stellar labs TC38 User manual

Model TC38
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.
© 2018 Stellar Industries, Inc.
Rev 1
PN 95157
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®TC38 Telescopic Crane Owner’s Manual
Model TC38 Manual Revisions
Date of Revsion Section Revised Description of Revision
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®TC38 Telescopic Crane Owner’s Manual | Page iii
Table of Contents
Introduction .........................................................................................................iv
Chapter 1 - Specications..................................................................................... 1
Model TC38 Specications .................................................................................1
TC38 Capacity .....................................................................................................2
Chapter 2 - Installation .......................................................................................... 3
General Installation .............................................................................................3
Installer Notice ...................................................................................................3
Torque Data Chart ............................................................................................4
Installation Overview ........................................................................................5
TC38 Mounting Detail ..........................................................................................5
TC38 Installation Drawing - PN 91598 ................................................................6
Flatbed Body Reinforcement .............................................................................6
Control Kit - PN 96174 ..........................................................................................7
Control Kit Installation Drawing - PN 96175 .......................................................8
TC Series Wiring Diagram ....................................................................................9
Hydraulic Kit - PN 91597 ....................................................................................10
Hydraulic Kit - PN 91597 (cont.) ........................................................................11
Hydraulic Kit - PN 91597 (cont.) ........................................................................12
TC38 Hydraulic Schematic ...............................................................................13
Hydraulic Kit Installation Drawing - PN 92250 ................................................14
Optional Power Unit Assembly - PN 77897 ......................................................15
Face Seal/O-Ring Size Chart ............................................................................16
Stability Procedure ............................................................................................17
Crane Load Level Indicator .............................................................................18
Decal Placement - PN 76878 ...........................................................................19
Chapter 3 - Assembly Drawings ......................................................................... 21
Base Assembly - PN 90744 ................................................................................21
Gear Bearing Assembly - PN 69735 .................................................................22
Mast Assembly - PN 90747 ................................................................................23
Boom Assembly - PN 90606 ..............................................................................24
Boom Bill - PN 90606 ..........................................................................................25

Page iv | Stellar®TC38 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®TC38 Telescopic Crane Owner’s Manual | Page 1
7.43in 9.46in 13.03in
26.37in
ROTATIONAL
CLEARANCE
50deg
5deg
16.88in
50.00in
20.41in
69.26in
5.53in
54.11in
ROTATION STOP
OVERLAP ZONE
13.81in
11.81in
11.81in
14.88in
236.56in EXTENDED
49.87in
64.56in RETRACTED
17.94in
63.95in
CG
EXTENDED
CG
RETRACTED
78.91in
64.92in
Chapter 1 - Specications
Model TC38 Specications
TC38 Crane
Crane Rating: 26,660 ft.lbs (36.1 kNm)
Max Lifting Capacity: 4,940 lbs (2,241 kg)
Max Reach: 19.7 ft (6.0 m)
Slewing Angle: 410°
Operating Pressure: 2,750 psi
Pump Capacity: 2.5 gpm (9.5 lpm)
Shipping Weight: 1,000 lbs (454 kg)

Page 2 | Stellar®TC38 Telescopic Crane Owner’s Manual
TC38 Capacity
0 ft
(0 m)
0 ft
(0 m)
3 ft
(0.91 m)
6 ft
(1.83 m)
9 ft
(2.74 m)
12 ft
(3.66 m)
15 ft
(4.57 m)
18 ft
(5.49m)
21ft
(6.40 m)
24 ft
(7.32 m)
3 ft
(0.91 m)
6 ft
(1.83 m)
9 ft
(2.74 m)
12 ft
(3.66 m)
15 ft
(4.57 m)
3 ft
(0.91 m)
6 ft
(1.83 m)
9 ft
(2.74 m)
12 ft
(3.66 m)
15 ft
(4.57 m)
18 ft
(5.49 m)
21 ft
(6.40 m)
556 Kg
6.00 m
1225 lbs
19.7 ft
665 Kg
4.97 m
1465 lbs
16.3 ft
869 Kg
3.93 m
1915 lbs
12.9 ft
1252 Kg
2.77 m
2760 lbs
9.1 ft
2241 Kg
1.65 m
4940 lbs
5.4 ft
TC38
556 Kg
6.00 m
1225 lbs
19.7 ft

Stellar®TC38 Telescopic Crane Owner’s Manual | Page 3
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 TC13
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 4 | Stellar®TC38 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®TC38 Telescopic Crane Owner’s Manual | Page 5
1. Use the dimensional specications to properly size and position the crane for mounting.
2. Use the detail on the following page to drill .82” diameter holes into the mounting plate.
3. Use a crane or lifting device capable of lifting the weight of the TC13 (See specications
for shipping weight details).
4. Connect straps or chain from the lifting device to the main boom of the TC13.
5. Remove motor to allow installation of the mounting bolts.
6. Use four (4) 0.75-10 UNC Grade 8 bolts, washers, and nuts. (See install drawing for details)
7. Using the lifting device, lower the TC13 just above the mounting surface and start the
bolts. Have someone assist in leveling the crane.
8. Secure the crane using the mounting hardware provided. Note: longer or shorter bolts
may be required – recommended thread engagement into crane base is 0.75” – use
grade 8, zinc plated bolts only.
9. Torque the bolts to proper torque.
10. Remove supporting crane.
11. Hook up hydraulics and electrical using the schematics provided later in this chapter.
Installation Overview
0.75-10 TAPPED HOLE
TYP 4
11.81
11.81
5.91
5.91
5.38
TC38 Mounting Detail

Page 6 | Stellar®TC38 Telescopic Crane Owner’s Manual
1
2
NOT SHOWN:
DECAL KIT 76878
LEVEL 76483
PN 91598
USE 0.75-10 UNC GRADE 8
BOLTS, WASHERS, & NUTS
NOTE: LENGTH NOT SPECIFIED DUE TO
VARYING MOUNTING REQUIREMENTS MANUAL KIT 76334
.YTQNOITPIRCSEDTRAPMETI
1C5942 PLATE SERIAL # TRUCK (NOT SHOWN)1
28176 SCREW DRIVE #4X0.31 RND HD U ZINC 1
BOTH SIDES
0.50 PLATE
0.25 PLATE
TUBE 3X3X0.38
BOLT TO
TRUCK FRAME
0.25 PLATE
WELD TO BODY
LONG SILL
0.19 PLATE
TC38 Installation Drawing - PN 91598
Flatbed Body Reinforcement
If it has been determined that the destination body won’t support
the crane with a fully rated load, the body must be reinforced. Use
1/4” llet welds and an AWS qualied welder to proceed as shown in
this drawing:

Stellar®TC38 Telescopic Crane Owner’s Manual | Page 7
.YTQNOITPIRCSEDTRAPMETI
196172 RADIO CTRL ASM 7 FCTN CDT TC CRANES V3 1
276554 ISOLATOR RUBBER 0.25-20X1.13 4
30478 CAP SCR 0.25-20X0.50 HHGR5 4
NOT SHOWN:
WIRE HARNESS 76678
BACKUP CABLE 84201
DOCKING STATION 75105
REFER TO INST DWG 96175
1
3
2
PN 96174
Control Kit - PN 96174

Page 8 | Stellar®TC38 Telescopic Crane Owner’s Manual
RECEIVER - RADIO (PART OF 1) RADIO CONTROLLER ASSEMBLY WIRE HARNESS TBOOM CRANE TRANSMITTER - RADIO (PART OF 1)
4
2
PD1
B
AB
AB
AB
A
ABABABAB
PROPORTIONAL
VALVE
ROT ROT
CCW
CW
MAIN
DOWN UP
MAIN
RETRACT
EXTENSION
EXTEND
EXTENSION
AB
PRESSURE
TRANSDUCERS
MOMENTARY OPTION
LATCH OPTION
HYD POWER UNIT SIGNAL
+12V CRANE POWER SUPPLY
GROUND
(BLACK)
BA
BA
ANTI TWO-BLOCK
BOOM
STOP
WITHOUT WINCH: CONNECT BOOM STOP AND A2B CIRCUITS
PD2
BASE END
ROD END
3
PN 96175
Control Kit Installation Drawing - PN 96175

Stellar®TC38 Telescopic Crane Owner’s Manual | Page 9
TC Series Wiring Diagram

Page 10 | Stellar®TC38 Telescopic Crane Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI
1 73943 VB 3 SECT W/PROP STER4GPM-8 VALVE DEUTSCH 1
1SENARCCTKCABREVOC649372
1SENARCCTTNORFREVOC749373
2KCOL83.0REHSAW32504
8TALFSSU52.0REHSAW04305
25RGHH00.3X61-83.0RCSPAC9490C6
45RGHH05.0X02-52.0RCSPAC87407
25RGHH57.0X02-52.0RCSPAC97408
2COLYN5RGHH02-52.0TUN33309
PART NUMBERS NOT SHOWN:
91599 - HOSE KIT TC13 X1
4043 - HOSE PROTECTOR 0.50 AS-B-17 WIDTH 2.25 X20FT
32302 - FTG 4-4 MFS-MFS SWIVEL STRAIGHT X1
12171 - FTG 6-6 MFS-MFS SWIVEL STRAIGHT X1
0882 - FTG 6 FFS CAP X1
C2032 - FTG 4 FFS CAP X1
REFER TO INST DWG 92250
A
5
9
SCALE 1 : 5
DETAIL A
8
2
3
7
5
6
4
7
5
1
PN 91597
Hydraulic Kit - PN 91597

Stellar®TC38 Telescopic Crane Owner’s Manual | Page 11
.YTQNOITPIRCSEDTRAPMETI
4THGIARTSBROM-SFM4-4GTF1921D1
409BROAM-SFM4-4GTF8911C2
3D0511 FTG 4 MORB PLUG HOLLOW HEX1
209BROF-BROAM4-4GTF718154
539780 GAUGE OIL LF 2.5 0-6000 CBM SAE1
1THGIARTSBROM-SFM6-6GTF97206
3THGIARTSBROM-SFM6-4GTF2294C7
8 73943 VB 3 SECT W/PROP STER4GPM-8 VALVE DEUTSCH 1
7
4
5
8
3
2
1
1
6
PN 91597
Hydraulic Kit - PN 91597 (cont.)

Page 12 | Stellar®TC38 Telescopic Crane Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI
1 C1111FTG 10-6 MORB-FORB STRAIGHT REDUCER2
2C4922 FTG 4-6 MFS-MORB STRAIGHT3
409BROAM-SFM4-4GTF8911C3
451817 FTG 4-4 MAORB-FORB 90 2
596171 FTG 4-4-4 MAORB-FORB-FORB TEE1
6 28485 TRANSDUCER PRESSURE 5000 PSI2
209BROAM-SFM6-4GTF83337
6
6
1
2
3
4
5
3
7
7
PN 91597
Hydraulic Kit - PN 91597 (cont.)

Stellar®TC38 Telescopic Crane Owner’s Manual | Page 13
TC38 Hydraulic Schematic

Page 14 | Stellar®TC38 Telescopic Crane Owner’s Manual
NOTE: USE HOSE PROTECTOR
P/N 4043 OVER ALL HOSES
PN 92250
Hydraulic Kit Installation Drawing - PN 92250

Stellar®TC38 Telescopic Crane Owner’s Manual | Page 15
Optional Power Unit Assembly - PN 77897
PN 77897
.YTQNOITPIRCSEDTRAPMETI
177896POWER UNIT 12V 2.5GPM 4 GAL RSRVR1
2D0790 WASHER 0.50 SAE FLAT YELLOW GR88
38833CAP SCR 0.50-13X2.00 HHGR8 4
45468 NUT 0.50-13 HHGR8 NYLOC4
5C6162 FTG 12-12 MP-MP HEX NIPPLE STRAIGHT 1
1DAEHRETLIF6226C6
1TROHSRETLIF7226C7
8 16145 GAUGE PRES FILTER SERVICE CI201
953485 FTG 12-6 MP-FP REDUCER BUSHING1
10 77898FTG 6-6 MJ-MP STRAIGHT 1
8
4
3
10
9
6
7
5
2
1
NOTE: ALL PARTS TO BE SHIPPED LOOSE
NOT SHOWN
P/N 78242, WIRE HARNESS TC POWER UNIT
P/N 78243, WIRE HARNESS TC POWER UNIT OVERRIDE

Page 16 | Stellar®TC38 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