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 Notification.
© 2022 Stellar Industries, Inc.
Rev 1
PN 128008
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®9621 Telescopic Crane Owner’s Manual
MODELNO. SERIALNO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENTINFORMATION
http://www.stellarindustries.com/ip
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]
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.
MODEL NO. SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENT INFORMATION
http://www.stellarindustries.com/ip
The serial tag is located on the curb
side of the crane mast. Write your info
below for easy reference if you need to
contact Stellar®Customer Service.

Stellar®9621 Telescopic Crane Owner’s Manual | Page iii
Table of Contents
Introduction ............................................................................................................................................iv
Chapter 1 - Specifications......................................................................................................................... 1
Model 9621 Specifications .................................................................................................................... 1
Capacity Chart - Decal PN 127995...................................................................................................... 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 118530........................................................................................................................... 8
Electrical Circuit Grounding.................................................................................................................. 9
Hydraulic Kit - PN 122390 ..................................................................................................................... 10
Valve Bank - PN 125254 ....................................................................................................................... 11
Hydraulic Installation............................................................................................................................ 12
Winch Case Drain Installation............................................................................................................. 13
Hydraulic System .................................................................................................................................. 14
Face Seal/O-Ring Size Chart............................................................................................................... 14
Stability Procedure ............................................................................................................................... 15
Crane Load Level Indicator................................................................................................................ 16
Decal Placement - PN 127765............................................................................................................ 17
Chapter 3 - Assembly Drawings ............................................................................................................. 19
Base Assembly - PN 71166 ................................................................................................................... 19
Gear Bearing - PN 71041 ..................................................................................................................... 20
Mast Assembly - PN 128249................................................................................................................. 21
Winch - PN 105033................................................................................................................................ 22
Main Boom Assembly - PN 122423 ..................................................................................................... 23
Extension Boom Assembly - PN 125509.............................................................................................. 24
Extension Boom Material List - PN 125509.......................................................................................... 25
Main Cylinder Assembly - PN 122923 ................................................................................................. 26
Extension Cylinder Assembly - PN 125733.......................................................................................... 27
Snatch Block Assembly - PN 55898..................................................................................................... 28
Wireless Remote Replacement Parts................................................................................................. 29
Chapter 4 - Replacement Parts .............................................................................................................. 31

Page iv | Stellar®9621 Telescopic Crane Owner’s Manual
Introduction
Stellar®Crane are designed to provide safe and dependable service for a variety of operations.
With proper use and maintenance, these cranes will operate at peak performance for many years.
To promote this longevity, carefully study the information contained in this manual before putting
the equipment into service. Though it is not intended to be a training manual for beginners, this
manual should provide solid guidelines for the safe and proper usage of the crane.
Once you feel comfortable with the material contained in this manual, strive to exercise your
knowledge as you safely operate and maintain the crane. This process is vital to the proper use of
the unit.
A few notes on this manual:
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:
NOTICE
A NOTICE signal word indicates a practice not related to physical injury.
WARNING
A WARNING signal word indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
DANGER
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 all maintenance, operating, or repair
instructions pertinent to all possible situations. 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.
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].

Stellar®9621 Telescopic Crane Owner’s Manual | Page 1
Chapter 1 - Specifications
Model 9621 Specifications
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' 1" (7.05 m) from Crane Base
Stowed
Height (Crane Only): 40.50" (103 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:
2,025 lbs (918 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.

Page 2 | Stellar®9621 Telescopic Crane Owner’s Manual
Capacity Chart - Decal PN 127995

Stellar®9621 Telescopic Crane Owner’s Manual | Page 3
Dimensional Drawing 1
11'0"
3.37m
4.89m
16'0"
21'0"
6.41m
2'11"
0.88m
18'2"
5.54m
7.05m
23'1"
4.05m
13'4"
3'9"
1.15m
4'8"
1.41m

Page 4 | Stellar®9621 Telescopic Crane Owner’s Manual
43.75in
1.11m
0.53m
20.75in
34.94in
0.89m
11'-0"
3.36m
CG
1.03m
40.51in
3.92m
12'-10"
13.76in
0.35m
21.28in
0.54m
Dimensional Drawing 2

Stellar®9621 Telescopic Crane Owner’s Manual | Page 5
Chapter 2 - Installation
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®products 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 federal and
state regulations, as well as any OEM instructions such as chassis body builder guides.
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 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.
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®9621 Telescopic Crane Owner’s Manual
Torque Data Chart
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

Stellar®9621 Telescopic Crane Owner’s Manual | Page 7
Installation Overview
1. Determine that the mounting location for the 9621 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 9621
weighs approximately 2,025 lbs (918 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 9621.
5. Use six (6) 3” x 1” #8 bolts and six (6) #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 Stellar 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.
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
Control Kit - PN 118530
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
EXTENSION SENSOR
& INCLINOMETER
8
TRANSMITTER
3
6
DOCKING STATION
#1 / BLK SUPPLY (-)
#2 / RED SUPPLY (+) 12V/24V
#3 / GRN ALARM DISABLE GND INPUT
WHT OPTION OUTPUT
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 29FT 4 WIRE SEALED
ENCODER BOOM VECTOR 6M CANOPEN
TRANSDUCER PRESSURE 0-5000PSI #4 SAE DT
CTRLMODULEMECHCRANEG6
WIREHRNSMECHCRANECDTPLUSG6451RETRO
TETHER CABLE 10M M-F M12 SCANRECO
TAG TRANSMITTER SCANRECO
PIGTAIL ASM 14IN 2P WP SHRD
AB
A2B
SWITCH
CORD REEL
9
10
BA
PIGTAIL
13
A
B
BUTT CONNECT
GREEN (A)
RED (B)
PN 118530
NOTICE
Any modification to the crane control
system (electrical and/or hydraulic)
must be approved by Stellar.

Stellar®9621 Telescopic Crane Owner’s Manual | Page 9
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.

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 122390
Hydraulic Kit - PN 122390

Stellar®9621 Telescopic Crane Owner’s Manual | Page 11
HYDRAULIC SCHEMATIC
3
1
5
3
3
4
2
5
6
PN 125254
1125946 1VALVE RELIEF 125254
126270 SEAL KIT 125255
2125255 1VALVE FLW CTRL PRP 0-8 GPM DEL
126271 SEAL KIT 125946
3125256 3VALVE SOLND 3 POS 4 WAY 8GPM TANDEM DEL
4125257 1VALVE SOLND 3 POS 4 WAY 8GPM OPEN DEL
126269 SEAL KIT 125256/125257
5125947 8
37 FT LBS
20-22 FT LBS
25 FT LBS
25 FT LBS
3 FT LBSCOIL 12VDC DEUTSCH DEL
6125948 13FT LBSCOIL 12VDC DEUTSCH PROP DEL
ITEM PART No. QTY.DESCRIPTION TORQUE
Valve Bank - PN 125254

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 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

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 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

Page 14 | Stellar®9621 Telescopic Crane Owner’s Manual
Hydraulic System
Face Seal/O-Ring Size Chart
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

Stellar®9621 Telescopic Crane Owner’s Manual | Page 15
Stability Procedure
Definition 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 final 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 firm, level footing.
3. Operate the crane under partial load to assure operator proficiency and proper machine
function.
4. Put the radio into Stability Test Mode:
A. Push the four crane function switches up and hold until the screen reads “STB” in the
upper right corner (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.
NOTICE
The radio can only be put into stability mode five 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.

Page 16 | Stellar®9621 Telescopic Crane Owner’s Manual
Stability Procedure Continued...
9621 Stability Data
Max Horizontal Reach: 250” (From the center of rotation to boom tip)
Boost Stability Test Weight: 4,000 lbs.
Non-Boost Stability Test Weight: 3,390 lbs.
Test Procedure
1. Rotate the crane into Zone 1 position.
2. With the crane fully retracted and the boom
horizontal, winch the test weight off the
ground. Note: Keep weight within six inches of
the ground at all times.
3. Extend the boom outward until full extension
has been reached or until the truck becomes
unstable. (Again, use the winch to keep the
weight within six inches of the ground.)
4. If the boom goes full extension without
becoming unstable, the crane is termed stable
for this zone and 100% can be written in the
Zone 1 data box.
5. If the truck becomes unstable prior to going
full extension, retract the boom until the truck
becomes stable and measure the horizontal
reach in this position (center of rotation to
boom tip). This is the stable horizontal reach
for this zone. Stable horizontal reach divided by Maximum horizontal reach multiplied by 100
equals the percentage of rated capacity for this zone. Use the following formula to determine
the percentage of rated capacity:
6. Record this number in the data box for Zone 1. This is the revised capacity due to stability for this
zone.
7. Repeat this procedure for each zone until the worksheet is completed.
8. This is the revised capacity based on stability of this package.
Stellar®Cranes are shipped with a load level
indicator that is used to determine if the truck is
level (side to side) before using the crane to pick/
move a load. This level should be installed in the
isolated crane compartment of the body. If level
indicator is missing or damaged, please contact
Stellar Customer Support for a replacement.
Crane Load Level Indicator
PN 76483