 .........................................26
Cable & Hook Assembly - PN 55898 ...............................................27
CDT™ Radio Transmitter Assembly - PN 56647 ...............................28

Page iv | Stellar®9621 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®9621 Telescopic Crane Owner’s Manual | Page 1
Model 9621 Crane
Specifications Sheet
Page: 1 of 4
Crane Rating*:
70,800 ft-lbs (9.79 TM)
Standard Boom Length:
11'0" (3.35 m) from CL of Crane
Boom Extension:
Hydraulic 60" (152.4 cm)
Hydraulic 60" (152.4 cm)
Maximum Horizontal Reach:
21' 0" (6.40 m) from CL of Crane
Maximum Vertical Lift:
23' 0" (7.01 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 100' (30.48 m)
Boom Elevation:
-10º to +80º
Line Pull Speed:
60 ft/min (18.29 m/min)
Max. Single Part Line:
4,500 lbs (2,040 kg)
Max. Double Part Line:
9,000
lbs (4,080 kg)
Rotation (Worm Gear):
400º Power
Lifting Capacity**:
9,000 lbs @ 7'10" (4,080 kg @ 2.39 m)
3,365 lbs @ 21' (1,525 kg @ 6.40 m)
Power Supply:
2,235 lbs (1,015 kg)
9621 Standard
1st Stage:
2nd Stage:
PTO
& Pump:
8
gpm @ 2,500 psi
(30.3
lpm @ 172 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 9621 Specications

Page 2 | Stellar®9621 Telescopic Crane Owner’s Manual
Model 9621 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
-10º
80º
0º
15º
30º
45º
60º
PN 72810
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
Maximum 1 - part line capacity is
4500 lbs (2040 kg). For greater
loads, use 2 - part line.
0’
4’
6’
8’
10’
12’
14’
16’
18’
20’
22’
24’
7.3 m
6.7 m
6.7 m
6.1 m
5.5 m
5.5 m
4.9 m
4.3 m
4.3 m
3.7 m
3.7 m
3.1 m
2.4 m
2.4 m
1.8 m
1.8 m
1.2 m
1.2 m0.6 m
2’ 4’ 6’ 8’ 10’ 12’ 14’
15’
16’ 18’ 22’
0’
11’
3.35m
16’
4.88m
21’
6.40m
6535 lbs
2965 kg
5535 lbs
2510 kg
4490 lbs
2035 kg
3805 lbs
1725 kg
3420 lbs
1550 kg
2900 lbs
1315 kg
Boost
(If Equipped)
Standard
4080 kgs
4080 kgs
4080 kgs
9000#
9000#
9000#
9000#
9000 lbs
4080 kg
3000 lbs
1360 kg
3540 lbs
1605 kg
4325 lbs
1960 kg
5100 lbs
2310 kg
3300 lbs
1495 kg
3890 lbs
1760 kg
7425 lbs
3365 kg
8760 lbs
3970 kg
5165 lbs
2340 kg
6090 lbs
2760 kg
7005 lbs
3175 kg
8265 lbs
3745 kg
5425 lbs
2460 kg
6400 lbs
2900 kg
3960 lbs
1795 kg
4670 lbs
2115 kg
3950 lbs
1790 kg
4660 lbs
2110 kg
5900 lbs
2675 k5
6960 lbs
3155 kg
6435 lbs
2915 kg
5455 lbs
2475 kg
3365 lbs
1525 kg
2855 lbs
1295 kg
4425 lbs
2000 kg
3750 lbs
1700 kg
6295 lbs
2855 kg
7425 lbs
3365 kg
9000 lbs
4080 kg
9000 lbs
4080 kg
9000 lbs
4080 kg
Capacity Chart - Decal PN 72810

Stellar®9621 Telescopic Crane Owner’s Manual | Page 3
Model 9621 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
23'3"
7.09m
18'4"
5.59m
13'5"
4.09m
1'9"
0.54m
3'0"
0.91m
3'11"
1.19m
4'9"
1.45m
11'2"
3.40m
21'2"
6.45m
16'2"
4.93m
1'1"
0.33m
Dimensional Drawing 1

Page 4 | Stellar®9621 Telescopic Crane Owner’s Manual
Model 9621 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
42.00in
1.07m
11'-2"
[ 3.41m ]
42.02in
1.07m
19.19in
0.49m
24.54in
0.62m
CG
38.57in
12'-11"
[ 3.93m ]
0.98m
12.19in
0.31m
Dimensional Drawing 2

Stellar®9621 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 9621
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®9621 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®9621 Telescopic Crane Owner’s Manual | Page 7
1. Determine that the mounting location for the 9621 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
9621 weighs approximately 2,150 lbs (975 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 9621.
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 9621 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®9621 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 15/20/21 FT CRANE
SWITCH LIMIT E1161-B9111-6C INCLINOMETER 60 DEG PENNY AND GILES
CABLE BACKUP HETRONIC G2 (PART OF 1)
PN 73260
Control Kit - PN 73260

Stellar®9621 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
TRANSDUCER PRESSURE 5000 PSI
CORD REEL ASM 15/20/21 FT CRANE SWITCH LIMIT E1161-B9111-6C INCLINOMETER 60 DEG PENNY AND GILES
CABLE BACKUP HETRONIC G2 (PART OF 1)
8
6
7
5
PN 73367
Control Kit (Non-Boost) - PN 73367

Page 10 | Stellar®9621 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®9621 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®9621 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®9621 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®9621 Telescopic Crane Owner’s Manual
Hydraulic System

Stellar®9621 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®9621 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