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stellar labs Model 7621 Owner's Manual

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M
7621
odel
T
c
elescopic
rane
o
' M
wners
anual
installation • assembly drawings • parts
®
TM
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
Subject to Change without Notification.
www.stellarindustries.com
© 2013 Stellar Industries, Inc.

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  • Page 1 ’ M wners anual installation • assembly drawings • parts ® Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 Subject to Change without Notification. www.stellarindustries.com © 2013 Stellar Industries, Inc.
  • Page 2 7621 Manual Revisions Date of Revision Section Revised Description of Revision Chapter 2: Installation New Flip Sheave Design Implemented. Updated Extention Chapter 3: Assembly September 15th, 2011 Boom Assembly Drawings. Drawings...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Chapter 1 - Specifications ..............1 Capacity Chart - Decal PN 54958.............2 Chapter 2 - Installation................3 Installation Overview ................4 Control Kit - PN 54952 ................5 Control Kit (Non-Boost) - PN 55823 ............6 Hydraulic Kit - PN 52264 ..............7 Valve Bank - PN 52265.................8 Hydraulic Installation ................9 Winch Case Drain Installation ............10...
  • Page 4 7621 Owner’s Manual...

  • Page 5: Chapter 1 - Specifications

    Specifications Chapter 1 - Specifications Model 7621 Crane SPECIFICATION SHEET Crane Rating: 38,000 ft-lb (5.25 TM) Standard Boom Length: 11’ 0” (3.35 m) from CL of Crane Boom Extension: 1st stage: Hydraulic 60” (152.4 cm) 2nd stage: Hydraulic 60” (152.4 cm) Maximum Horizontal Reach: 21’...

  • Page 6: Capacity Chart - Decal Pn 54958

    7621 Owner’s Manual Capacity Chart - Decal PN 54958 Reach in Feet/Meters 7500 lbs 9000# Capacity in Pounds/Kilograms 3400 kg 4080 kgs 7470 lbs 7.01 m 3385 kg Boost 6330 lbs (If Equipped) 2870 kg 4050 lbs Standard 1835 kg 6.40 m 3435 lbs 1555 kg...

  • Page 7: Chapter 2 - Installation

    Installation Chapter 2 - Installation Notice: Read this Page Before Installation of the Crane General Installation Installation Notice This chapter is designed to serve as a According to Federal Law (49 cfr part 571), general guide for the installation of a Stellar each final-stage manufacturer shall 7621 Telescopic Crane on a Stellar Service complete the vehicle in such a manner that...

  • Page 8: Installation Overview

    7621 Owner’s Manual Installation Overview 1. Determine that the mounting location for the 7621 crane is at least 18” x 20” (45.7 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.

  • Page 9: Control Kit - Pn 54952

    Installation Control Kit - PN 54952 * WIRING OPTIONS FOR REMOTE CONTROL OF ENGINE SPEED: 1. POWER ON DEMAND (POD) MODE- ALLOWS AUTOMATIC SWITCHING OF HIGH IDLE BASED ON CRANE OPERATION. CORD REEL - OR - 2. ON/OFF MODE - ALLOWS MANUAL SELECTION OF HIGH IDLE. SWITCH INCLINOMETER SPEED CTRL OUTPUT 1...

  • Page 10: Control Kit (Non-Boost) - Pn 55823

    7621 Owner’s Manual Control Kit (Non-Boost) - PN 55823 * WIRING OPTIONS FOR REMOTE CONTROL OF ENGINE SPEED: 1. POWER ON DEMAND (POD) MODE- ALLOWS AUTOMATIC SWITCHING OF HIGH IDLE BASED ON CRANE OPERATION. - OR - CORD REEL 2. ON/OFF MODE - ALLOWS MANUAL SELECTION OF HIGH IDLE. SWITCH INCLINOMETER SPEED CTRL OUTPUT 1...

  • Page 11: Hydraulic Kit - Pn 52264

    Installation Hydraulic Kit - PN 52264 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...

  • Page 12: Valve Bank - Pn 52265

    7621 Owner’s Manual Valve Bank - PN 52265 HYDRAULIC SCHEMATIC PN 52265 25367 RELIEF VALVE 24685/24690 25368 SEAL KIT 25367 24960 VALVE FLW CTRL PRP/JP04C3150N 0-8 25369 SEAL KIT 24960/25381 25371 VALVE SOLND 3 POS 4 WAY TAND G04571 25373 SEAL KIT 25371/25372 44532 COIL 12VDC DUETSCH CAP012H...

  • Page 13: Hydraulic Installation

    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. next page for Case Drain Installation.

  • Page 14: Winch Case Drain Installation

    7621 Owner’s Manual Winch Case Drain Installation Installing the winch case drain The winch case drain must run directly to the reservoir to ensure no back pressure in the line. Use 3/8” hydraulic hose and fittings rated for a minimum of 300 psi. Locate the winch case drain line at the bottom of the crane base as shown in Fig.

  • Page 15: Hydraulic System

    Installation Hydraulic System...

  • Page 16: Stability Procedure

    7621 Owner’s Manual Stability Procedure Definition of Stability for the Stellar Telescopic Crane 7621 Stability Data Products: Max Horizontal Reach: 252” (From the center of A truck is stable until the load cannot be lifted off rotation to boom tip) the ground with the winch, without tipping over the Boost Stability Test Weight: 2520 lbs.

  • Page 17: Decal Placement - Pn 54957

    Installation Decal Placement - PN 54957 14,15 7621 ® ® Angle Indicator PN 54957 **THESE DECALS NOT INCLUDED WITH THE DECAL KIT *USE THESE DECALS WITH BODY PACKAGE 54588 DECAL CDT 2.00X2.00 25159 DECAL WARNING MANUAL OVERRIDES 12451 DECAL HOISTING PERSONNEL 52270 DECAL VB CONTROL MECH CRANE D1197...
  • Page 18 7621 Owner’s Manual...

  • Page 19: Chapter 3 - Assembly Drawings

    Assembly Drawings Chapter 3 - Assembly Drawings Base Assembly - PN 50364 GASKET SHOWN AS REFERENCE PN 50364 47869 BEARING SWING DRIVE CAST 6620 GEARTEK C6069 MOTOR HYD ROSS MK080613AAAB D1345 FTG CPRSN 0.12NPT/0.25 TUBE D1810 TBE AIR SAEJ844 TYPE A .25 (RM) 56589 ZERK 1/8 NPT STRAIGHT LONG THREAD NOTE: ITEMS 1 INCLUDE GUARD &...

  • Page 20: Mast Assembly - Pn 54790

    7621 Owner’s Manual Mast Assembly - PN 54790 DO NOT GREASE THESE BUSHINGS PN 54790 27813 COLLAR 0.38X0.75X0.38 UHMW C5902 WASHER 0.63 SAE FLAT YELLOW GR8 D1034 CAP SCR 0.63-11X3.00 HHGR8 RED PATCH C0933 CAP SCR 0.31-18X4.50 HHGR5 44533 BUSHING HSG3235012S 2.00X0.75 11693 CAP SCR 0.63-11X1.75 HHGR8 52265...

  • Page 21: Main Boom - Pn 54941

    Assembly Drawings Main Boom - PN 54941 PN 54941 4381 BUSHING BPC32DXR32 2.00X2.00 54942 CYLINDER ASM 6620 INNER CDT 0340 WASHER 0.25 USS FLAT ZINC & 0478 CAP SCR 0.25-20X0.50 HHGR5 C6106 NUT 0.50-13 HHGR5 NYLOC & D0790 WASHER 0.50 SAE FLAT YELLOW GR8 &...

  • Page 22: Extension Boom Assembly - Pn 61824

    7621 Owner’s Manual Extension Boom Assembly - PN 61824 PN 61824 61825 EXT BOOM 2ND 7621 FS/CRADLE A2B 49316 CYLINDER EXT ASM 6620 2.0/2.0 9991 WEAR PAD 0.19X2.50 RND NYLATRON 27719 SPACER BOOM TIP 6620 UHMW 13339 SHEAVE 7621 8.00 DIA .38R/1.88THK 9363 WEAR PAD 1.12X2.00 RND NYLATRON 44 29...

  • Page 23: Extension Boom Assembly - Pn 61824 (Expanded)

    Assembly Drawings Extension Boom Assembly - PN 61824 (Expanded) See Parts Breakdown on Previous Page. PN 61824 Assembled View...

  • Page 24: Main Cylinder Assembly - Pn 54942

    7621 Owner’s Manual Main Cylinder Assembly - PN 54942 Manifold Assembly PN 41910 39425 MANIFOLD CBAL DOUBLE T11A WITH RELIEF 9803 Valve C- SUN CBBD-LJN-3500 C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON Cylinder Serial Tag Location PN 54942 50918 CYLINDER INNER 4.00X21.38 NEW MAST 41910 MANIFOLD ASM DUAL 10-1CBAL-RLF-CHK 44066...

  • Page 25: Extension Cylinder Assembly - Pn 49316

    Assembly Drawings Extension Cylinder Assembly - PN 49316 Cylinder Serial Tag Location PN 49316 37548 CYLINDER EXT 2 STAGE 2.0/2.0 PTD 60 14115 MANIFOLD ASM 6620 EXT CBBD-LJN-XVN 11882 CAP SCR 0.38-16X1.75 SH ZC 14601 CAP SCR 0.38-16X2.25 SH ZC 14442 TUBE ASM 0.38X23.25 EXT CYL 6620 14443...

  • Page 26: Snatch Block Assembly - Pn 56266

    7621 Owner’s Manual Snatch Block Assembly - PN 56266 PN 56266 Defau ITEM PART DESCRIPTION 13339 SHEAVE 7621 8.00 DIA .38R/1.88THK 53263PC PLATE SNATCH BLOCK 76/96/106/126 0347 NUT 0.38-16 HHGR5 NYLOC C0538 NUT 0.75-10 HHGR8 NYLOC 0532 CAP SCR 0.38-16X3.75 HHGR5 5841 CAP SCR 0.75-10X4.50 HHGR8 C6219...

  • Page 27: Cdt™ Radio Transmitter Assembly - Pn 56647

    Assembly Drawings CDT™ Radio Transmitter Assembly - PN 56647 SEE NOTE NOTE: 1) P/N'S 25999 & 24958 ARE OPTIONAL COVERS FOR THE SWITCHES AND TRIGGER PN 56647 20088 CONTROL HANDLE HOUSING 4 FCTN HET 56657 CONTROL HANDLE FACE PLT W/LABEL 6 FCTN CDT 35447 CONTROL HANDLE GRIP W/TRIGGER HT H2 24958...
  • Page 28 7621 Owner’s Manual...

  • Page 29: Chapter 4 - Replacement Parts

    Replacement Parts Chapter 4 - Replacement Parts PART# DESCRIPTION C6069 HYDRAULIC SWING MOTOR 25367 RELIEF VALVE 25368 SEAL KIT - RELIEF VALVE (25367) 24960 FLOW CONTROL VALVE 25369 SEAL KIT - FLOW VALVE (24960) 25371 SOLENOID VALVE TAND G04571 25373 SEAL KIT - SOLENOID VALVE (25371) 44532 COIL - 12VDC...
  • Page 30 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...

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