Stellar Industries Telescopic Crane 10628 Users Manual

2015-02-02

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 
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com Last Revision: 09/17/12
Subject to Change without Notification.
© 2012 Stellar Industries, Inc.
®
TM
10628 Manual Revisions
Date of Revision
September 15th, 2011
Description of Revision
New Flip Sheave Design Implemented. Updated Extention
Boom, Mast, Cable & Hook Assembly Drawings.
Section Revised
Chapter 2: Installation
Chapter 3: Assembly
Drawings
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 service@stellarindustries.com
Order Parts parts@stellarindustries.com
Warranty Information warranty@stellarindustries.com
Table of Contents
Table of Contents
Chapter 1 - Specifications ......................................................................1
Capacity Chart - Decal PN 54496....................................................2
Chapter 2 - Installation ...........................................................................3
Installation Overview ..........................................................................4
Control Kit - PN 52870 .........................................................................5
Control Kit (Non-Boost) - PN 58291 ...................................................6
Hydraulic Kit - PN 52264 .....................................................................7
Valve Bank - PN 52265........................................................................8
Hydraulic Installation ..........................................................................9
Winch Case Drain Installation .........................................................10
Hydraulic System...............................................................................11
Stability Procedure............................................................................12
Decal Kit Placement - PN 54762 .....................................................13
Chapter 3 - Assembly Drawings ..........................................................15
Base Assembly - PN 18027 ...............................................................15
Mast Assembly - PN 52488 ...............................................................16
Main Boom - PN 52869 .....................................................................17
Extension Boom Assembly - PN 61817 ............................................18
Extension Boom Assembly - PN 61817 (Expanded) ......................19
Main Cylinder Assembly - PN 43839 ...............................................20
Extension Cylinder Assembly - PN 28856 ........................................21
Cable & Hook Assembly - PN 55898...............................................22
CDT™ Radio Transmitter Assembly - PN 56647..............................23
Chapter 4 - Replacement Parts ...........................................................25
 10628 Owner’s Manual
Specifications
Chapter 1 - Specifications
Model 10628 Crane
SPECIFICATION SHEET
Crane Rating: 60,000 ft-lbs (8.29 TM)
Standard Boom Length: 12’ 6” (3.81 m) from CL of Crane
Boom Extension: 1st stage: Hydraulic 96" (243.8 cm)
2nd stage: Hydraulic 96" (243.8 cm)
Maximum Horizontal Reach: 28’ 6” (8.69 m) from CL of Crane
Maximum Vertical Lift: 30’ 4” (9.24 m)
(from crane base)
Boom Elevation: -5 to +80 degrees
Stowed Height: 35” (88.9 cm)
(crane only)
Mounting Space Required: 20” x 21” (50.8 x 53.3 cm)
Approximate Crane Weight: 2900 lbs (1315 kg)
Controls: Radio control standard for all functions.
Winch Specifications
Rope Diameter: 7/16" (1.11 cm)
Line pull speed: 60 ft/min (18.29 m/min)
Max. single part line: 5000 lbs (2268 kg)
Max. double part line: 10,000 lbs (4535 kg)
Rotation: 400 degree power
(worm gear)
Lifting Capacities: 4875 lbs @ 12’ 6” (2210 kg @ 3.81 m)
2950 lbs @ 20’6” (1335 kg @ 6.25 m)
2115 lbs @ 28’ 6” (960 kg @ 8.69 m)
Power Supply Required: PTO & Pump
(8 gpm @ 3000 psi)
(30.3 lpm @ 207 bar)
*Subject to change without notification
10628 Owner’s Manual
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
Maximum 1 - part line capacity is
5000lbs (2270kg). For greater
loads, use 2 - part line.
PN 54496
Reach in Feet/Meters
Capacity in Pounds/Kilograms
15º
30º
80º
75º
60º
45º
10000 lbs
4535 kg
10000 lbs
4535 kg 10000 lbs
4535 kg
10000 lbs
4535 kg
8760 lbs
3975 kg
6735 lbs
3055 kg
7945 lbs
3600 kg
5425 lbs
2460 kg
6400 lbs
2900 kg
4980 lbs
2260 kg
5875 lbs
2660 kg
4875 lbs
2210 kg
5750 lbs
2605 kg
2950 lbs
1335 kg
3480 lbs
1575 kg
2115 lbs
960 kg
2495 lbs
1130 kg
7405 lbs
3355 kg
8735 lbs
3960 kg
4040 lbs
1830 kg
4765 lbs
2160 kg
2970 lbs
1345 kg
3505 lbs
1585 kg
2410 lbs
1095 kg
2840 lbs
1285 kg
2170 lbs
985 kg
2560 lbs
1160 kg
3035 lbs
1375 kg
3580 lbs
1620 kg
3335 lbs
1510 kg
3935 lbs
1780 kg
4120 lbs
1870 kg
4860 lbs
2205 kg
5530 lbs
2505 kg
6525 lbs
2955 kg
9950 lbs
4515kg
10000 lbs
4535 kg
10000 lbs
4535 kg
0'
0 m
3'
.914m
6'
1.83 m
9'
2.74 m
12'6”
3.81 m
28'6”
8.69 m
20'6”
6.25 m
12'
3.66 m
3'
.914
6'
1.83 m
9'
2.74 m
15'
4.57 m
18'
5.49 m
21'
6.40 m
24'
7.01 m
27'
8.23 m
30' 4”
9.25 m
Boost
(If Equipped)
Standard
Capacity Chart - Decal PN 54496
Installation
Chapter 2 - Installation
General Installation
This chapter is designed to serve as a
general guide for the installation of a Stellar
10628 Telescopic 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 (800) 321 3741.
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:
PTO and Pump installation instructions are
provided by the corresponding
manufacturers. For more information on
which PTO and Pump fit your application,
please contact your local Stellar Distributor
or Stellar Customer Service.
Installation Notice
According to Federal Law (49 cfr part 571),
each final-stage manufacturer shall
complete the vehicle in such a manner that
it conforms to the standards in effect on the
date of manufacture of the incomplete
vehicle, the date of final completion, or a
date between those two dates. This
requirement shall, however, be superseded
by any conflicting provisions of a standard
that applies by its terms to vehicles
manufactured in two or more stages.
Therefore, the installer of Stellar cranes and
bodies is considered one of the
manufacturers of the vehicle. As such a
manufacturer, the installer is responsible for
compliance with all applicable federal and
state regulations. They are required to
certify that the vehicle is in compliance with
the Federal Motor Vehicle Safety Standards
and other regulations issued under the
National Traffic and Motor Vehicle Safety
Act.
Please reference the Code of Federal
Regulations, title 49 - Transportation, Volume
5 (400-999), for further information, or visit
http://www.gpoaccess.gov/nara/index.html
for the full text of Code of Federal
Regulations.
Notice: Read this Page Before Installation of the Crane
Important: 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.
10628 Owner’s Manual
1
2
NOTE:
STABILITY DECAL P/N 16881
IS PART OF THIS KIT
2.38
6.88
7.38
7.38
6.00
.YTQNOITPIRCSEDTRAPMETI
1 5199 CAP SCR 1.00X8X3.00 HHGR8 ZY6
2 6538 WASHER 1.00 SAE FLAT YELLOW GR86
Front Motor
14.75
PN 13539
13.75
14.75
1.063
6 Places
WARNING!
The use of this crane on a
body not capable of handling
the loads imposed on it may
result in serious injury or
death.
Installation Overview
1. Determine that the mounting location for the 10628 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 10628 weighs
approximately 2900 lbs (1315 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 10628.
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 10628 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 Chapter 8 - Hydraulics - Electrical.
Note: If questions should arise during any portion of this installation, please contact Stellar Customer
Service at (800) 321-3741.
Installation
PN 52870
Control Kit - PN 52870
10628 Owner’s Manual
PN 58291
Control Kit (Non-Boost) - PN 58291
Installation
NOTE: USE 32" OF HOSE PROTECTOR
P/N 17288 OVER THE ROTATION HOSES
NOTE: USE 12" OF HOSE PROTECTOR
P/N 17288 OVER THE 3 WINCH HOSES
PN 52264
Hydraulic Kit - PN 52264
10628 Owner’s Manual
Valve Bank - PN 52265
Installation
Hydraulic Installation
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
 10628 Owner’s Manual
Winch Case Drain Installation
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)
Installation 
Hydraulic System
 10628 Owner’s Manual
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 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
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 avail-
able.
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.
10628 Stability Data
Max Horizontal Reach: 342” (From the center of
rotation to boom tip)
Boost Stability Test Weight: 2945 lbs.
Non-Boost Stability Test Weight: 2495 lbs.
Stability Procedure
Installation 
Decal Kit Placement - PN 54762
PN 54762 *USE THESE DECALS WITH BODY PACKAGE
**THESE DECALS NOT INCLUDED WITH THE DECAL KIT
1
2
®®
10628
ITEM
01
*04
02
*03
*05
*06
09
*07
*08
*10
*11
*12
*13
15
14
DECAL HOISTING PERSONNEL
DECAL STELLAR LOGO 6.5 x 18
DESCRIPTION
PART No.
52681
PART No.ITEM
QTY
*16
2
12451
DESCRIPTION QTY
1
DECAL ASME/ANSI B30.22/B30.5
DECAL GREASE WORM DRIVE BEARINGS
DECAL-ROTATION ALIGNMENT
C4545 DECAL-ELECTROCUTION 5x13
DECAL CAPACITY
DECAL 10628 IDENTIFICATION52687
54496
DECAL-DANGER
DECAL-DANGERC4540
C4544
DECAL MANUAL EXT12452
4
*19
*17
2
C5910
*18
2
C5911
DECAL-STELLAR 4x9.5
DECAL-STELLAR 2x4.5
C0568
1
*20
*21
1
4214
DECAL-DIESEL
DECAL-SERVICE
9188 DECAL-ROTATE/ GR EA SE
DECAL-DANGER
DECAL-ELECTROCUTION 2x2.754186
4189
DECAL-DANGER
DECAL-DANGER O.R.
4190
C4795
4188
1
24
22
1
12300
*23
1
C4541
DECAL-TWO BLOCKING
DECAL-CRANE STOWING
15171
1
25
26
2
15172
1
1
3
2
1
1
1
1
1
1
DECAL VB CONTROL MECH CRANE
DECAL STELLAR MADE IN THE USA
DECAL SNATCH BLOCK CAP 7 TON
DECAL WARNING OVERLOAD DEVICE
DECAL CAUTION STOW HOOK
52270
31
DECAL-ELECTROCUTION 4.5x7.5
DECAL-DANGER MOVING O.R.C5918
C1179
DECAL-ANGLE INDICATOR SS
DECAL ANGLE INDICATOR CS
D1197
D1196
27
2
24712
28
2
28256
35234
30**
1
29
1
56405
1
1
1
1
1
32 25159 DECAL WARNING MANUAL OVERRIDES 1
3
26
14,15
27
22
29
28
30
25
9
60
50
0
20
30
10
40
Angle Indicator
80
70
33
33 54588 DECAL CDT 2.00X2.00 2
 10628 Owner’s Manual
Assembly Drawings 
10
8
7
1
6
2
3
4
9
GASKET SHOWN AS REFERENCE
14
12
10
11
5
.YTQNOITPIRCSEDTRAPMETI
1 11453 BEARING SWING DRIVE CAST BASE 66201
1EDILS 004 0283 POTS245112
3C6069 MOTOR HYD ROSS MK080613AAAB1
4D1307 CAP SCR 0.50-13X1.25 SH2
5 44551PC GUARD TTB 6620 CRANE LZR1
6 13959 CAP SCR 1.00-8 X .63 PLASTIC2
2TALF 52.0 REHSAW04307
8 0479 CAP SCR 0.25-20X0.75 HHGR52
9 21151GASKET MOTOR 008-10056-11
10 D1345 FTG CPRSN 0.12NPT/0.25 TUBE2
11 D1810 TBE AIR SAEJ844 TYPE A .25 (RM)1
131.0 EPIP RELPUOC GTF6522C21
28RG TALF 05.0 REHSAW0970D31
14 56589 ZERK 1/8 NPT STRAIGHT LONG THREAD 1
PN 18027
Base Assembly - PN 18027
Chapter 3 - Assembly Drawings
 10628 Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI
112621/12601 TSAM384341
227813 COLLAR 0.38X0.75X0.38 UHMW2
3C5902 WASHER 0.63 SAE FLAT YELLOW GR818
4D1034 CAP SCR 0.63-11X3.00 HHGR8 RED PATCH14
5 0343 WASHER 0.31 USS FLAT ZINC4
6C0933 CAP SCR 0.31-18X4.50 HHGR52
7 0342 NUT 0.31-18 HHGR5 NYLOC 2
844533BUSHING HSG3235012S 2.00X0.75 4
9 11693 CAP SCR 0.63-11X1.75 HHGR8 4
10 52490 CAP SCR 6MMX30MM HH 8.8(GR5)4
11 57917 WINCH 5000 TH2CC00243 W/100 FT ROPE 1
12 52265 VB 4 SECT W/PROP STER8GPM DEUTSCH1
PN 52488
DO NOT GREASE
THESE BUSHINGS
12
1
3
4
11
3
9
75
2
5
6
8
10
Mast Assembly - PN 52488
Assembly Drawings 
6WASHER 0.38 SAE FLAT YELLOW GR8C635314
2NUT 0.50-13 HHGR5 NYLOCC610613
16WASHER 0.50 SAE FLAT YELLOW GR8D079012
8CAP SCR 0.50-13X1.25 HHGR81066611
2PIN CAP 0.44X1.75X0.19 SS932010
6PIN CAP 0.56X2.50X0.1991429
.YTQNOITPIRCSEDTRAPMETI
1 43481INNER BOOM 10628/126281
2 43839 CYLINDER ASM 5.50X21.38 1
2T&D 91.01X00.2 NIPPZ90793
4 27720 SPACER ROPE GUIDE 6620 UHMW2
5 13395WEAR PAD 3.00X3.00X1.00 NYLATRON 2
18275 LEER DROC661916
288.2X88.2X52.0 LA ETALP154537
1THGIARTS TPN 8/1 KREZ2951c8
.YTQNOITPIRCSEDTRAPMETI
15 9843 CAP SCR 0.38-16X0.75 HHGR82
16 10172 CAP SCR 0.50-13X1.00 HHGR84
17 0347 NUT 0.38-16 HHGR5 NYLOC 4
18 0335 CAP SCR 0.38-16X1.25 HHGR52
19 12168 CAP SCR 0.38-16X9.00 HHGR52
20 4381BUSHING BPC32DXR32 2.00X2.004
21 0340 WASHER 0.25 USS FLAT ZINC2
22 0478 CAP SCR 0.25-20X0.50 HHGR51
23 0068BUSHING BPC16DXR24 1.00X1.502
24 D1194PC PLATE ANGLE INDICATOR 2
10269 EDIUG EPOR TKRBCP5343152
26 13398PC PLATE WEAR PAD SUPPORT 96202
1GED 06 RETEMONILCNI3943572
28 18765WASHER #6 SAE FLAT ZINC 2
2SS COLYN HH 23-6# TUN6700D92
30 18618 SCREW #6-32X1.00 PHMS PH2
1T&D 88.8X00.2 NIPPZ117913
1T&D 83.8X00.1 NIPPZ217923
1LYNIV KLB 52.0 PMALC6065C33
34 0480 CAP SCR 0.25-20X1.00 HHGR51
33
5
26
12
11
12
24 12
13
20
16
12
9
9
12
16
31
2
9
915
14
10
32
30
23
9
12
16
9
12
16
15
14
20
10
19
25
4
17
18
17
34
22
6
21
1
7
8
3
3
23
27 28
29
14
NOTE: INCLINOMETER MOUNTS
INSIDE THE BOOM. VIEW SHOWS
POSITION OF INCLINOMETER
PN 52869
Main Boom - PN 52869
 10628 Owner’s Manual
PN 61817
See Next Page for
Expanded View.
.YTQNOITPIRCSEDTRAPMETI
1TS1 82601 MOOB TXE777431
2 61816 EXT BOOM 2ND 10628/12628 FS/CRADLE A2B1
3 28856CYLINDER EXT ASM 5728 16920P1
4 9991 WEAR PAD 0.19X2.50 RND NYLATRON4
183.4X00.1 PORD RAET NIPPZ004315
6 27719SPACER BOOM TIP 6620 UHMW2
7 43858 SHEAVE 10621 9.25 DIA .44R/1.88THK 2
2HCNYL 65.1X91.0 NIP35758
9 13396WEAR PAD 2.50X2.50X1.00 NYLATRON 2
10 13397PC PLATE 1ST EXT 9620 WEAR PAD 2
283.2X83.2X52.0 LA ETALP2545311
12 61050 PLATE SHEAVE MOUNTING FS/CRADLE 106/1262
105.4X00.1 HCTIH NIP4282131
14 61051 MNT CRADLE LH FS/CRADLE A2B 106/1261
15 61048 CRADLE FS/CRADLE A2B 106/1261
16 61049 LINK FS/CRADLE A2B 106/126 W/HOLES1
17 35105 SWITCH LIMIT E1117-B9111-6C1
18 61054 MNT CRADLE RH FS/CRADLE A2B 106/1261
1621/601 B2A ELDARC/SF KNIL8395691
1RS 91.4X00.1 NIPPZ0867302
21 27710SPRING ANTI 2 BLOCK CRADLE A2B 2
2LYNIV KLB 83.0 PMALC8700C22
1LYNIV KLB 13.0 PMALC9721332
24 C6353 WASHER 0.38 SAE FLAT YELLOW GR86
25 C6219 WASHER 0.75 SAE FLAT YELLOW GR81
26 D0790 WASHER 0.50 SAE FLAT YELLOW GR818
2CNIZ TALF SSU 13.0 REHSAW343072
2CNIZ TALF SSU 52.0 REHSAW043082
2CNIZ TALF EAS 01# REHSAW8710D92
30 0867 MACHY WASHER 1.00ID 14GA2
31 58681 CAP SCR 0.75-10X2.50 HHGR81
32 10666 CAP SCR 0.50-13X1.25 HHGR88
33 0490 CAP SCR 0.31-18X3.50 HHGR52
34 0420 CAP SCR 0.31-18X0.75 HHGR5 1
35 0478 CAP SCR 0.25-20X0.50 HHGR52
36 0484 CAP SCR 0.31-18X0.50 HHGR51
37 C1000 CAP SCR 0.50-13X5.00 HHGR52
38 C1002 CAP SCR 0.50-13X6.00 HHGR51
39 9843 CAP SCR 0.38-16X0.75 HHGR82
40 0489 CAP SCR 0.31-18X2.50 HHGR51
3COLYN 5RGHH 81-13.0 TUN243014
3COLYN 5RGHH 31-05.0 TUN6016C24
43 31132 CAP SCR #10-24X0.550 SH SS 18-82
44 61053 BOLT SHOULDER 0.38X0.50 0.31-18X0.504
252.X05.3X65.0 PAC NIP023954
104HCS 31.3 X05.0 EPIPCP8451664
47 61549COLLAR 1.13X2.00X1.13 W/HOLE 1
1CCPK KROF 00.1 HCTIH NIP5215484
4
37
43
5
7
27
45 30
22
41
32
2
6
8
26
10
9
1
31 25
33
3
15
24
38
11
12
39
8
29
20
4
26
42
45
24
39
34
16
44 35
24
28
18
12
17
14
46
41
40
47
48
13
26
19
Extension Boom Assembly - PN 61817
Assembly Drawings 
PN 61817
See Parts Breakdown
on Previous Page.
Assembled View
48
46
24
13
8
30
39
7
43
12
22
28
6
35
12
44
18
24
27
34
5
8
41
16
45
20 45
24
39
14
29
17
42
26
36
27 23
21
33
37
38
26
42
26
47
41
40
26
19
Extension Boom Assembly - PN 61817 (Expanded)
 10628 Owner’s Manual
2
4
2
3
2
2
3
1
.YTQNOITPIRCSEDTRAPMETI
1 43838 CYLINDER 5.50X21.38 1
2 0279 FTG ADAPT 6-F5OLO-S 4
344066TUBE ASM 0.38X8.25 MAIN 10628/126282
441910MANIFOLD ASM DUAL 10-1CBAL-RLF-CHK1
PN 43839
Cylinder
Serial Tag
Location
Manifold Assembly
PN 41910
2
3
5
4
1
4
.YTQNOITPIRCSEDTRAPMETI
1 39425 MANIFOLD CBAL DOUBLE T11A WITH RELIEF1
1NCX-DEXC KCEHC EVLAV809142
1ISP 008 NAL-ADDR EVLAV709143
4 9803 Valve C- SUN CBBD-LJN-35002
5C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON1
Main Cylinder Assembly - PN 43839
Note: Main Cylinder uses
Stellar Seal Kit P/N 35646
Assembly Drawings 
5
4
3
2
6
7
7 1
.YTQNOITPIRCSEDTRAPMETI
TXE REDNILYCP0296111DETNIAP 02961
1NVX-NJL-DBBC TXE 0266 MSA DLOFINAM511412
1CZ HS 52.2X61-83.0 RCS PAC106413
2CZ HS 57.1X61-83.0 RCS PAC288114
18263 LYC TXE GNOL X 83.0 MSA EBUT682715
18275 LYC TXE TROHS X 83.0 MSA EBUT582716
257.3 - 00.3 25# PMALC ESOH927427
P/N 28856
Cylinder
Serial Tag
Location
Extension Cylinder Assembly - PN 28856
Note: Upper/Lower
Extension Cylinder uses
Stellar Seal Kit P/N C6304
 10628 Owner’s Manual
26.50
.YTQNOITPIRCSEDTRAPMETI
1 43858 SHEAVE 10621 9.25 DIA .44R/1.88THK1
2 53263PC PLATE SNATCH BLOCK 76/96/106/1262
1RETTOC 60.4X00.1 NIPPZ478933
200.2X57.0X44.0 RALLOC346444
5 0347 NUT 0.38-16 HHGR5 NYLOC 2
6C0538 NUT 0.75-10 HHGR8 NYLOC 1
7 0532 CAP SCR 0.38-16X3.75 HHGR52
8 5841 CAP SCR 0.75-10X4.50 HHGR8 1
9C6219 WASHER 0.75 SAE FLAT YELLOW GR82
10 0867 MACHY WASHER 1.00ID 14GA2
1SS KOOH V GNIHSUBPZ4489311
2HCNYL 65.1X91.0 NIP357521
13 26762 HOOK 7 TON SWIVEL CROSBY 10286321
14 13436 PIN .38X4.00 QUICK RELEASE 1
PN 55898
3
12
6
9
1
4
4
11
2
2
7
7
13
2
9
8
14
12
10
5
10
Cable & Hook Assembly - PN 55898
Assembly Drawings 
PN 56647
.YTQNOITPIRCSEDTRAPMETI
1 20088 CONTROL HANDLE HOUSING 4 FCTN HET1
2 56657 CONTROL HANDLE FACE PLT W/LABEL 6 FCTN CDT 1
1NTCF 4 HCTIWS OIDAR DRAUG583423
4 35447 CONTROL HANDLE GRIP W/TRIGGER HT H21
524958RUBBER BOOT TRIGGER GUARD HET1
6 22600 SWITCH TOGGLE HET RADIO 630193006
7 35441 BATTERY TUBE AA HETRONIC RADIO1
1LX AVON POTS E HCTIWS658748
3
SEE NOTE
7
5
4
1
2
8
6
NOTE: 1) P/N'S 25999 & 24958 ARE OPTIONAL COVERS
FOR THE SWITCHES AND TRIGGER
CDT™ Radio Transmitter Assembly - PN 56647
 10628 Owner’s Manual
Replacement Parts 
Chapter 4 - Replacement Parts
PAR T# DESCRIPTION
C6069 HYDRAULIC SWING MOTOR
25367 RELIEF VALVE
25368 SEAL KIT - RELIEF VALVE
24960 FLOW CONTROL VALVE
25369 SEAL KIT - FLOW CONTROL VALVE
25371 SOLENOID VALVE TAND G04571
25373 SEAL KIT - SOLENOID VALVE
44532 COIL - 12VDC
41910 MANIFOLD ASM - MAIN CYLINDER
9803 C-BALANCE VALVE
41907 RELIEF VALVE - CYLINDER MANIFOLD
41908 CHECK VALVE
14115 MANIFOLD ASM - EXTENSION CYLINDER
14390 O'RING - MANIFOLD ASM EXT. CYLINDER
44534 PRESSURE SWITCH
6397 HYD PRESSURE GUAGE
C2027 O'RING - # 4 FACE SEAL
C2028 O'RING - # 6 FACE SEAL
C2029 O'RING - # 8 FACE SEAL
D1245 O'RING - # 4 SAE
D1246 O'RING - # 6 SAE
D1247 O'RING - # 8 SAE
25895 WORM GEAR - BEARING SWING DRIVE
25896 BEARING & SEAL KIT - BEARING SWING DRIVE
35646 SEAL KIT (MAIN LIFT CYLINDER)
C6304 SEAL KIT (EXTENSION CYLINDER)
44066 TUBE ASM - MAIN CYLINDER
14442 TUBE ASM - EXTENSION CYLINDER
14443 TUBE ASM - EXTENSION CYLINDER
4380 BUSHING 2.00"x 1.50"
4381 BUSHING 2.00"x 2.00"
0068 BUSHING
44533 BUSHING 2.00" x 0.75"
9991 WEAR PAD 2.50" ROUND
13395 WEAR PAD 3.00"X3.00"X1.00"
13396 WEAR PAD 2.50"X2.50""X1.00"
8377 PIN CAP .56 X 3.50 X .25
7403 PIN CAP .44 X 2.50 X .25
D0790 WASHER 0.50 FLAT GR8
10172 CAP SCR. 0.50-13 X 1.00"
43858 SHEAVE
43857 WIRE ROPE
12824 HITCH PIN 1.00" X 4.50"
13436 QUICK RELEASE PIN .38 X 4.00"
5753 LYNCH PIN
53493 INCLINOMETER 60 DEGREE
11938 LIMIT SWITCH
31670 WEIGHT & CHAIN ASSY - ANTI-2-BLOCK
35105 LIMIT SWITCH - ANTI-2-BLOCK (CRADLE/BASKET STYLE)
43488PC CRADLE PLATE - ANTI-2-BLOCK (CRADLE/BASKET STYLE)
61048 CRADLE FS/CRADLE A2B (After 8/1/2011)
27710 SPRING - LIMIT SWITCH ANTI-2-BLOCK (CRADLE/BASKET STYLE)
43488PC CRADLE PLATE - ANTI-2-BLOCK (CRADLE/BASKET STYLE)
19166 CORD REEL
56647 RADIO TRANSMITTER (HETRONIC RADIO)
35441 BATTERY TUBE (AA) HOLDER (HETRONIC RADIO)
47856 E-STOP SWITCH (HETRONIC RADIO)
22600 TOGGLE SWITCH (HETRONIC RADIO)
35447 HANDLE / TRIGGER ASM (HETRONIC RADIO)
35916 BACK UP CABLE CONTROL - HETRONIC RADIO SYSTEM
26762 HOOK 7-TON
38676 7-TON HOOK SAFETY LATCH ASM.
C1592 GREASE ZERK
4460 GEAR BEARING GREASE - MOLUBE (Open Teeth)
Limited Warranty Statement
Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under
proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. This warranty
shall cover the following:
Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, and Stellar X-Tra-Lift Systems:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date
ofmanufacture,
Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of
manufacture, and
Thirty-six (36) month warranty on all Stellar Manufactured structural parts from the date recorded by Stellar as the in-service date, not to extend beyond
forty-eight (48) months from date of manufacture.
Stellar Tarper Systems:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date
of manufacture and
Three (3) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond fifteen (15) month from date of
manufacture.
The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, the
factory ship date will be used.
Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option)
of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-
applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24-hours of notification by
the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.
Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service
personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party
prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged parts
must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of
the warranty claim.
Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type
of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence
of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any
field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service
provider.
All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides
other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellar-manufactured
product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any
way not approved, in writing, by Stellar.
The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the
ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the
product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in
question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear,
accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and maintenance
duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such
duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.
The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above.
In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of delay, or for any
special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use,
wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.
All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not
participate in, or obligate itself to, any such warranty.
Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products
theretofore manufactured.
This warranty will apply to all Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, Stellar X-Tra-Lift
Systems, and Stellar Tarper Systems shipped from Stellar’s factory after January 1st, 2010. The warranty is for the use of the original owner only and is not
transferable without prior written permission from Stellar.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR
INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Revision Date: February 2010 Document Number: 37040

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