MODEL 9000

ARTICULATING CRANE
OWNERS MANUAL
Safety Operation Maintenance Installation Parts

Stellar Industries, Inc.

190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Subject to Change without Notification.
Fax: 641-923-2811
2013 Stellar Industries, Inc. www.stellarindustries.com Last Revision: 08/19/13
 9000 Manual Revisions
Date of Revision Section Revised Description of Revision

October 22, 2008 Chapter 8: Updated Hydraulic Kit Versions to reflect engineering
Hydraulics - Electrical changes (New Pressure Switch).
Chapter 9:
Replacement Parts

January 15, 2009 Chapter 7:

Assembly Drawings Updated Base Assembly Drawing, Control Kit, and
Chapter 8: Replacement Parts to reflect engineering changes
Hydraulics - Electrical (Hetronic Remote).
Chapter 9:
Replacement Parts

July 1, 2012 All Sections. Updated Assembly Drawings, Installation Drawings,

Maintenance, Specifications, and Replacement Parts to
reflect engineering changes (New crane style).

December 10, 2012 Chapter 7: Updated Stabilizer Assembly, Control Kit and Hydraulic Kit
Assembly Drawings (Engineering changes).
Chapter 8:
Hydraulics - Electrical
Table of Contents
Table of Contents i

Introduction ..........................................................................................ii
Chapter 1 - Safety....................................................................................1
Chapter 2 - Operation.............................................................................3
Unit Operation Overview....................................................................3
Crane Operation (Fully Proportional Version) ..................................4
Manual Operation ..............................................................................4
Radio Remote Operation...................................................................4
Hook Precautions ................................................................................5
Crane Transport ...................................................................................5
Crane Precautions ..............................................................................5
Operator Information..........................................................................6
Chapter 3 - Maintenance .......................................................................7
Holding Valve Inspection Procedure ................................................9
Lubrication Recommendations .........................................................9
Grease Line Kit - PN 61641................................................................10
Torque Data Chart ............................................................................11
Gear-Bearing Bolt Maintenance .....................................................11
Chapter 4 - Specifications ....................................................................13
Capacity Chart - Decal PN 64835 ..................................................14
Chapter 5 - Decals ................................................................................15
Decals of Note...................................................................................15
Decal Kit Placement Kit 30488.........................................................18
Chapter 6 - Installation..........................................................................19
General Installation ...........................................................................19
Install Kit - PN 61405 ...........................................................................20
Chapter 7 - Assembly Drawings...........................................................21
Base Assembly - PN 61090 ................................................................21
Base Assembly Rear Mount Australia Stop - PN 67400 .................22
Stabilizer Assembly - PN 61089 .........................................................23
Mast Assembly - PN 29350................................................................24
Mast Cylinder Assembly - PN 29352 ................................................25
Main Boom Assembly - PN 29354 ....................................................26
Main Boom Cylinder Assembly - PN 29356.....................................27
Extension Boom Assembly - PN 61204 .............................................28
Extension Boom Cylinder Assembly - PN 61219 .............................29
Reservoir Assembly - PN 61201.........................................................30
Chapter 8 - Hydraulics - Electrical.......................................................31
Control Kit - PN 61546........................................................................32
Control Kit 434MHz - PN 67402 .........................................................33
Hydraulic Kit - PN 61547 ....................................................................34
Chapter 9 - Replacement Parts............................................................35
Chapter 10 - Troubleshooting ...............................................................37
BMS-2 Receiver Troubleshooting .....................................................39
ii 9000 Owners Manual
Introduction
Stellar Cranes 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 shall remain with the crane at all
times. Information contained within this
manual does not cover all maintenance,
operating, or repair instructions pertinent to
all possible situations.
Please be aware that some sections of this
manual contain information pertaining to
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
Order Parts
Warranty Information
Stellar manufactured cranes in general and
may or may not apply to your specific
model.
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 service@stellarindustries.com.
ATTENTION
Failure to adhere to the
instructions could result in
property damage or even serious
bodily injury to the operator or
others close to the crane.
service@stellarindustries.com
parts@stellarindustries.com
warranty@stellarindustries.com

Chapter 1 - Safety
Please Read the Following Carefully! This portion of
the manual contains information regarding all
Stellar manufactured cranes. Some items
contained within this chapter may not apply to your
specific equipment.
Safety should be the number one thought on every
operators mind. Three factors should exist for safe
operation: a qualified operator, well-maintained
equipment, and the proper use of this equipment.
The following information should be read and
understood completely by everyone working with
or near the crane before putting the unit into
operation.
Please take note that Stellar Industries, Inc. is not
liable for accidents incurred by the crane because
of non-fulfillment from the operators side of current
rules, laws, and regulations.
GENERAL
It is the responsibility of the owner to instruct the
operator in the safe operation of your equipment
and to provide the operator with properly
maintained equipment.
Trainees or untrained persons shall be under the
direct supervision of qualified persons.
Do not operate equipment under the adverse
influence of alcohol, drugs, or medication.
PERSONAL SAFETY
Keep clear of all moving parts.
Always wear the prescribed personal safety devices.
Always wear approved accident-prevention clothing
such as: protective helmets, anti-slip shoes with steel
toes, protective gloves, anti-noise headphones,
protective glasses, and reflective jackets with
breathing apparatus. Consult your employer
regarding current safety regulations and accident-
prevention equipment.
Do not wear rings, wristwatch, jewelry, loose-fitting or
hanging clothing such as ties, torn garments, scarves,
unbuttoned jackets or unzipped overalls, which could
get caught up in the moving parts of the crane.
Keep a first-aid box and a fire extinguisher readily
available on the truck. Regularly check to make sure
the fire extinguisher is fully charged and the first-aid
kit is stocked.
Safety 1
Do not use controls and hoses as handholds. These
parts move and cannot provide stable support.
Never allow anyone to ride the crane hook or load.
MAINTENANCE SAFETY
Never modify or alter any of the equipment, whether
mechanical, electrical, or hydraulic, without explicit
approval from Stellar Industries.
Do not perform any maintenance or repair work on
the crane unless authorized and trained to do so.
Release system pressure before attempting to make
any adjustments or repairs.
Do not attempt service or repair when the PTO is
engaged.
Failure to correctly plumb and wire the crane can
cause a malfunction and damage to the crane
and/or operator.
Decals are considered safety equipment. They must
be maintained, as would other safety devices. Do
not remove any Decals. Replace any Decals that
are missing, damaged, or not legible.
The safety instruction plates, notices, load charts and
any other sticker applied to the crane or service
body must be kept legible and in good condition. If
necessary, replace them.
STABILITY
Know the crane components and their capabilities
and limitations. Overloading the crane may result in
serious injury to self and others, and damage to the
equipment and immediate surroundings.
Never exceed manufacturers load ratings. These
ratings are based on the machines hydraulic,
mechanical, and structural design rather than
stability.
The supporting surface under the service truck must
be able to support the weight of the machine and its
load. Use stabilizer pads if necessary.
Park the vehicle on level ground and extend the
stabilizers fully out and then down.
Keep feet and legs clear when lowering stabilizer
jacks.
Never operate the crane without making sure the
stabilizers are positioned on stable, flat ground.
2 9000 Owners Manual

Crane Controls
Set the parking brake and disengage the drive axle
before attempting a lift.
1. Be familiar with the sequence and operation of
LOAD SAFETY
the crane controls.
Operate the crane in compliance with the load
capacity chart at all times. Know the weight of the
2. Each individual crane function should have
load being lifted. Do not rely on the overload device
control function decals. Replace them
to determine maximum rated loads.
immediately if they are missing or illegible.
Never use a sling bar or anything larger than the
3. Keep hands, feet and control levers free from
hook throat that could prevent the hook latch from
mud, grease and oil.
closing. This would negate the safety feature.
4. Be familiar with the remote control and how it
Do not apply side loads to the booms.
operates before attempting to lift a load.
Do not leave a crane load suspended or
unattended.
5. Be prepared before beginning operation of the
crane:
Do not walk under suspended loads.
All protective guards must be in place.
Be aware of the surroundings: low branches,
Do not position any load over a person nor should
power lines, unstable ground.
any person be permitted to place him or herself
Be sure all safety devices provided are in
under a load.
place and in good operating condition.
Be prepared for all situations. Keep fire
Do not use the boom or the winch to drag a load.
extinguisher and first aid kit near.
Be sure all regular maintenance has been
Do not use the crane boom to push downward onto
performed.
anything.
Visually inspect all aspects of the crane for
physical damage.
ELECTROCUTION
Check for fluid leaks.
Allow extra space for swaying power lines in windy
Make sure the stabilizers are down and stable.
conditions.

Keep a minimum of ten feet between any portion of

the crane and an electrical line. Add an additional
12" for every additional 30,000 Volts or less.
Remember - Death or serious injury can occur when
working near power lines or during electrical storms.
Use a signal person when operating near electrical
sources.
ATTENTION
Stellar Industries, Inc. is not liable for
accidents incurred by the crane
because of the operators non-fulfillment
of current rules, laws and regulations

ENVIRONMENT
Do not operate the crane during electrical storms.

In extreme cold, allow adequate time to warm the

truck before engaging the PTO. Do not rev the truck
engine and over speed the hydraulic pumps as
permanent damage to the pumps may occur.
Follow the vehicle owners manual regarding
operating the vehicle in such adverse conditions.

In dusty work areas, every effort must be taken to

keep dust and sand out of the moving parts of the
machinery.

In high humidity work areas, keep parts as dry as

possible and well lubricated.

Chapter 2 - Operation
This chapter contains information regarding the
operation of Stellar manufactured articulating
cranes. Please study the following pages to ensure
your familiarity with the operation process. This
understanding is vital to the safe and efficient
operation of the crane.
Job-Site Set-Up
Thoroughly plan the lift before positioning the vehicle.
Consider the following:
1. The vehicle should be positioned in an area free
from overhead obstructions to eliminate the need
for repositioning.
2. Position the vehicle so that it is impossible for any
portion of the equipment to come within the
minimum required safe distance of any power line.
Maintain a clearance of at least 10 feet between
any part of the crane, load line, or load, and any
electrical line or apparatus carrying up to 50,000
volts. One foot additional clearance is required for
every additional 30,000 volts or less. Remember to
allow for winds that cause power lines to sway. It is
recommended that a signal person be used when
the vehicle is set-up near power lines.
3. The vehicle should also be positioned on a firm
and level surface that will provide adequate
support for the stabilizer loading. Use extreme
caution when setting up near overhanging banks
or excavations.
4. The parking brake must be set on the vehicle and
the drive axle disengaged before performing a
crane operation.
5. The stabilizers must be extended to stabilize the
truck before beginning operation.
NOTICE
The parking brake must be fully engaged
in order to operate any Stellar
Equipment.
Unit Operation Overview
1. Engage the PTO
2. Turn on Power to Crane
3. Position Stabilizers
4. Operate Crane
5. Store Stabilizers
6. Turn Off Power to Crane
7. Disengage the PTO
Operation 3
1. Engage the PTO
A. Engage the parking brake.
B. Place the transmission in the Neutral position.
C. Make certain the PTO switch is in the off
position.
D. Start the vehicle engine.
E. Depress the clutch on manual transmission
vehicles.
F. Engage the PTO switch for cable and air type
shifters. Turn on the dash switch for electrical
operated style. Consult vehicle owners manual
for location and operation of OEM style in-dash
PTO switch.
G. Slowly release the clutch on a manual
transmission vehicle.
H. Allow a few moments to warm the hydraulic
system oil. In cold weather, it is especially
important to let the system run for a few minutes
before operating.
2. Turn on Power to Crane
Activate power to the crane and stabilizers. The
power switch is located on the control panel in the
vehicle cab.
3. Position Stabilizers
Once the PTO is engaged, extend the stabilizers
using the control levers or switches marked
stabilizer. These may be located on the crane
base or in the compartment under the crane.
4.Operate Crane
A. Turn on necessary power to the crane.
B. Activate toggle switch for desired crane function.
D. Activate the variable speed trigger to control the
desired function.
E. When operation is complete, store remote handle
in a safe, dry location.
5. Store Stabilizers
Retract stabilizers using the control levers or switches
marked stabilizer.
6. Turn Off Power to Crane
Deactivate power to crane and stabilizers.
7. Disengage the PTO
A. On manual transmission vehicles, depress the
clutch pedal completely.
B. Disengage the PTO switch.
C. If vehicle is a manual transmission, release the
clutch pedal gradually.
4 9000 Owners Manual

Crane Operation (Fully Proportional Version)

Radio Remote Operation Manual Operation

The crane is operated by a radio control system

which operates an electronic valve bank. The
controller (as shown above) operates the following
functions:

Main Boom Up and Down
Outer Boom Up and Down
Extension Boom In and Out
Rotation Clockwise and Counter-Clockwise
TireMan Clockwise and Counter-Clockwise
TireMan Pad Clockwise and Counter-Clockwise
TireMan Open and Close
To operate the crane, activate the desired toggle
switch. The crane will not function until the trigger
on the remote handle is activated. The crane
speed will change as the trigger is pulled or
released.
Note: If the crane does not operate, check the
batteries located in the remote handle and
replace if necessary.
In case of radio failure, the crane can be
operated using manual overrides located on the
valve bank.
Valve Manual Override Operation
1. Switch to Manual Operation:
Flip the toggle switch (shown below) up to
Manual
2. Operate Levers on the Valve Bank:
Push or pull levers to operate listed function.
3. Switch Controls Off:
Flip the toggle switch to the middle Off
position.
4. Have Unit Serviced.

Note About Battery Condition

The batteries included with this equipment may be
rechargeable. To keep rechargeable batteries in
optimal working condition, follow these simple
guidelines:

1. Keep battery away from moisture. Store in a

cool, dry location.
2. Do not store or carry battery so that metal
objects can contact exposed metal end. Keep
battery cap on when not in use.
3. The batteries should be recharged when they
fail to produce sufficient power.
4. Never attempt to open the battery for any
reason.
 Operation 5

Crane Precautions Crane Transport

1. Movement of the control levers should be
slow and smooth to meter oil flow for safe
operation. Avoid jerky and sudden
movements.
2. The crane controls should be clearly marked
with decals. If these are missing or
illegible,replace immediately. (See Chapter
5: Decals)
3. Lift load slightly off the ground to check the
safety of the cargo. Do not use stability to
determine the safety. Consult the capacity
charts and strictly adhere to them.
4. Be constantly aware of the boom position
when operating the controls.
5. The boom tip should be centered directly
over the load before making the lift to avoid
swinging.
6. Do not drag loads with the crane.
7. Do not attempt to lift fixed loads.
8. Do not load boom in a sideways direction.
9. Know the weight of the rigging and load to
avoid overloading the crane.
10. Do not extend or rotate a load over
anyone.
11. Wear protective gear such as hard hat,
safety glasses, steel-toed boots, and gloves.
Before transporting the crane, do the following:
1. The crane must be in the stored position.
2. Stabilizers must be securely stowed and not
extended horizontally or vertically.
3. Hook and sheave assemblies must be
securely fastened to prevent swinging.
4. All loose accessories, tools, and remote
controls must be securely stored in their
respective compartments or fasteners.
5. The PTO must be disengaged.
6. The parking brake must not be released
until all of the above procedures are
completed.
7. Do not drive the carrier vehicle while a load
is present on the hook.
8. Do not drive the carrier vehicle with less
than proper tire inflation.
9. Do not drive the carrier vehicle in areas
where the vertical clearance is unknown.
10. Do not allow personnel to ride on the
equipment during transport.

Hook Precautions
1. Hooks are designed and manufactured to lift
specific loads. The specified rated load of a
hook applies to loads held uniformly in direct
tension and does not take into account
shock loads, hook tip loading, side loading,
bending, torsional, or related loads.
2. Do not attempt to lift a load that is larger
than the load rating of the hook.
3. Never use a hooks yield point as an
indicator of its capacity.
4. Do not use a hook to lift personnel.
5. Know the rated load of the hook in use.
6. Never weld attachments to a finished hook
in field applications. This will alter and
destroy the design properties of the hook
material.
7. Keep fingers, hands, body, and loose
clothing from between the hook and the
load.
8. Avoid shock loading.
9. Inspect the hook regularly for excessive wear The crane MUST be in the stored position before transporting.

and maintain it in safe operating condition.

6 9000 Owners Manual
Operator Information
OPERATOR REQUIREMENTS
1. Operation is limited to the following
people:
A. Designated individual.
B. Trainees under direct supervision
of the designated individual.
C. Test or maintenance individual.
D. Crane Inspector.
2. Operators must meet the following
physical qualifications:
A. Vision of at least 20/30 Snellen in
one eye and 20/50 in the other,
with or without corrective lenses.
B. Ability to distinguish colors if color
differentiation is required.
C. Adequate hearing, with or
without a hearing aid.
D. No physical or emotional defects
that may create a hazard to the
operator or others.
E. Normal depth perception and
coordination.
3. In addition to the physical qualifications,
Operators must:
A. Demonstrate the ability to
understand all decals, the
owners manual, and any other
information required for safe
operation of the crane.
B. Be able to demonstrate the ability
to safely control the crane.
C. Know all safety regulations.
D. Be responsible for maintenance
requirements.
E. Understand and be fully capable
of implementing all emergency
procedures.
F. Understand the operating
procedures as outlined by this
manual, ANSI B30.2, and
Federal/State Laws.
OPERATOR CONDUCT
1. Operators will not engage in any
operation that would cause them to divert
attention away from the operation of the
crane.
2. Operators are responsible for all
operations under their direct control.
3. Operators will not leave a suspended
load unattended.
4. Operators will be familiar with the
equipment and the maintenance required
for proper care.
HANDLING THE LOAD
1. Size of the load:
A. Do not load the crane beyond
the rated capacity.
B. It is the responsibility of the
operator to know the weight of
the handled load.
2. Attaching the load:
A. Attach the load to the hook by
means of slings or other approved
devices.
B. Do not wrap the hoist rope
around the load.
3. Moving the load:
A. Make certain that the crane is
level and properly blocked.
B. Ensure that the load is secure and
balanced within the sling before
moving it.
C. Be sure that the crane is stable
before moving the load. Use
stabilizer pads to ensure the
proper distribution of weight.
D. Do not drag the load sideways.
E. Make sure the hook is brought
over the load to minimize
swinging.
F. No suspended load should pass
over a person.
G. Avoid sudden starts and stops
when moving a load.
 Maintenance 7

Chapter 3 - Maintenance
WARNING Daily Inspection
Read the following before performing any Daily Inspection should occur each day
maintenance on the crane. before the crane is put into use. Each day,
inspect the crane for all of the following:
1. Only authorized service personnel are to
1. Hydraulic oil level.
perform maintenance on the crane.
2. Loose parts or damage to structures or
2. Disengage the PTO before any service or
weld.
repair is performed.
3. Cylinder movement due to leakage.
3. Do not disconnect hydraulic hoses while
4. Hoses and gearboxes for evidence of oil
there is still pressure in those components.
leaks.
4. Before disconnecting hydraulic
5. Controls, including hand throttle for
components, place the boom on the
malfunction or adjustment.
ground or have it supported, shut off the
6. Truck hand brake operation.
engine, release any air pressure on the
7. All securing hardware such as cotter
hydraulic reservoir, and move pedals and
pins, snap rings, hairpins, and pin
control levers repeatedly through their
keepers for proper installation.
operating positions to relieve all pressures.
8. All safety covers for proper installation.
5. Keep the crane and service body clean
9. Cylinder holding valves for proper
and free from grease build-up, oil and
operation.
dirt to prevent slippery conditions.
10. Wire rope for broken wires, extensive
6. Perform all safety and maintenance
wear, distortion, and heat damage.
checks before each period of use.
7. Replace parts with Stellar Industries, Inc.
Periodic Inspection
approved parts only.
Periodic Inspection should occur while the
8. Immediately repair or have repaired any
crane is in use. For the duration of the
components found to be inadequate.
usage, inspect the crane for all of the
following:
Maintenance Procedures
1. Loose bolts and fasteners.
1. Position the crane where it will be out of
2. All pins, bearings, shafts, and gears for
the way of other operations or vehicles in
wear, cracks, or distortion to include all
the area.
pivots, stabilizers, sheave pins, and
2. Be sure boom is lowered to the ground or
bearings.
otherwise secured from dropping.
3. Hydraulic systems for proper operating
3. Place all controls in the off position and
pressure.
secure operating features from
4. Main frame mount bolts.
inadvertent motion.
5. Cylinders for:
4. Disconnect power source.
A. Damaged rods.
5. Relieve hydraulic oil pressure from all
B. Dented barrels.
hydraulic circuits before loosening or
C. Drift from oil leaking internally.
removing hydraulic components.
D. Leaks at rod seals or holding valves.
6. Label or tag parts when disassembling.
6. PTO drive line system for proper
alignment, lubrication, and tightness.
7. Hydraulic hose and tubing for evidence
of damage such as blistering, crushing,
or abrasion.
8 9000 Owners Manual
Weekly Inspection
Weekly Inspection should occur at the
beginning of every work week. Each week,
inspect the crane for all of the following:
1. Lubrication of points required by
lubrication chart located in this chapter.
2. Proper operation of load hook safety
latch.
3. Presence of this owners manual.
Monthly Inspection
Monthly Inspection should occur at the
beginning of every work month. Each
month, inspect the crane for all of the
following:
1. Frame bolt tightness - turn barrel nuts and
mounting bolts during the first month of
operation on new machines and then
quarterly thereafter.
2. Cylinders and valves for leaks.
3. Lubrication.
4. Load hook for the following:
a. Cracks or having more than 5%
normal throat opening.
b. Any visible bend or twist from the
plane of the unbent hook.
5. Structural members for bends, cracks, or
broken members.
6. All welds for breaks and cracks.
7. All pins and keepers for proper
installation.
8. All control, safety, and capacity placards
for readability and secure attachment.
9. Inspect all electrical wires and
connections for worn, cut, or
deteriorated insulation and bare wire.
Replace or repair wires as required.
10. Tightness of all boom wear, pad-
retaining bolts.
Service
The following general suggestions should be
helpful in analyzing and servicing your
crane. Using the following systematic
approach should be helpful in finding and
fixing problems:
1. Determine the problem.
2. List and record possible causes.
3. Devise checks.
4. Conduct checks in a logical order to
determine the cause.
5. Consider the remaining service life of
components against the cost of parts
and labor necessary to replace them.
6. Make the necessary repair.
7. Recheck to ensure that nothing has been
overlooked.
8. Functionally test the new part in its
system.
Inspection Checklist
For a more detailed outline of scheduled
inspection points, refer to the Stellar Crane
Inspection Log. This document is an
essential guide for the daily, monthly,
quarterly and annual inspection tasks that
will help maintain the quality of your Stellar
product.
ATTENTION
Every six (6) months, remove the hydraulic
pump from the PTO and lubricate the
splines using Chelsea Lubricant #379831 or
Stellar PN 20885. Failure to lubricate shaft
splines will cause damage to the PTO and
Hydraulic pump.
Stellar Industries recommends the first
filter change to occur after the first 250
hours of service.* The second, and
every subsequent change, should
occur after every 1,000 hours of
service. By following these guidelines,
the hydraulic oil should last up to 6,500
hours.
*Note: These recommendations are based on normal working
parameters. If operating in less than favorable conditions
(excessive dust, moisture, etc.), be sure to check the filter
gauge often for filter change notice.
 Maintenance 9

Holding Valve Inspection Procedure

The cylinders are equipped with holding valves that prevent sudden movement of the cylinder rods
in the event of a hydraulic hose or hydraulic component failure. The valve is checked in the
following manner:
1. Identify the cylinder in question.
2. Identify the holding valves and the cylinder direction in question.
a. Cylinder Extend.
b. Cylinder Retract.
3. Place the machine so that the cylinder will be located in the appropriate testing
position.
4. Pick the load (Do not exceed capacity, rated or stability).
5. Disengage hydraulics.
6. Operate crane functions.
A. If the cylinder creeps (lowering the load), replace the holding valve.
B. If the cylinder does not creep (load stays suspended), the valve is operational.

Lubrication Recommendations
Crane Lubrication
Component Location Recommendation
Reservoir
Below 5F High VI, low pour, ISO 22, AW hydraulic oil
Hydraulic System
-5F to 90F High VI, low pour, ISO 32, AW hydraulic oil
Above 90F ISO 46, AW hydraulic oil
Open Gear Teeth Crane Rotation Gear Lithium complex, NLGI 2 grease with moly
Worm Drive Bearings Crane Rotation Gear,
(including turntable Inside Crane Lithium complex, synthetic based NLGI 00 grease
bearing inner race) Compartment
Cylinders Crane Pivot Areas Lithium complex, NLGI 2 grease
Synthetic 80W-90 gear oil with friction modifiers, API
Winch Winch Drum
GL-5
Wear Pad Lubrication Extension Booms Synthetic lubricant containing Teflon

Compressor Lubrication
Component Location Recommendation
Reciprocating Single
Compressor Crankcase ISO 100 compresser oil
Stage
Reciprocating Double
Compressor Crankcase ISO 100 compresser oil
Stage
Compressor Crankcase
-15F to 86F Synthetic performing ISO 32 compresser oil
Screw Compressor
-23F to 100F Synthetic performing ISO 46 compresser oil
32F to 113F Synthetic performing ISO 68 compresser oil

Greasing the Crane

Lubricate all grease gun points with
Extreme Pressure Grease - Stellar P/N: 22059.
10 9000 Owners Manual

Grease Line Kit - PN 61641

03,08

06,08

04,08
06,09
04,08

05,08
11,12,13,14

02,08

16,17,18
TYP 3
15 07,10
TYP 7

PN 61641
ITEM PART# DESCRIPTION QT Y
01 40083 HOSE KIT 9000 GREASE KIT (Incl:2-6) 1
02 40084 HOSE 0.13(549-01-01-2-2-2-84) (1)
03 37554 HOSE 0.13(549-01-01-2-2-2-126) (1)
04 41925 HOSE 0.13(549-01-01-2-2-2-185) (2)
05 37558 HOSE 0.13(549-01-01-2-2-2-248) (1)
06 42106 HOSE 0.13(549-01-01-2-2-2-224) (2)
07 C2256 FTG CPLR PIPE 0.13 7
08 37561 FTG ADAPT 90 MNPTF/FNPSM 2107-2-2 6
09 37562 FTG ADAPT 45MNPTF/FNPSM 3107-2-2 1
10 56589 ZERK 1/8 NPT STRAIGHT LONG THREAD 7
11 C0078 CLAMP 0.38 BLK VINYL 1
12 0480 CAP SCR 0.25-20X1.00 HHGR5 1
13 0333 NUT 0.25-20 HHGR5 NYLOC 1
14 0340 WASHER 0.25 USS FLAT ZINC 2
15 61640PC BRACKET GREASE LINE/TANK HEATER 9000 PC WHT 1
16 C0090 CAP SCR 0.31-18X1.00 BTNHD SS 3
17 0343 WASHER 0.31 USS FLAT ZINC 3
18 0342 NUT 0.31-18 HHGR5 NYLOC 3
 Maintenance 11

Gear-Bearing Bolt Maintenance

WARNING: Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of
the identical grade and size. Once a bolt has been torqued to 75% of its proof load and
then removed, the torque coefficient may no longer be the same as when the bolt was
new thus giving indeterminate damp loads after torquing.

Torque Data Chart

GRADE 5 GRADE 8 GRADE 9

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

When using the torque data in the chart,
the following rules should be observed:
1. Bolt manufacturers particular
specifications should be consulted when
provided.
2. Flat washers of equal strength must be
used.
3. All torque measurements are given in
foot-pounds. To convert to inch-pounds,
multiply by 12.
4. 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
above.
5. Torque values for socket-head capscrews
are the same as for Grade 8 capscrews.
12 9000 Owners Manual

This page intentionally left blank.


Chapter 4 - Specifications
Model 9000 Crane
SPECIFICATION SHEET
Crane Rating:
Standard Boom Length:
Boom Extension:
Maximum Horizontal Reach:
Maximum Vertical Lift:
(From Truck Frame)
Cylinder Specifications
Inner Lift Cylinder:
Outer Lift Cylinder:
Extension Cylinder:
Rotation:
(Worm Gear Drive)
Lifting Capacities:
Power Supply Required:
Controls:
Stowed Height:
(Above Truck Frame)
Mounting Space Required:
Approximate Shipping Weight:
Specifications 13
90,000 ft-lbs (12.44 ton meters)
13 1 (3.99 m) from CL of Crane
Hydraulic 41" (104 cm)
167 (5.05 m) from CL of Crane
223 (6.78 m)
6 (15.24 cm) bore with integral
pilot operated counterbalance valves.
5 (12.70 cm) bore with integral
pilot operated counterbalance valves.
3 12 (8.89 cm) bore with integral
pilot operated counterbalance valves.
290 degree power
9,000 lbs @ 10 (4080 kg @ 3.03 m)
6,880 lbs @ 131 (3120 kg @ 3.99 m)
5,425 lbs @ 167 (2460 kg @ 5.05 m)
PTO & Pump (Proportional Inlet VB)
(8.0 gpm @ 3000 psi)
(30.3 lpm @ 206 bars)
PTO & Pump (Fully Proportional VB)
(12.0 gpm @ 3000 psi)
(45.4 lpm @ 206 bars)
Proportional Radio Controls standard for
all functions.
75 (190.5 cm)
37 (94 cm)
4,800 lbs (2175 kg)
14 9000 Owners Manual

Capacity Chart - Decal PN 64835

10 131 167
CAPACITY 3.05m 3.99m 5.05m
257
CHART 7.80m

226
6.86m

10
3.05m

10 131 167
3.05m 3.99m 5.05m
9000 lbs 6880 lbs 5425 lbs
4080 kg 3120 kg 2460 kg

0
0m

CRANE
GROUND 0
0m
190 STATE STREET GARNER, IA 50438
PHONE: (800) 321-3741 FAX: (641) 923-2812 64835
 Decals 15

Chapter 5 - Decals
Decals of Note

DANGER DANGER
ELECTROCUTION HAZARD
This remote control box does THIS CRANE IS NOT INSULATED
not provide you and others with
DEATH OR SERIOUS INJURY
protection against WILL RESULT FROM CONTACT
ELECTROCUTION OR INADEQUATE CLEARANCE

HAZARD
Maintain safe clearances from electrical lines. Allow for
boom, electrical line, and load line swaying.

This crane does not provide protection from contact with

DEATH OR SERIOUS INJURY or proximity to an electrically charged conductor.
will result if the boom, load or Maintain a clearance of at least 10 feet between any part
loadline should become of the crane, loadline or load and any electrical line
electrically charged. carrying up to 50,000 volts.

One foot additional clearance is required for every

additional 30,000 volts or less.
MAINTAIN SAFE CLEARANCES
C1179
FROM POWER LINES
4186

Electrocution Hazard Decal Electrocution Hazard Decal

Location: Crane Base Cover
Function: To inform the operator of the hazard
associated with contact or proximity to
electrical lines, the possible consequences
should the hazard occur and how to avoid the
hazard.
PN: 4186
Location: Crane Mast
Function: To inform the operator that the crane
is not insulated and the possible consequences
if the crane would come into contact with
power lines or electrically charged
conductors., and how to avoid the hazard.
PN: C1179

DANGER DANGER
ELECTROCUTION HAZARD A MOVING OUTRIGGER
DEATH OR SERIOUS INJURY will result WILL CAUSE
from contact with the load, the crane or the vehicle
if the boom or loadline should become electrically
charged. SERIOUS CRUSHING INJURY
KEEP CLEAR OF TRUCK AND LOAD
C4545
Do not operate any outrigger unless you or a signal

Electrocution Hazard Decal

person can see that all personnel are clear of the
outrigger and its ground contact point.
Location: Each side of truck body, Front & Rear
C5918

Bumper
Function: To inform the operator and other
personnel in the work area of the hazard
associated with contact or proximity to electrical
lines, the possible consequences should the hazard
occur and how to avoid the hazard.
PN: C4545
Moving Stabilizer Hazard Decal
Location: Inside Stabilizer Leg - Both Sides
Function: To inform the operator of the hazard
associated with stabilizer operation, the possible
consequences should the hazard occur, and how
to avoid the hazard. PN: C5918
16 9000 Owners Manual

DANGER DANGER
FAILURE TO OBEY THE FOLLOWING FAILURE TO OBEY THE FOLLOWING
WILL RESULT IN WILL RESULT IN
DEATH OR SERIOUS INJURY
DEATH OR SERIOUS INJURY
Follow all recommended inspections and
maintenance practices listed in the equipment INSTABILITY OR
manufacturers manuals. If manuals are STRUCTURAL DAMAGE
missing from this equipment, contact
manufacturer for replacement. Read, understand and follow the equipment
load and work area charts.
Do not modify or alter this equipment without
written manufacturers approval. Use only Do not exceed winch or equipment ratings.
manufacturer approved attachments or parts
on this equiupment. Weights of accessories attached to the
boom or loadline must be deducted from
Equipment must be mounted on factory the load chart ratings or be added to the
recommended chassis. If re-mounted or load weight.
rebuilt, the equipment must be re-certified.
Do not exceed jib load ratings at reduced
4190
boom lengths. 4189

Operation Hazard Decal Operation Hazard Decal

Location: Inside Stabilizer Leg - Street Side
Function: To inform the operator and other
personnel in the work area of the hazard
associated with improper maintenance and
unauthorized modifications, the possible
consequences should the hazard occur, and
how to avoid the hazard.
PN: 4190
Location: Inside Stabilizer Leg - Street Side
Function: To inform the operator of the
hazard associated with overloading the
crane, the possible consequences should
the hazard occur, and how to avoid the
hazard.
PN: 4189

DANGER DANGER
FAILURE TO OBEY THE FOLLOWING AN UNTRAINED OPERATOR
WILL RESULT IN SUBJECTS HIMSELF AND
OTHERS TO
DEATH OR SERIOUS INJURY
DEATH OR SERIOUS INJURY
Inspect equipment and its operation daily.
For equipment stability, use only on solid, YOU MUST NOT OPERATE
level surface with outriggers properly THIS EQUIPMENT UNLESS
extended.
Equipment must be level.
Operate all controls slowly and smoothly. You have been trained in the safe
Never operate the equipment with operation of this equipment.
personnel under boom or load.
Keep load under boom tip. Do not side You read, understand and follow the
load boom or drag loads. Avoid free safety and operating recommendations
swinging loads. contained in the equipment manufacturers
Keep at least 3 wraps of loadline on manuals, your employers work rules and
winch drum. applicable government regulations.
For travel, boom and outriggers must be
in stowed position.
C4540
C4544

Training Decal: Operation Hazard Decal

Location: Inside Stabilizer Leg - Street Side
Function: To inform the operator of the need
for proper inspection procedures, and the
possible consequences of operation without
inspection. PN: C4544
Location: Crane Base Cover
Function: To inform the operator of the need
for proper training, familiarity with safe
operating procedures and, the possible
consequences without training.
PN: C4540
 Decals 17

DANGER DANGER

STOWING & UNFOLDING BOOM

WILL CAUSE OUTRIGGERS WILL CAUSE
DEATH OR SERIOUS INJURY SERIOUS CRUSHING INJURY

STAND CLEAR
Stand on the opposite side of the boom
when unfolding or stowing the crane.
C4541
C4795

Moving Boom Hazard Decal

Foot Crushing Hazard Decal
Location:Inside Crane Compartment, on
Location: Inside Stabilizer Leg - Both Sides
Compartment Door
Function: To inform the operator and other
Function: To inform the operator and other
personnel in the work area of the hazard
personnel in the work area of the hazard
associated with the operation of the stabilizers, the
associated with a moving boom, especially
possible consequences should the hazard occur,
while stowing and unfolding the crane, the
and how to avoid the hazard. PN: C4795
possible consequences should the hazard
occur, and how to avoid the hazard.
PN: C4541
18 9000 Owners Manual

Decal Kit Placement Kit 30488

27
24

30
 
  
  

CAPACITY
CAPACITY 3.05m
3.05m 3.99m
3.99m 5.05m
5.05m
 

CHART 7.80m
7.80m

 

6.86m
6.86m

21 3.
 

05m
3.05m
9000 llbs
4080 kg
bs
g

3.


99m
3.99m
6880 llbs
3120 kg

5.
bs 5425 llbs
g 2460 kg
bs
g
05m
5.05m
3.





05m
3.05m



0m

CRANE
GROUND 

0m
190 STATE STREET
STATE GARNER, IA 50438
PHONE: (800) 321-3741 FAX: (641) 923-2812
FAX: 64835

DANGER

12
(/(&752&87,21+$=$5'
(/(&
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21+$=$5'
7+,6&5$1(,6127,168/$7('
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DEATH
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boom, el
boom, lect
ectricall line,
electrical line, and
and load
load line
line sw aying.
ay
swaying.

7KLVFUDQHGRHVQRWSURYLGHSURWHFWLRQIURPFRQWDFWZLWK
7KLVFUDQHGRHVQRWSURYLGHSURWHFWLRQIURPFRQWDFWZLWK
or p
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electrically charged conductor.
conductor.

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of tthe
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50,000 volts.

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2
additional 30,
additional 000 volts
30,000 volts or
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C1179
C1179

8
DANGER

26 DANGER

10
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672:,1
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oom
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e cr ane.
C
C4541
4541

15 2875,**(56:,//&$86(
2875,*

STAND
**
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SERIOUS CRUSHING

ST
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Y

C479
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e
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11
i g
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DANGER
Pr
Proudly
oudly Designed
Designed nly
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y.
actured
and Manufactur
a Manufactured
in the USA by 16973
16973

335234
52234

STABILIZER
A MOVING STABILIZER
-NOTICE- WILL CAUSE
This crane has been designed
and manufactured
manufactured to ASME/ANSI
B30.22 and/or B30.5 specifications. 15172
SERIOUS CRUSHING INJUR
INJURY
Y

1 27
Do not operate
operate any stabilizer unless you or a signal
are
person can see that all personnel ar e clear of the
re the
ground
d contact
stabilizer and its ground conta
act point.
oin
nt.
C5918
C5918

DANGER

13
)$,/85(722%(<7+()2//2:,1*
)$,/85(722%(<7+()2//2:
$ :,1*
:,/
//5(68/
/7
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5
-NOTICE- DEA
DEATH
TH OR SERIOUS INJURY
INJURY
LUBRICATE
LU BRICA
C TE
E WORM
WOR
ORM
M GEAR
GEAR WITH ,QVSHFWHTXLSPHQWDQGLWVRSHUDWLRQGDLO\
, VSHFWHTXLSPHQWDQG GLWVRSHUD DWLRQGD
DLO\
STELLAR GREASE (PN 4460) ONLY.
ONLY.
- DO
DO NOT RUN
RUN WORM DRY-
DRY- )RUHTXLSPHQWVWDELOLW\XVHRQO\RQVROLG
)RUHTXLSPHQWWVWDELOLW\XVHRQO\RQVROLG G

24
level surface with
with outriggers properly
9188

extended.
(TXLSPHQWPXVWEHOHYHO
(TXLSPHQWPXVWE EHOHYHO
2SHUDWHDOOFRQWUROVVORZO\DQGVPRRWKO\
2 HUDWHD DOOFRQWWUROVVORZO\DQGVPRR RWKOO\
\

14
1HYHURSHUDWHWKHHTXLSPHQWZLWK
1HYHURSH HUDWHWKHHTXLSPHQWZLWK
personnel under boom or load.
.HHSORDGXQGHUERRPWLS'RQRWVLGH
.HHSOR RDGXQGGHUERRPWL 'RQRWVLGH
load boom or drag loads. Avoid Avoid free
swinging loads.
.HHSDWOHDVWZUDSVRIORDGOLQHRQ
.HHSDWOHDVWZUDSV VR
RIIORDGOL HRQ
winch
w inch drum.
)RUWUDYHOERRPDQGRXWULJJHUVPXVWEH
)RUWUDYHOERRRRPDQGRXWULJ JHUVP VWEH
JJ
in stowed position.

C
C4544
4544

DANGER
)$,/85(722%(<7+()2//2:,1*
)$,/85(7
72
22%(<7+()2//2:
:,1*

9
:,
: //5(68/
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DEATH
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INJURY
)ROORZDOOUHFRPPHQGHGLQVSHFWLRQVDQG
)ROORZDOOUHFRPPHQG
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Remote
Remote OFF
O
OF
FF
maintenance practices listed in the equipment
manufacturers
manufacturer s manuals. If manuals are
Manual
Manual Stabilizer missing from this equipment, contact
manufacturer for replacement.

ON
ON 'RQRWPRGLI\RUDOWHUWKLVHTXLSPHQWZLWKRXW
'RQRRWPRG
GLI\RUDOWHUWK
KLVHTXLSPHQWZLWKR W

29
written manufacturers approval. Use only
Flood Light manufacturer approved attachments or parts
on this equipment.
OFF
OFF
F
(TXLSPHQWPXVWEHPRXQWHGRQIDFWRU\
(T LSPHQWPXVWE EHPRX WHGRQID
DFWR
RU\
recommended chassis. If re-mounted or
rebuilt, the equipment must be re-certified.

ON
ON
4190

Speed Contr ol
Control

OFF
OFF
F

TOOL CIRCUIT MUST BE OF

TOOL F
OFF
TO OPERATE
TO OPERATE AUX
AUX OUTRIGGERS
OUTRRIGG
GERS
ON
ON

7
T
TOOL
OOL
CIRCUIT

OFF
F
OFF
P
PNN 16620
16620

10 DANGER

2
2875,**(56:,//&$86(
875,**
*(56:,,//&$86
6(
SERIOUS CRUSHING
SERIOUS CRUSHING INJURY
INJURY

STAND
STAND CLE
CLEAR
AR
C4795

11
DANGER
MOVING
AM STABILIZER
OVING S TABILIZER
WILL
WIL CAUSE
L CA USE

SERIOUS
SER
S ER
RIOUS CR
CRUSHING
USHING IINJURY
NJURY
Do
Do not
no
ot operate
oper
eratate
e any stabilizer
stab
stabil
ilizer
er unless you
you or
y or a signal
signal
person
pe son can see that
erso that all personnel
per sonnel are
erso are clear
ar of
of the
he
stabilizer
stab ilizer and its
abiliz its ground
und contact
ground contact point.
point.
C
C5918
5918

25
INNER CYL
INNER CYL NNER C
INNER
IN YL
CYL NNER/MAST
INNER/MAST
IN UTER CYL
OUTER
OU CYL
BASE
BASE ROD PIN BASE
BASE

OU
UTER
R CYL
OUTER CYL IN
NNER/OUT
UTER
ER
INNER/OUTER GEAR
GEAR
ROD PIN EXT CYL
EXT CYL BEARING
BEARING

41918

23
15171
months.
GREASE every 3 months.

ess e grease)
Apply 3 pumps of EP2
e s
fully.
then rotate crane fully.
e e pressure
GREASE

(extreme

C4540
C4540
manufacturers
anufacturer s
and
d

4
DANGER

ules an
INJURY
SERIOUS INJURY

recommendations
operating recommendations

rules
OPERATOR
ATOR

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regulations.
gulations.
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43469
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E , IA 50438

4214

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20
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641-923-3741
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800-321-3741
321-3741
CONTACT:
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4187

ACTIVATE
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ROTATION

CONTROL

28
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HAZARD
LECTROCUTION HAZARD

ho

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ott provide

sh
DEATH OR SERIOUS INJURY
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In
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or loadline
aiin
DANGER

electrically charged.
e .
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aga

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2 22

PN 30488
16* C5910 DECAL-STELLAR 4x9.5 1
15 15172 DECAL ASME/ANSI B30.22/B30.5 1
14 9188 DECAL WORM GEAR LUBRICATION
LUBRICATION
T 1 30 47404 PANEL
DECAL SWITCH PANEL 23000 1

13 16973 ATTACHMT
DECAL-STELLAR APPROVED ATT
ATTACHMT 2 29 65108 PLATE
DECAL SWITCH PLAT 9000 (FULLY
TE Y PROP VERSION)
(FULLLY VE 1
12 C1179 DECAL-ELECTROCUTION 4.5x7.5 2 28 43469 DECAL VB CONTROL 23000 (FULLY PROP VERSION)
(FULLY 1
11 C5918 DECAL-DANGER MOVING O.R. 2 27** 54589 DECAL STELLAR 8X22.25 2
10 C4795 DECAL-DANGER O.R. 2 26 35234 DECAL STELLAR MADE IN THE USA 1
09 4190 DECAL-DANGER 1 25 41918 DECAL 9000 GREASE KIT 1
08 C4541 DECAL-DANGER STOWING 2 24 54594 DECAL-9000 IDENTIFICA
IDENTIFICATION
ATION
TION 2
07 4189 DECAL-DANGER 1 23 15171 DECAL GREASE WORM DRIVE BEARINGS 1
06* 4186 DECAL-ELECTROCUTION 2x2.75 1 22 13036 DECAL CRANE OUTRIGGER 1
05 C4544 DECAL-DANGER 1 21 64835 DECAL-CAPACITY
DECAL-CAPACITY 2
04 C4540 DECAL-DANGER 1 20 4214 DECAL-SERVICE
DECAL-SERVICE 1
03* C4545 DECAL-ELECTROCUTION 5x13 4 19* 4305 DECAL-FLOOD LIGHT 1
02 4187 DECAL-ELECTROCUTION 3.25x7.5 1 18* C0568 DECAL-DIESEL FUEL ONLY
ONLY 2
01 4188 DECAL-ALIGNMENT 1 17* C5911 DECAL-STELLAR 2x4.5 3
ITEM P
PART
ART No. DESCRIPTION QTY ITEM PART No.
PART DESCRIPTION QTY

PACKAGE)
* THESE DECALS NOT SHOWN (USE WITH BODY PACKAGE)
**THESE DECAL NOT INCLUDED WITH THE DECAL KIT
 Installation 19

Chapter 6 - Installation
Notice: Read this Page Before Installation of the Crane
General Installation
This chapter is designed to serve as a general guide for the installation of a Stellar 9000
Articulating 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. Check with Stellar Industries before
installing this crane on a body other than a Stellar Service Body.

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.

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.
20 9000 Owners Manual

Install Kit - PN 61405

7
7

6
3

PN 61405
2 IT EM PART D E SC RI PTION Q TY.
1 60517 BASE 9000 FOLD OVER STABILIZER 1
2 58516 TIE DOWN ROD HIAB 122 8
3 58660 PLATE MOUNTING HIAB 122 4
4 8202PC FRAME SUPPORT 15000 CRANE 4
5 58658 MT G B LO C K H I A B 1 22 4
6 6538 WASHER 1.00 SAE FLAT YELLOW GR8 16
7 61558 NUT 1.00-8 HHGR8 16
8 61559 NUT 1.00-8 HHGR8 TOP LOCKING 8

5
6

8
 Assembly Drawings 21

Chapter 7 - Assembly Drawings

Base Assembly - PN 61090
30
31
13

32

33
11 34

35
32 23
24
22
13 25 29 1
7 10 28
17
14 20
19
17
41

40
19 17
2
9
14 27
13
5
37 38 26
14 6 15
18
13 17
12
36
8 4
16 3
PN 61090
ITEM PART DESCRIPTION QTY.
1 60517 BASE 9000 FOLD OVER STABILIZER 1
2 51658 VB 7 SECT DANFOSS PVG32 1
3 41338 FILTER ZINGA 23000 1
4 41339 CLAMP ZINGA FILTER 23000 1
5 61642 VB 2 SECT W/PB VDM6-4-4-YE-HP PB REMOVE 1
6 22918PC BRACKET E-STOP 28000 1
7 61092 BAR PANIC 9000 FOLD OVER STABILIZER 1
8 22921 E-STOP PANIC BAR 28000 1
9 49327PC PLATE SWITCH MTG 15000 1
10 D0045 BACKUP ALARM .97 DECIBAL 1
11 61096 COVER 9000 FULLY PROP FOLD OVER STABILIZER 1
12 0485 CAP SCR 0.31-18X1.25 HHGR5 3
13 0343 WASHER 0.31 USS FLAT ZINC 22
14 0342 NUT 0.31-18 HHGR5 NYLOC 9
15 C0930 CAP SCR 0.31-18X3.00 HHGR5 2
16 0437 CAP SCR 0.25-20X1.25 HHGR5 2
17 0340 WASHER 0.25 USS FLAT ZINC 10
18 0333 NUT 0.25-20 HHGR5 NYLOC 2
19 0479 CAP SCR 0.25-20X0.75 HHGR5 4
20 0486 CAP SCR 0.31-18X1.50 HHGR5 2
21 C0922 CAP SCR 0.31-18X1.00 HHGR5 2
22 10976 CAP SCR 6MMX12MM HHGR8 4
23 63815 BEARING SWING DRIVE 9000 170-00055-5 1
24 33941 MOTOR 9000, WHITE 500260C3120DEAAA 1
25 D1295 CAP SCR 0.50-13X1.50 SH 4
26 5841 CAP SCR 0.75-10X4.50 HHGR8 20
27 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 20
28 D1312 CAP SCR 0.63-11X3.50 HHGR8 2
29 2826 NUT 0.63-11 HHGR5 NYLOC 2
30 44605PC GUARD TTB 6000 CRANE LZR 1
31 0484 CAP SCR 0.31-18X0.50 HHGR5 4
32 D1345 FTG CPRSN 0.12NPT/0.25 TUBE 2
33 D1810 TBE AIR SAEJ844 TYPE A .25 (RM) 2.5
34 C2256 FTG CPLR PIPE 0.13 1
35 c1592 ZERK 1/8 NPT STRAIGHT 1
36 59075 CAP SCR #10-24X0.63 BTNHD ZC 2
37 D0178 WASHER #10 SAE FLAT ZINC 2
38 C4956 NUT #10-24 HH NYLOC SS 2
40 66286 SOLENOID VALVE ASM 3 WAY 2 POS W/ RELIEF 1
41 0438 CAP SCR 0.25-20X2.25 HHGR5 2
22 9000 Owners Manual

Base Assembly Rear Mount Australia Stop - PN 67400

30
31
13

32

33
11 34

35
32 23
24
22
13 25 29 1
7 10 28
17
14 20
19
17
41

40
19 17
2
9
14 27
13
5
37 38 26
14 6 15
18
13 17
12
36
8 4
16 3
PN 67400
ITEM PART DESCR IPTION QTY.
BASE 9000 FULLY PROP FOLD OVER STABILIZER
1 67401 REAR MNT(AUS STOP) 1
2 51658 V B 7 S ECT DA NFO S S PV G3 2 1
3 41338 FILTER ZINGA 23000 1
4 41339 CLAMP ZINGA FILTER 23000 1
5 61642 VB 2 SECT W/PB VDM6-4-4-YE-HP PB REMOVE 1
6 22 9 1 8 PC B R AC K ET E-S T OP 2 80 00 1
7 61092 BAR PANIC 9000 FOLD OVER STABILIZER 1
8 22921 E-STOP PAN IC BAR 280 00 1
9 49327PC P LATE SWITC H MTG 15000 1
10 D0045 BACK UP ALARM .97 DE CIBAL 1
11 61096 COVER 9000 FULLY PROP FOLD OVER STABILIZER 1
12 0485 C A P S C R 0 . 31 - 1 8 X 1 . 25 H H G R 5 3
13 034 3 W A S HER 0.31 USS FL A T ZI N C 22
14 0342 NUT 0.31-18 HHGR5 NYLOC 9
15 C0930 CAP SCR 0.31-18X3.00 HHG R5 2
16 04 37 CAP SCR 0.25-20X1.25 HHGR5 2
17 0340 W A SHER 0.25 USS FL A T ZI N C 10
18 0333 NUT 0.25-20 HHGR5 NYLOC 2
19 0479 CAP SC R 0.25-20X0.75 HHGR5 4
20 0486 CAP SCR 0.31-1 8X1.50 HHGR5 2
21 C0922 CAP SCR 0.31-18X1.00 HHGR5 2
22 10976 CAP SC R 6MMX12MM HHGR8 4
23 63815 BEARING SWING DRIVE 9000 170-00055-5 1
24 33941 MOTOR 9000, WHITE 500260C3120DEAAA 1
25 D1295 CA P SCR 0.5 0- 13X1.50 SH 4
26 5841 CAP SCR 0.75-10X4.50 HHGR8 20
27 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 20
28 D1312 CAP SCR 0.63-1 1X3. 50 HHGR8 2
29 2826 NUT 0.63-11 HHGR5 NYLOC 2
30 44605PC GUARD TTB 6000 CRANE LZR 1
31 048 4 C A P S C R 0 . 3 1 - 1 8 X 0 . 50 H H G R 5 4
32 D 1 3 45 FT G C PRS N 0 .1 2 NP T /0.2 5 T UB E 2
33 D1810 TBE AIR SAEJ844 TYPE A .25 (RM) 2.5
34 C2256 FTG CPLR PIPE 0.13 1
35 c1592 ZERK 1/8 NPT STRAIGHT 1
36 59075 CAP SCR #10-24X0.63 BTNHD ZC 2
37 D 0 17 8 W ASHE R #10 SA E FLA T ZINC 2
38 C4956 NUT #10-24 HH NYLOC SS 2
40 66286 SOLENOID VALVE ASM 3 WAY 2 POS W/ RELIEF 1
41 0438 CAP SCR 0.25-20X2.25 HHGR5 2
 Assembly Drawings 23

Stabilizer Assembly - PN 61089

BASE WELDMENT SHOWN AS REFERENCE

13
12
11
13 9
9
12 5
11 12
10
8 13
6
4 8
10
13 5
11 11
12 13

12 2

2 11

3 13
1
12
7
3

PN 61089
IT EM P A RT DE S C R I PT IO N QTY.
1 54322ZP PIN 2.50X10.38 D&T 2
2 13817 BUSHING BPC40DXR24 2.50X1.50 4
3 13343 BUSHING BPC40DXR16 2.50X1.00 4
4 66281 OUTRIGGER LEG WLDMT 9000/TM20165 2
5 9710ZP P I N 2 . 0 0 X 1 1 .6 9 S R / D& T 4
6 66283 CYLINDER 5.00X24.50 WHITE 2
7 66282 OUTRIGGER PAD 9000/TM20165 2
8 4381 BUSHING BPC32DXR32 2.00X2.00 4
9 4379 BUSHING BPC32DXR40 2.00X2.50 4
10 44533 BUSHING COMPOSITE 2.00X0.75 4
11 5145 PIN CAP 0.56X3.00X0.19 12
12 D0790 WASHER 0.50 SAE FLAT YELLOW GR8 12
13 10172 CAP SCR 0.50-13X1.00 HHGR8 12
14 c1592 ZE R K 1/ 8 N P T ST RA I GH T 2
24 9000 Owners Manual

Mast Assembly - PN 29350

8
7 11
2 10
9
2
12
6
7
5 1

8 9
9 8
2
4
3

2
7 6
Note: Main Lift Cylinder uses
Stellar Seal Kit P/N 38971
7
8
9

PN 29350
ITEM PART DESCRIPTION Q TY.
1 27 981 MAST 9000 1
2 0635 BUSHING 40DXR32 GARLOCK 4
3 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 18
4 4974 CAP SCR 0.75-10X2.50 HHGR8 ZY 18
5 29352 CYLINDER ASM 6.00X28.63 1
6 97 30 ZP P I N 2 .50X13.25 D & T 2
7 8377 PIN CAP 0.56X3.50X0.19 4
8 D0790 WASHER 0.50 FLAT GR8 4
9 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 4
10 30009 HOSE CLAMP 9000 1
11 0523 W ASHER 0 .38 LOC K 2
12 C0944 CAP SCR 0.38-16X1.75 HHGR5 2
 Assembly Drawings 25

Mast Cylinder Assembly - PN 29352

2
4

3 2

NOTE: BUSHING SHOWN FOR REFERENCE

5 PN 29352
ITEM PART DES CRIPT ION QT Y.
1 29351 CYLINDER 6.00X28.63 1
2 0279 FTG 6-6 MFS-MORB STRAIGHT 4
3 16154 MANIFOLD DOUBLE T11A 3500 PSI 1
4 29353 TUBE ASM 0.38X11.39 YZ 2
5 0635 BUSHING 40DXR32 GARLOCK 4
26 9000 Owners Manual

Main Boom Assembly - PN 29354

12
3

6
8
10
5
11
7
9
4 2 10 11

Note: Secondary Cylinder

12
uses Stellar Seal Kit P/N 38680

PN 29354
ITEM P ART DE SCRIP TION Q T Y.
1 28366 INNER BOOM 9000 1
2 29356 CYLINDER ASM 5.00X30.00 1
3 0635 BUSHING 40DXR32 GARLOCK 4
4 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2
5 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2
6 29358ZP P IN, 2.50X10.13 D&T 1
7 9709ZP P I N 2 . 0 0 X 1 0. 1 9 D & T 1
8 8377 PIN CAP 0.56X3.50X0.19 2
9 5145 PIN CAP 0.56X3.00X0.19 2
10 D0790 WASHER 0.50 FLAT GR8 4
11 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 4
12 c1592 Z E RK 1 / 8 N PT S T R A I G H T 2
 Assembly Drawings 27

Main Boom Cylinder Assembly - PN 29356

3
2
5
4
2

5
PN 29356
I TE M PART DES CRIPT ION Q T Y.
1 29355P CYLINDER 5.00X30.00 1
2 0279 FTG 6-6 MFS-MORB STRAIGHT 4
3 29357 T UBE A S M 0 . 3 8 X 1 3.89 YZ 2
4 16154 MANIFOLD DOUBLE T11A 3500 PSI 1
5 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4

NOTE: BUSHINGS SHOWN FOR REFERENCE

28 9000 Owners Manual

Extension Boom Assembly - PN 61204

5
2

19 21
11
16
20 15
18
19 11 7
7 8
11
13 18
22 18
22 18
8 19
14 10
11
11 18 19
14 19 7
12
9
1 11
18 19
4

18 17

PN 61204
ITEM PART DE SC RI PTION Q TY.
1 61205 OUTER BOOM 9000 V2 1
2 61206 EXT BOOM 9000 V2 1
3 30483 WEAR PAD 0.34X3.00 RND 2
4 9435 WEAR PAD 1.34X3.00 RND NYLATRON 6
5 61219 CYLINDER ASM EXT 9000 V2 1
6 29551PC CO VER WEAR PAD 9000 6
7 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 4
8 20042ZP PIN 2 .00X12.13 D&T 2
9 2 0 0 43 Z P PIN 2.00X10.38 D &T 1
10 29552ZP PIN 2.00X5.63 D&T 1
11 5145 P IN CAP 0.56X3.00X0.19 8
12 26762 HOOK 7 TON SWIVEL CROSBY 1028632 1
13 51 9 2 PI N HITCH 1.25X 5 .13 1
14 28496PC COL L A R 1. 2 8 x 2 .0 0x 1 . 0 0 2
15 8622 CLAMP HOSE/TUBE AG-2 2
16 c1592 ZERK 1/8 NPT STRAIGHT 1
17 10666 CAP SCR 0.50-13X1.25 HHGR8 24
18 D0790 WASHER 0.50 SAE FLAT YELLOW GR8 32
19 10172 CAP SCR 0.50-13X1.00 HHGR8 8
20 0343 WASHER 0.31 USS FLAT ZINC 2
21 0342 NUT 0.31-18 HHGR5 NYLOC 2
22 0067 BUSHING BPC-2426-24 1.50X1.50 3
 Assembly Drawings 29

Extension Boom Cylinder Assembly - PN 61219

3
1

3
2

PN 61219
ITEM PART D E SCRIP TION Q TY.
1 61220 CYLINDER 3.50X41.50 1
2 53516 MANIFOLD CBAL DOUBLE T2A SUN CBDD-LJN-XAJ 1
3 1556 FTG 8-8 MFS-MAO R B 90 2
4 155 4 F T G 8 - 8 MF S - M O R B S T R A I G H T 2
5 53517 TUBE ASM 0.50X5.81 YZ 1
6 54312 TUBE ASM 0.50X50.28 YZ 1
7 C0927 C A P S C R 0 . 3 1 - 1 8 X 2 .2 5 H H G R 5 2
30 9000 Owners Manual

Reservoir Assembly - PN 61201

7

11

6
15
4 9
16

17
10
19

18 8

14

13
20
1
12
21 5

PN 61201
I T EM PA RT D E S C RI P T I O N QTY.
1 60526 RSRVR 30 GAL W/HEATER 9000 FOLD DOWN STABILIZER 1
2 15463 THERMO SIGHT GAUGE 1
3 42184 FILTER TANK TOP MPF1841AG7A10HBVR 1
4 63029 CAP FILL ASM W/NECK 1
5 C2126 MAGNETIC PLUG DRAIN 3/4" 1
6 58284 GASKET TANK TOP FILTER 1
7 0492 CAP SC R 0 .3 8- 16 X0 .75 H HGR5 4
8 C6327 FILTER STRAINER 35GAL TF-2030 1
9 C1058 FTG 32-32XCLOSE MP-MP NIPPLE STRAIGHT BLK 1
10 C4 750 VALVE BALL 2.00 1
11 C4730 FT G 32 -3 2 M P-H B S TRA I GH T 1
12 C0 9 2 2 CA P S C R 0. 3 1- 1 8 X1. 0 0 H H G R 5 4
13 0 52 2 W A S HER 0 . 31 LO C K 4
14 0343 WA SHER 0.3 1 US S FLAT Z INC 4
15 D1263 FTG HOSE BARB 0.38 HOSE X 0.38 90DG 1
16 0478 CAP SCR 0.25-20 X0.50 HHGR5 12
17 0340 WASHE R 0. 2 5 US S F LAT Z INC 12
18 1 11 4 9 G A SK E T A RC T I C F O X H E A T E R #A - 6 1 1 1
19 11442PC PLATE COVER TAN K HEATER FLANGE 1
20 13002 D E C A L H Y D O I L S P E C IF IC A T IO N MO B I L 1
21 42971 DECAL OIL FILTER CHANGE 1

Chapter 8 - Hydraulics - Electrical
WARNING!
Please read the following section before
performing any work on the
hydraulic/electrical system of your crane.
This section contains vital safety information
and maintenance guidlines for your crane.
If questions should arise, please contact
Stellar Customer Service at 800-321-3741
Never modify or alter any of the equipment,
whether mechanical, electrical, or hydraulic,
without Stellar Industries approval.
Release system pressure before attempting to
make adjustments or repairs.
Do not attempt service or repair when PTO is
engaged.
Disassemble and assemble hydraulic
components on a clean surface.
Clean all metal parts in a nonflammable
cleaning fluid. Then lubricate all components
to aid in assembly.
Hydraulic fluid expands when heated. This
raises the pressure in an unventilated tank.
Release the tank pressure before removing the
cap completely. Failure to do so may cause
the oil to shoot out of the tank very rapidly and
cause severe burns.
Warning! If hydraulic fluid escapes, the boom
or crane can fall immediately. Make sure the
ground or blocking is supporting the boom
before performing any maintenance or repair.
Hydraulics - Electrical 31
Do not rely on the hydraulic fluid to support
the boom or crane.
Contaminants in a hydraulic system affect
operation and will result in serious damage to
the system components. Dirty hydraulic
systems are a major cause of component
failures.
If evidence of foreign particles is found in the
hydraulic system, flush the system.
When installing metal hydraulic tubes, tighten
all bolts finger tight. Then , in order, tighten the
bolts at the rigid end, the adjustable end, and
the mounting brackets. After tubes are
mounted, install the hoses. Connect both
ends of the hose with all bolts finger tight.
Position the hose so it does not rub the
machine or another hose and has a minimum
of bending and twisting. Tighten bolts in both
couplings.
Due to manufacturing methods, there is a
natural curvature to a hydraulic hose. The
hose should be installed so any bend is with
this curvature.
32 9000 Owners Manual

Control Kit - PN 61546

PN 61546
 Hydraulics - Electrical 33

Control Kit 434MHz - PN 67402

PN 67402
34 9000 Owners Manual

Hydraulic Kit - PN 61547

34
2 3 4 5 6 6 12

23
19 19 19 19 19 19 19

21,22 21,22 21,22 21,22 21,22 21,22 21,22

26

35,24,
17

2 3 4 5 6 6 12
34

PN 61547
 Replacement Parts 35

Chapter 9 - Replacement Parts

HYDRAULIC SYSTEM COMPONENTS COMPRESSOR COMPONENTS (SHD66 OPTIONAL)
PART# DESCRIPTION PART# DESCRIPTION
39780 OIL PRESSURE GAUGE 3853 PILOT VALVE 145/175 PSI
50234 DUMP VALVE C4913 SOLENOID VALVE (SHD66 COMPRESSOR)
50235 COIL - DUMP VALVE C4914 PRESSURE RELIEF VALVE (SHD66 COMPRESSOR)
50230 REDUCING VALVE C0864 AIR PRESSURE SWITCH -HOBBS (SHD66 COMPRESSOR)
50231 ACTUATOR D0840 FAN - COOLER
66286 SELECTOR VALVE 12V (SOLENOID VALVE ASSY 3 WAY 2 POSITION) C1129 HYDRAULIC OIL COOLER
63515 SELECTOR VALVE COIL 7471 LOW PRESSURE INTAKE VALVE ASSEMBLY (SHD66 COMPRESSOR)
25367 RELIEF VALVE 7472 HIGH PRESSURE INTAKE VALVE ASSEMBLY (SHD66 COMPRESSOR)
61642 2 SECTION VALVE ASSY - (STABILIZER CONTROL VALVE)
47860 FILTER ELEMENT - HIGH PRESSURE SERVICE KITS / FILTERS / LUBRICATION
63938 FILTER GAUGE - HIGH PRESSURE FILTER ASM PART# DESCRIPTION
42184 HYDRAULIC RETURN FILTER ASM (HYDRAULIC RESERVOIR) 64837 9000 CRANE 458 MHz Radio system W/SHD66 COMPRESSOR SERVICE KIT
47820 HYDRAULIC FILTER ELEMENT (USED IN PART# 42184) 4559 AIR FILTER (SHD66 COMPRESSOR)
44534 PRESSURE SWITCH (OVERLOAD) 47820 HYDRAULIC RETURN FILTER (CRANE / COMPRESSOR)
33941 HYDRAULIC SWING MOTOR 37864 SERVICE KIT - 250 HOUR (SHD66 COMPRESSOR)
63029 FILL CAP ASSY - HYDRAULIC RESERVOIR 4460 MOLUBE GREASE-EXTERNAL GEAR TEETH FOR SWING GEAR BEARINGS)
15463 THERMO SIGHT GAUGE C0087 SYNTHETIC COMPRESSOR OIL ( 1 QT )
C6327 FILTER STRAINER
C2027 O RING (#4 FACE SEAL) (HYDRAULIC FITTINGS) MISCELLANEOUS COMPONENTS
C2028 O RING (#6 FACE SEAL) (HYDRAULIC FITTINGS) PART# DESCRIPTION
C2029 O RING (#8 FACE SEAL) (HYDRAULIC FITTINGS) 51263 FLOOD LIGHTS (CRANE AND BODY)
32223 O RING (#10 FACE SEAL) (HYDRAULIC FITTINGS) 5033 STROBE LIGHT (CRANE AND BODY)

Call 800-321-3741 to Order

D1245 O RING (#4 SAE PORT SIDE) (HYDRAULIC FITTINGS)
D1246 O RING (#6 SAE PORT SIDE) (HYDRAULIC FITTINGS)
D1247 O RING (#8 SAE PORT SIDE) (HYDRAULIC FITTINGS)
D1248 O RING (#10 SAE PORT SIDE) (HYDRAULIC FITTINGS)
C6305 SEAL KIT (OUTRIGGER CYLINDER) K-0500-250-16
38971 SEAL KIT (MAIN LIFT CYLINDER)
38680 SEAL KIT (SECONDARY CYLINDER)
67100 SEAL KIT (EXTENSION CYLINDER) K-0350-200-48
C1090 COUNTER BALANCE VALVE (STABILIZER CYLINDERS)
16154 MANIFOLD ASSEMBLY (MAIN AND SECONDARY CYLINDERS)
9803 COUNTER BALANCE VALVE (CYLINDERS)
29353 TUBE ASSEMBLY (MAIN LIFT CYLINDER)
29357 TUBE ASSEMBLY (SECONDARY CYLINDER)
13554 QUICK COUPLER-HYDRAULIC 0.38 FEMALE
13555 QUICK COUPLER-HYDRUALIC 0.38 MALE
13556 QUICK COUPLER-HYDRAULIC 0.50 FEMALE
13557 QUICK COUPLER-HYDRAULIC 0.50 MALE

ASSEMBLY COMPONENT PARTS

PART# DESCRIPTION
59140 WORM GEAR - ROTATION GEAR BEARING
59141 BEARING & SEAL KIT - ROTATION GEAR BEARING
0067 BUSHING 1.50" X 1.50"
0635 BUSHING 2.50" X 2.00"
4379 BUSHING 2.00" X 2.50"
4380 BUSHING 2.00" X 1.50"
4381 BUSHING 2.00" X 2.00"
8819 BUSHING 2.00" X 1.00"
44533 BUSHING 2.00" X 0.75"
8377 PIN CAP 0.56" X 3.50" x 0.25"
5145 PIN CAP 0.56" X 3.00" x 0.25"
10172 CAP SCREW 0.50-13 X 1.00" GRADE 8
D0790 WASHER .50 SAE FLAT GRADE 8
C1592 GREASE ZERK 1/8 NPT STRAIGHT
9435 WEAR PAD 1.34" X 3.00" ROUND
30483 WEAR PAD 0.34" X 3.00" ROUND
26762 HOOK 7-TON
5192 HITCH PIN 1.25" X 5.13"
28496PC COLLAR - HOOK
38676 SAFETY LATCH
30009 HOSE CLAMP (CRANE MAST)
8622 HOSE CLAMP (SECONDARY)

ELECTRICAL COMPONENTS
PART# DESCRIPTION
50911 PADDLE SWITCH (HETRONIC RADIO REMOTE)
47856 E-STOP SWITCH (HETRONIC RADIO REMOTE)
47863 BATTERY (HETRONIC RADIO REMOTE)
35916 CABLE BACK UP (HETRONIC RADIO REMOTE)
D0045 ALARM (OVERLOAD)
41922 RADIO REMOTE SYSTEM (TRANSMITTER & RECEIVER)
50219 RADIO REMOTE SYSTEM (TRANSMITTER & RECEIVER) (458) CHINA
50220 RADIO REMOTE SYSTEM (TRANSMITTER & RECEIVER) (434) AUSTRALIA
C6072 BOSCH RELAY
22921 E-STOP SWITCH (PANIC BAR)
61562 CONTACT SWITCH (PANIC BAR) Switch inside E-stop housing (22921)
61563 ROTARY SWITCH
61699 POINTER BAR KNOB
C4815 TOGGLE SWITCH - ON/OFF
36 9000 Owners Manual

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Chapter 10 - Troubleshooting
This chapter will list a number of potential problems that may occur while
operating the crane. Most problems are easily solved using the solutions
portion of this chapter. If problems persist, please contact Customer Service
at Stellar Industries 1-800-321-3741.
Problem: Crane will not operate.
Solutions:
Make sure that the parking brake is
engaged.
Make sure that the PTO is engaged.
Make sure that there is 12V power going
to the radio receiver. If there is no power
going to the receiver, trace back to the
power source and check for a blown fuse
or loose ground connection. Refer to
radio remote troubleshooting guide at the
end of this chapter.
Make sure that the transmitter batteries
are fully charged. (Rechargeable
batteries are good for 11 months or 200
charges)
Make sure that the hydraulic pump is
operating at its rated flow or GPMs.
Check the flow by using the flow meter to
determine the GPMs. It is possible that the
hydraulic pump is getting weak. If this is
suspected, contact Stellar Customer
Service.
Problem: Crane will operate manually but
will not operate electrically.
Solutions:
Make sure that there is 12V power going
to the radio receiver. If there is no power
going to the receiver, trace back to the
power source and check for a blown fuse
or loose ground connection. Refer to
radio remote troubleshooting guide at the
end of this chapter.
Make sure that the parking brake is
engaged.
Make sure that the parking brake switch is
working properly. Check the parking
brake switch by performing a continuity
test. If the switch is defective, simply
replace it.
Troubleshooting 37
Problem: Not all crane functions operate
using the radio remote transmitter or crane
operates intermittently.
Solutions:
Make sure that the toggle switch is
working properly. If the switch is
defective, simply replace it.
Make sure that there is power going from
the valve bank coil solenoid or to the
function that will not operate. If no power
is going to the coil solenoid, check wiring
connections on wire harness plug
connector for broken wires, loose
connection or poor crimp. If power is
going to the solenoid valve, it may not be
opening to allow hydraulic oil to the
function that is not operating. Remove
stem valve, thoroughly clean, lubricate,
and reinstall valve. Do not over tighten. If
the valve will not close, simply replace it.
Problem: Two functions operate at the same
time while only toggling one function.
Solutions:
Make sure that the solenoid valves
manual override sleeves are all in the
center position.
Determine the function that is operating
on its own. Check to see if there is power
going to the solenoid valve from a
function that should not be operating. If
voltage is present at the solenoid valve
without operating the function, the toggle
switch has failed and is stuck in the on
function. If no voltage is present, the
solenoid valve may be partially open.
Remove the stem valve, thoroughly
clean, lubricate, and reinstall the valve.
Do not over tighten. If valve will not close,
simply replace it.
38 9000 Owners Manual
Problem: Crane only operates at full speed.
Solutions:
Check to see if there is 12V power constantly
going to the proportional valve. If 12 volts are
showing up at the proportional valve without
pulling on the transmitter trigger, the
handle/trigger assembly may be defective. If
8 volts are showing at the proportional valve,
it is possible that the valve is stuck open and
will not close. Remove the valve, clean it
thoroughly and reinstall. Do not over tighten.
If the problem persists, replace the
proportional valve.
Check to see if the manual override on the
proportional valve is turned out. Turn the
manual override on the flow valve in.
Problem: Crane operates slowly.
Solutions:
Make sure that the crane is receiving the
recommended GPMs to operate.
Check the level of hydraulic fluid in the
reservoir. Add fluid as needed.
Check to see if the valve bank orifice is
plugged. If so, replace the orifice. Call Stellar
Customer Service for instructions.
Make sure the proportional valve is receiving
12V power when fully engaging the
transmitter trigger. If there is not 12V power
while pulling the trigger, check for loose
connections inside the transmitter or replace
the handle trigger assembly. If the
proportional valve is receiving 12 volts, loosen
the solenoid holding nut and check to see if
the solenoid coil is magnetizing. If no polarity
is present, replace the coil. If coil is
magnetizing, remove the stem valve,
thoroughly clean, lubricate, and reinstall the
valve.
Problem: Cylinder drifts outward or downward.
Solutions:
Check to see if there is air in the hydraulic
system. Operate all cylinders connected to
the hydraulic system. Start with the extension
cylinder, then operate the main boom, winch,
rotation, and ending with the hydraulic
stabilizers, if installed. When operating, extend
each cylinder halfway out, retract all the way
in, and then extend until the cylinder rod is at
the end of its stroke. Operate cylinders slowly
so air is pushed thru the system to the reservoir.
Repeat this cycle 2-3 times.
Make sure the holding valves are operating
properly. Remove, clean, and then inspect
each holding valve. When removing a
holding valve, always relieve the pressure
inside the cylinder by loosening jam nut of the
holding valve and turning set screw
inward/clockwise. Count the number of turns
until the set screw is seated. When reinstalling
the holding valve, make sure the valve is reset
by turning the set screw the number of turns it
took to relieve the pressure. Finish by
tightening the jam nut.
Check the cylinder rod for scratches. If a
scratch is located on the cylinder rod,
hydraulic fluid can pass thru and cause a loss
of pressure. Replace cylinder rod or cylinder.
Check to see if the piston seals are damaged.
If they show signs of damage, install a new
cylinder seal kit.
Problem: Single crane function will not operate
(Will not pressurize), because the valve section
shuttle ball is not releasing.
Solutions:
Locate a different valve section further down
stream from the valve section that is not
functioning. Note: Use a function other than
any rotation sections such as crane rotation,
tireman rotation, or pad rotation. Operate the
valve section or crane function further down
stream from the faulty valve section. Extend
the cylinder or cylinders until full extension is
achieved and hold. While holding that
function, operate the faulty valve section
function, then quickly release the handle
assembly of the valve section that was being
held. By pressurizing the the function further
down stream and quickly releasing the
handle, the back pressure should release the
shuttle ball on the faulty valve section. This
may not work the first time so repeat the
above procedure until the faulty function
operates properly.
If problems persist, please contact
Stellar Customer Service at:
1-800-321-3741
39
40 9000 Owners Manual
Available on some systems. Consult BMS-2 Operator Manual for details.
Problem
System will not initialize after
normal start-up procedure.
The transmitter is turned on,
but does not transmit (Power
LED not flashing)
Transmitter is transmitting
(Power LED flashing), but
crane will not respond.
All crane/machine
motions operate
intermittently
Some crane/machine
motions operate
intermittently
BMS-2 Receiver Troubleshooting
Probable Cause
E-Stop reset
Joystick or paddle lever not in
center position.
E-Stop switch engaged.
Battery fully discharged.
No power to the receiver.
Battery is discharged.
Coder board fuse.
Broken key switch.
Coder board failure.
E-Stop switch engaged.
Transmitter out of range.
Joystick, paddle lever or switch
not in center position when
transmitter turned on.
Receiver power off.
Blown fuse in receiver.
E-Stop failure in transmitter.
E-Stop failure in receiver. Red E- Check wiring on E-Stop module, decoder module, E-Stop decoder module. Secure
Stop LEDon decoder board is
illuminated.
E-Stop module failure.
Receiver antenna loose or
missing.
External antenna (if used) has
loose connection, poor grounding Section for operational precautions.
or interference.
Connector wiring too close to
power wiring.
Connector inside receiver is
loose.
Crane/machine motion wiring may Check wiring from receiver to plug and from plug to crane/machine motion
be loose.
Connector inside receiver is
loose.
Connector wiring too close to
power wiring.
Troubleshooting 40
Correction
Push the Start button again. If the system is being initialized from an E-Stop
condition, the Start button must be pressed twice - first to clear the E-Stop, then
again, to start the system.
Be sure that all joysticks and paddle levers are in center position when the Start
button is activated.
Pull out E-Stop switch. Restart system by pressing Start twice.
Check battery to ensure a full charge. Replace with fully charged battery if
necessary.
Check the diagnostic Display on the side of the receiver to be sure power is
applied. Ensure that the system is securely grounded to the negative battery
terminal. The Display also indicates normal transmitter communication,
interference, and E-Stop conditions.
Replace battery with a fully charged battery.
Check fuse and replace if necessary.
Check wiring on key switch. Replace key switch, wiring or contact element.
Contact Hetronic or your Dealer.
Pull out the E-Stop pushbutton and press the Start/Horn pushbutton.
Take the transmitter back into the range of the receiver. Press the Start/Horn
pushbutton.
Ensure that all control devices are in center (neutral) position when the Start button
is activated.
Turn on power to receiver.
Check all fuses. Replace if necessary.
Check E-Stop pushbutton for damage. Check wiring to contact element for broken
or disconnected wires. Repair or replace E-stop pushbutton or wiring.
any loose connections.
Replace E-Stop module.
Tighten or replace antenna.
Tighten antenna and ground connection. See "Connecting an External Antenna"
Control wiring must be run separately from power wiring.
Check all connectors, reseat if necessary.
actuator.
Check all connectors, reseat if necessary.
Control wiring must be run separately from power wiring.
41
 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 Stellars 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
of manufacture,
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.

Stellars obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellars 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 Stellars 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 Stellars 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 Stellars 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