Stellar Industries 7628 Users Manual Telescopic Crane

2015-02-02

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 
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com Last Revision: 09/17/12
Subject to Change without Notification.
© 2012 Stellar Industries, Inc.
®
TM
7628 Manual Revisions
Date of Revision
September 15th, 2011
Description of Revision
New Flip Sheave Design Implemented. Updated Extention
Boom Assembly Drawings.
Section Revised
Chapter 2: Installation
Chapter 3: Assembly
Drawings
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741
Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST
Or email at the following addresses:
Technical Questions, and Information service@stellarindustries.com
Order Parts parts@stellarindustries.com
Warranty Information warranty@stellarindustries.com
Table of Contents
Table of Contents
Chapter 1 - Specifications ......................................................................1
Capacity Chart - Decal PN 55114 .....................................................2
Chapter 2 - Installation ...........................................................................3
Installation Overview ...........................................................................4
Control Kit - PN 54968 ..........................................................................5
Control Kit (Non-Boost) - PN 56490.....................................................6
Hydraulic Kit - PN 52264.......................................................................7
Valve Bank - PN 52265.........................................................................8
Hydraulic Installation ...........................................................................9
Winch Case Drain Installation ..........................................................10
Hydraulic System................................................................................11
Stability Procedure.............................................................................12
Decal Placement - 54970 .................................................................13
Chapter 3 - Assembly Drawings ..........................................................15
Base Assembly - PN 50364.................................................................15
Mast Assembly - PN 62795 ................................................................16
Main Boom - PN 54960 ......................................................................17
Extension Boom Assembly - PN 61831 .............................................18
Extension Boom Assembly - PN 61831 (Expanded)........................19
Main Cylinder Assembly - PN 54961.................................................20
Extension Cylinder Assembly - PN 50929 .........................................21
Snatch Block Assembly - PN 56266 ..................................................22
CDT™ Radio Transmitter Assembly - PN 56647 ...............................23
Chapter 4 - Replacement Parts ...........................................................25
 7628 Owner’s Manual
Specifications
Chapter 1 - Specifications
Model 7628 Crane
SPECIFICATION SHEET
Crane Rating: 38,000 ft-lb (5.25 TM)
Standard Boom Length: 12’6” (3.81 m) from CL of Crane
Boom Extension: 1st stage: Hydraulic 90"(228.6 cm)
2nd stage: Hydraulic 90"(228.6 cm)
Maximum Horizontal Reach: 28’6” (8.69 m) from CL of Crane
Maximum Vertical Lift: 30’4” (9.24 m)
(from crane base)
Boom Elevation: -5 to +80 degrees
Stowed Height 35.50” (90.2 cm)
(crane only)
Mounting Space Required 20 x 21 inches (50.8 x 53.3 cm)
Approximate Crane Weight 1900 lbs (885 kg)
Controls Radio control standard
for all functions.
Winch Specification
Rope Diameter: 3/8"(.952 cm)
Line pull speed: 60 ft/min (18.29 m/min)
Max. single part line: 3750 lbs (1700 kg)
Max. double part line: 7500 lbs (3400 kg)
Rotation: 400 degree power
(worm gear)
Lifting Capacities 3040 lbs @ 12’6” (375 kg @ 3.81 m)
1335 lbs @ 28’6” (605 kg @ 8.69 m)
Power Supply Required PTO & Pump
(8 gpm @ 3000 psi)
(30.3 lpm @ 207 bar)
*Subject to change without notification
7628 Owner’s Manual
0'
0 m
3'
.914m
6'
1.83 m
9'
2.74 m
12'6”
3.81 m
28'6”
8.69 m
20'6”
6.25 m
12'
3.66 m
3'
.914
6'
1.83 m
9'
2.74 m
15'
4.57 m
18'
5.49 m
21'
6.40 m
24'
7.01 m
27'
8.23 m
30' 4”
9.25 m
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
Maximum 1 - part line capacity is
3750 lbs (1700 kg). For greater
loads, use 2 - part line.
PN 55114
Reach in Feet/Meters
Capacity in Pounds/Kilograms
15º
30º
80º
75º
60º
45º
Boost
(If Equipped)
Standard
7500 lbs
3400 kg
7500 lbs
3400 kg
5545 lbs
2515 kg
4260 lbs
1930 kg
5030 lbs
2280 kg
3435 lbs
1555 kg
4850 lbs
2200 kg
3150 lbs
1425 kg
3720 lbs
1685 kg
3040 lbs
1375 kg
3585 lbs
1625 kg
1845 lbs
835 kg
2175 lbs
985 kg
1335 lbs
605 kg
1575 lbs
715 kg
7500 lbs
3400 kg
4685 lbs
2125 kg
5330 lbs
2415 kg
6330 lbs
2870 kg
7470 lbs
3385 kg
2555 lbs
1155 kg
3015 lbs
1365 kg
1880 lbs
850 kg
2220 lbs
995 kg
1525lbs
690 kg
1800 lbs
815 kg
1375 lbs
620 kg
1620 lbs
735 kg
1920 lbs
870 kg
2265 lbs
1025 kg
2110 lbs
955 kg
2490 lbs
1130 kg
2605 lbs
1180 kg
3075 lbs
1395 kg
3500 lbs
1585 kg
4130 lbs
1870 kg
6300 lbs
2855 kg
7430 lbs
3370 kg
6540 lbs
2965 kg
Capacity Chart - Decal PN 55114
Installation
Chapter 2 - Installation
General Installation
This chapter is designed to serve as a
general guide for the installation of a Stellar
7628 Telescopic Crane on a Stellar Service
Body. Each installation is considered unique
so certain portions of this chapter may or
may not apply to your direct application. If
a question should arise during the installation
process, please contact Stellar Customer
Service at (800) 321 3741.
This crane is designed for use with a Stellar
Service Body installed on a vehicle that
meets the minimum chassis requirements of
the crane. It is the installer’s responsibility to
assure that the crane is mounted on a
platform that will support the maximum
crane rating of this crane.
Notice:
PTO and Pump installation instructions are
provided by the corresponding
manufacturers. For more information on
which PTO and Pump fit your application,
please contact your local Stellar Distributor
or Stellar Customer Service.
Installation Notice
According to Federal Law (49 cfr part 571),
each final-stage manufacturer shall
complete the vehicle in such a manner that
it conforms to the standards in effect on the
date of manufacture of the incomplete
vehicle, the date of final completion, or a
date between those two dates. This
requirement shall, however, be superseded
by any conflicting provisions of a standard
that applies by its terms to vehicles
manufactured in two or more stages.
Therefore, the installer of Stellar cranes and
bodies is considered one of the
manufacturers of the vehicle. As such a
manufacturer, the installer is responsible for
compliance with all applicable federal and
state regulations. They are required to
certify that the vehicle is in compliance with
the Federal Motor Vehicle Safety Standards
and other regulations issued under the
National Traffic and Motor Vehicle Safety
Act.
Please reference the Code of Federal
Regulations, title 49 - Transportation, Volume
5 (400-999), for further information, or visit
http://www.gpoaccess.gov/nara/index.html
for the full text of Code of Federal
Regulations.
Notice: Read this Page Before Installation of the Crane
Important: When installing welder units to the service
bodies, it is highly recommended that a surge
protector is installed on the chassis batteries to protect
the crane radio receiver, wiring and other electronic
devices from an unexpected electrical spike or surge.
Failure to do so could result in extensive damage to
the service body and crane electrical circuit.
7628 Owner’s Manual
2
1
FRONT
Motor
Hole Mounting Detail
Ø1.063
7.38
14.75
7.38
14.75
Ø6.00
4 Places
65382
ITEM NO. PART NO.
1 5199
QTY.
WASHER 1.00 SAE FLAT YELLOW GR8
CAP SCR 1.00X8X3.00 HHGR8 ZY
DESCRIPTION
4
4
WARNING!
The use of this crane on a
body not capable of handling
the loads imposed on it may
result in serious injury or
death.
Installation Overview
1. Determine that the mounting location for the 6628 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.
3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 6628 weighs
approximately 1900 lbs (885 kg). Note: cranes are shipped with rotation positioned at 200 degrees of 400
degree system. This will allow for easy installation of the crane and permanent connection of all hydraulic
and electrical components prior to repositioning into the crane saddle.
4. Connect straps or chain from the lifting device to the lifting rings on the Stellar 6628.
5. Use four (4) 1” x 3” #8 bolts and four (4) #8 flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the Stellar 6628 just above the crane compartment and start the bolts.
Have someone assist in leveling the crane. Note: the rotation motor should be to the door side of crane
compartment and the boom should be extended back over the rear bumper.
9. Secure the crane using the mounting hardware provided. Note: longer or shorter cap screws may be
required – recommended thread engagement into crane base is 1.75” – use grade 8, zinc plated cap
screws only.
10. Torque the cap screws to 680 ft-lbs.
11. Remove supporting crane.
12. Hook-up hydraulics and electrical.
Note: If questions should arise during any portion of this installation,
please contact Stellar Customer Service at (800) 321-3741.
Installation
PN 54968
Control Kit - PN 54968
7628 Owner’s Manual
PN 56490
Control Kit (Non-Boost) - PN 56490
Installation
NOTE: USE 32" OF HOSE PROTECTOR
P/N 17288 OVER THE ROTATION HOSES
NOTE: USE 12" OF HOSE PROTECTOR
P/N 17288 OVER THE 3 WINCH HOSES
PN 52264
Hydraulic Kit - PN 52264
7628 Owner’s Manual7628 Owner’s Manual
HYDRAULIC SCHEMATIC 4
3
1
4
3
4
3
2
PN 52265
YTQNOITPIRCSEDTRAPMETI
1 25367 RELIEF VALVE 24685/24690 1
25368 SEAL KIT 25367
2 24960 VALVE FLW CTRL PRP/JP04C3150N 0-8 1
25369 SEAL KIT 24960/25381
3 25371 VALVE SOLND 3 POS 4 WAY TAND G04571 4
25373 SEAL KIT 25371/25372
4 44532 COIL 12VDC DUETSCH CAP012H 9
Valve Bank - PN 52265
Installation
Hydraulic Installation
 7628 Owner’s Manual 7628 Owner’s Manual
Winch Case Drain Installation
Installing the winch case drain
1. The winch case drain must run directly to the reservoir to ensure no back pressure in the line.
2. Use 3/8” hydraulic hose and fittings rated for a minimum of 300 psi.
3.
4. Attach one end of the winch case drain to 3/8 swivel fitting located in step 3.
5. Route the winch case drain hose directly to the reservoir.
6. Connect the second end of the winch case drain to unshared fitting on the top of the reservoir as
shown in Fig 2.
Fig.1 Fig. 2
Locate the winch case drain line at the bottom of the crane base as shown in Fig. 1 (Blue Hose).
Note: Both the main pressure and winch case drane line use a 3/8” swivel fitting. Verify the winch
case drain is attached to the hose that is connected to the winch motor.
(Blue)
Installation 
Hydraulic System
 7628 Owner’s Manual 7628 Owner’s Manual
Definition of Stability for the Stellar Telescopic Crane
Products:
A truck is stable until the load cannot be lifted off
the ground with the winch, without tipping over the
truck. Every Stellar crane installed must be tested for
stability to determine the actual load capacity of
the final truck package. The actual test data must
be recorded and supplied with the truck at the time
of in-service and should be kept with the truck at all
times. The following procedure will test the truck
package for stability and will provide a stability
capacity chart. The load limit information shown on
the stability capacity chart is formulated on 85%
tipping.
Set Up:
1. Locate the truck on a test course in position for
loading and engage travel brakes.
2. Set stabilizers so that they make contact with firm,
level footing.
3. Operate the crane under partial load to assure
operator proficiency and proper machine
function.
4. Put the radio into Stability Test Mode:
A. Push the bottom four switches up and hold until
all lights come on (approximately 5 seconds.)
B. At this point ,the crane will have enough
capacity to handle the weight for the stability
test.
C. The radio will timeout of stability mode after 30
minutes or when the E-Stop button is pushed.
Note: The radio can only be put into stability mode
five times. After that, the radio would have to be
returned to Stellar to be reprogrammed to allow
additional stability testing. All other radio functions
will work properly even if stability mode is not avail-
able.
Test Procedure
1. Rotate the crane into Zone 1 position.
2. With the crane fully retracted and the boom
horizontal, winch the test weight off the ground.
Note: Keep weight within six inches of the ground
at all times.
3. Extend the boom outward until full extension has
been reached or until the truck becomes unstable
(Again, use the winch to keep the weight within six
inches of the ground.)
4. If the boom goes full extension without becoming
unstable, the crane is termed stable for this zone
and 100% can be written in the Zone 1 data box.
5. If the truck becomes unstable prior to going full
extension, retract the boom until the truck
becomes stable and measure the horizontal
reach in this position (center of rotation to boom
tip). This is the stable horizontal reach for this zone.
Stable horizontal reach divided by Maximum
horizontal reach multiplied by 100 equals the
percentage of rated capacity for this zone. Use
the following formula to determine the
percentage of rated capacity:
6. Record this number in the data box for Zone 1.
This is the revised capacity due to stability for this
zone.
7. Repeat this procedure for each zone until the
worksheet is completed.
8. This is the revised capacity based on stability of
this package.
7628 Stability Data
Max Horizontal Reach: 342” (From the center of
rotation to boom tip)
Boost Stability Test Weight: 1860 lbs.
Non-Boost Stability Test Weight: 1575 lbs.
Stability Procedure
Installation 
PN 54970
*USE THESE DECALS WITH BODY PACKAGE
**THESE DECALS NOT INCLUDED WITH THE DECAL KIT
1
2
®®
7628
3
26
14,15
27
22
29
28
30
25
9
60
50
0
20
30
10
40
Angle Indicator
80
70
ITEM
01
*04
02
*03
*05
*06
09
*07
*08
*10
*11
*12
*13
15
14
DECAL HOISTING PERSONNEL
DECAL STELLAR LOGO 6.5 x 18
DESCRIPTION
PART No.
52681
PART No.ITEM
QTY
*16
2
12451
DESCRIPTION QTY
1
DECAL ASME/ANSI B30.22/B30.5
DECAL GREASE WORM DRIVE BEARINGS
DECAL-ROTATION ALIGNMENT
C4545 DECAL-ELECTROCUTION 5x13
DECAL CAPACITY
DECAL 7628 IDENTIFICATION55113
55114
DECAL-DANGER
DECAL-DANGERC4540
C4544
DECAL MANUAL EXT12452
4
*19
*17
2
C5910
*18
2
C5911
DECAL-STELLAR 4x9.5
DECAL-STELLAR 2x4.5
C0568
1
*20
*21
1
4214
DECAL-DIESEL
DECAL-SERVICE
9188 DECAL-ROTATE/GREASE
DECAL-DANGER
DECAL-ELECTROCUTION 2x2.754186
4189
DECAL-DANGER
DECAL-DANGER O.R.
4190
C4795
4188
1
24
22
1
12300
*23
1
C4541
DECAL-TWO BLOCKING
DECAL-CRANE STOWING
15171
1
25
26
2
15172
1
1
3
2
1
1
1
1
1
1
DECAL VB CONTROL MECH CRANE
DECAL STELLAR MADE IN THE USA
DECAL SNATCH BLOCK CAP 5 TON
DECAL WARNING OVERLOAD DEVICE
DECAL CAUTION STOW HOOK
52270
31
DECAL-ELECTROCUTION 4.5x7.5
DECAL-DANGER MOVING O.R.C5918
C1179
DECAL-ANGLE INDICATOR SS
DECAL ANGLE INDICATOR CS
D1197
D1196
27
2
24712
28
2
28256
35234
30**
1
29
1
38472
1
1
1
1
1
32 25159 DECAL WARNING MANUAL OVERRIDES 1
33
33 54588 DECAL CDT 2.00X2.00 2
Decal Placement - 54970
 7628 Owner’s Manual 7628 Owner’s Manual
Assembly Drawings 
.YTQNOITPIRCSEDTRAPMETI
1 47869 BEARING SWING DRIVE CAST 6620 GEARTEK 1
1EDILS 004 0283 POTS245112
3C6069 MOTOR HYD ROSS MK080613AAAB1
11-65001-800 ROTOM TEKSAG151124
5D1345 FTG CPRSN 0.12NPT/0.25 TUBE2
6D1810 TBE AIR SAEJ844 TYPE A .25 (RM)1
131.0 EPIP RELPUOC GTF6522C7
8 56589 ZERK 1/8 NPT STRAIGHT LONG THREAD 1
2HS 00.2X31-05.0 RCS PAC594359
NOTE: ITEMS 1 INCLUDE GUARD & GUARD FASTENERS
8
2
3
GASKET SHOWN AS REFERENCE
4
5
6
5
7
9
1
PN 50364
Base Assembly - PN 50364
Chapter 3 - Assembly Drawings
 7628 Owner’s Manual 7628 Owner’s Manual
PN 62795
DO NOT GREASE
THESE BUSHINGS
2
1
3
4
5
3
6
10 8
7
8
9
11
13
.YTQNOITPIRCSEDTRAPMETI
112621/12601 TSAM384341
252265VB 4 SECT W/PROP STER8GPM DEUTSCH1
3C5902 WASHER 0.63 SAE FLAT YELLOW GR818
4D1034 CAP SCR 0.63-11X3.00 HHGR8 RED PATCH14
5 63517 WINCH 3750 TH2CC230246 W/120 FT ROPE 1
6 11693 CAP SCR 0.63-11X1.75 HHGR8 4
7 27813 COLLAR 0.38X0.75X0.38 UHMW2
4CNIZ TALF SSU 13.0 REHSAW34308
9C0933 CAP SCR 0.31-18X4.50 HHGR52
2COLYN 5RGHH 81-13.0 TUN243001
11 44533 BUSHING HSG3235012S 2.00X0.754
13 52490 CAP SCR 6MMX30MM HH 8.8(GR5) 4
Mast Assembly - PN 62795
Assembly Drawings 
32
12
11
10
6
2
16
19
7
POSITION OF INCLINOMETER
34
16 26
19
15
19
20
28
21
26
27
17
9
23
22
1
24
25
8
17
12
5
17
5
12
12
17
5
18
31
30
29
13
NOTE: INCLINOMETER MOUNTS
INSIDE THE BOOM. VIEW SHOWS
14
33
2PLATE ANGLE INDICATORD1194PC9
2PIN CAP 0.44X1.75X0.19 SS93208
1PIN 1.00X8.38 D&T9712ZP7
1PIN 2.00X8.88 D&T9711ZP6
6PIN CAP 0.56X2.50X0.1991425
2CAP SCR 0.38-16X9.00 HHGR51216814
1CAP SCR 0.25-20X0.50 HHGR5047813
14CAP SCR 0.50-13X1.00 HHGR81017212
2PLATE WEAR PAD SUPPORT9545PC11
2WEAR PAD 1.12X2.00 RND NYLATRON936310
.YTQNOITPIRCSEDTRAPMETI
18266 MOOB RENNI643051
2 54961 CYLINDER ASM 7628 INNER 1
242-8161-ISQ GNIHSUB86003
2T&D 91.01X00.2 NIPPZ90794
.YTQNOITPIRCSEDTRAPMETI
15 0335 CAP SCR 0.38-16X1.25 HHGR52
16 9843 CAP SCR 0.38-16X0.75 HHGR82
17 D0790 WASHER 0.50 SAE FLAT YELLOW GR818
18 0340 WASHER 0.25 USS FLAT ZINC2
19 C6353 WASHER 0.38 SAE FLAT YELLOW GR86
10269 EDIUG EPOR TKRBCP5343102
21 27720 SPACER ROPE GUIDE 6620 UHMW2
22 0480 CAP SCR 0.25-20X1.00 HHGR51
18275 LEER DROC6619132
24 0425 MACHY WASHER 1.25ID 10GA2
1THGIARTS TPN 8/1 KREZ2951c52
26 4381BUSHING BPC32DXR32 2.00X2.00 4
27 C6106 NUT 0.50-13 HHGR5 NYLOC 2
28 0347 NUT 0.38-16 HHGR5 NYLOC 4
1GED 06 RETEMONILCNI3943592
30 18765 WASHER #6 SAE FLAT ZINC2
31 18618 SCREW #6-32X1.00 PHMS PH2
2SS COLYN HH 23-6# TUN6700D23
1LYNIV KLB 52.0 PMALC6065C33
PN 54960
Main Boom - PN 54960
 7628 Owner’s Manual 7628 Owner’s Manual
PN 61831
See Next Page for
Expanded View.
.YTQNOITPIRCSEDTRAPMETI
18266 TS1 MOOB TXE867431
18267 DN2 MOOB TXE238162
3 50929CYLINDER EXT ASM 6628 2.0/2.01
4 9991 WEAR PAD 0.19X2.50 RND NYLATRON4
183.4X00.1 PORD RAET NIPPZ004315
6 27719SPACER BOOM TIP 6620 UHMW2
7 13339 SHEAVE 7621 8.00 DIA .38R/1.88THK2
2HCNYL 65.1X91.0 NIP35758
9 9363 WEAR PAD 1.12X2.00 RND NYLATRON2
2TROPPUS DAP RAEW ETALPCP545901
11 0425 MACHY WASHER 1.25ID 10GA2
12 61050 PLATE SHEAVE MOUNTING FS/CRADLE 106/1262
105.4X00.1 HCTIH NIP4282131
14 61051 MNT CRADLE LH FS/CRADLE A2B 106/1261
15 61048 CRADLE FS/CRADLE A2B 106/1261
16 61049 LINK FS/CRADLE A2B 106/126 W/HOLES1
17 35105 SWITCH LIMIT E1117-B9111-6C1
18 61054 MNT CRADLE RH FS/CRADLE A2B 106/1261
1RS 91.4X00.1 NIPPZ0867391
20 27710SPRING ANTI 2 BLOCK CRADLE A2B 2
2LYNIV KLB 83.0 PMALC8700C12
1LYNIV KLB 13.0 PMALC9721322
23 C6353 WASHER 0.38 SAE FLAT YELLOW GR86
24 C6219 WASHER 0.75 SAE FLAT YELLOW GR81
25 D0790 WASHER 0.50 SAE FLAT YELLOW GR818
2CNIZ TALF SSU 13.0 REHSAW343062
2CNIZ TALF SSU 52.0 REHSAW043072
2CNIZ TALF EAS 01# REHSAW8710D82
29 0867 MACHY WASHER 1.00ID 14GA2
30 58681 CAP SCR 0.75-10X2.50 HHGR81
31 10666 CAP SCR 0.50-13X1.25 HHGR88
32 0490 CAP SCR 0.31-18X3.50 HHGR52
33 0420 CAP SCR 0.31-18X0.75 HHGR5 1
34 0478 CAP SCR 0.25-20X0.50 HHGR52
35 0484 CAP SCR 0.31-18X0.50 HHGR51
36 C1000 CAP SCR 0.50-13X5.00 HHGR52
37 C1002 CAP SCR 0.50-13X6.00 HHGR51
38 9843 CAP SCR 0.38-16X0.75 HHGR82
39 0489 CAP SCR 0.31-18X2.50 HHGR51
3COLYN 5RGHH 81-13.0 TUN243004
3COLYN 5RGHH 31-05.0 TUN6016C14
42 31132 CAP SCR #10-24X0.550 SH SS 18-82
43 61053 BOLT SHOULDER 0.38X0.50 0.31-18X0.504
252.X05.3X65.0 PAC NIP023944
104HCS 31.3 X05.0 EPIPCP8451654
46 61549COLLAR 1.13X2.00X1.13 W/HOLE 1
1CCPK KROF 00.1 HCTIH NIP5215474
1621/601 B2A ELDARC/SF KNIL8395684
36
42
5
7
26
44 29
21
40
31
6
8
25 10
9
1
30
24
32
3
4
23
37
11
12
38
8
12
28
19
4
25
41
44
23
38
33
16
43
34
23
27
18
14
17
15
45
40
39
46
47
13
25
48
3
Extension Boom Assembly - PN 61831
Assembly Drawings 
PN 61831
See Parts Breakdown
on Previous Page.
Assembled View
47
45
6
23
13
8
38
6
29
42
12
21
27
7
34
12
43
18
23
26
33
5
8
40
16
44
19
44
23
38
14
28
17
41
25
35
26
22
20
32
36
37
25
41
25
46
40
39
25
48
Extension Boom Assembly - PN 61831 (Expanded)
 7628 Owner’s Manual 7628 Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI
150928 CYLINDER 4.50X21.38 NEW MAST 1
4S-OLO5F-6 TPADA GTF97202
341910 MANIFOLD ASM DUAL 10-1CBAL-RLF-CHK 1
444066TUBE ASM 0.38X8.25 MAIN 10628/12628 2
PN 54961
2
4
1
2
4
2
3
2
Cylinder
Serial Tag
Location
Note: This cylinder uses
Stellar Seal Kit PN 35655
.YTQNOITPIRCSEDTRAPMETI
139425 MANIFOLD CBAL DOUBLE T11A WITH RELIEF 1
1NCX-DEXC KCEHC EVLAV809142
1ISP 008 NAL-ADDR EVLAV709143
441906 VALVE C-BAL SUN CBCH-LJN 3500 2
5C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 1
3
5
4
1
2
4
Manifold Assembly
PN 41910
Main Cylinder Assembly - PN 54961
Assembly Drawings 
PN 50929
.YTQNOITPIRCSEDTRAPMETI
1 50919 CYLINDER EXT 6628 2 STAGE 2.0/2.0 1
214115MANIFOLD ASM 6620 EXT CBBD-LJN-XVN 1
3 11882 CAP SCR 0.38-16X1.75 SH ZC 2
4 14601 CAP SCR 0.38-16X2.25 SH ZC 1
5 31652 TUBE ASM 0.38X 72.86 EXT CYL 6628 1
6 31651 TUBE ASM 0.38X 119.75 EXT CYL 6628 1
7 24729 HOSE CLAMP #52 3.00 - 3.75 2
71
5
2
4
6
3
7
Cylinder
Serial Tag
Location
Extension Cylinder Uses:
Upper Seal Kit - PN 54778
Lower Seal Kit - PN 20310
Extension Cylinder Assembly - PN 50929
 7628 Owner’s Manual 7628 Owner’s Manual
3
12
6
9
1
4
4
11
2
2
7
7
13
2
9
8
14
12
10
5
10
PN 56266
ITEMPARTDESCRIPTION Defau
lt
1 13339 SHEAVE 7621 8.00 DIA .38R/1.88THK1
2 53263PC PLATE SNATCH BLOCK 76/96/106/1262
1RETTOC 60.4X00.1 NIPPZ478933
200.2X57.0X44.0 RALLOC346444
5 0347 NUT 0.38-16 HHGR5 NYLOC 2
6C0538 NUT 0.75-10 HHGR8 NYLOC 1
7 0532 CAP SCR 0.38-16X3.75 HHGR52
8 5841 CAP SCR 0.75-10X4.50 HHGR8 1
9C6219 WASHER 0.75 SAE FLAT YELLOW GR82
10 0867 MACHY WASHER 1.00ID 14GA2
1SS KOOH V GNIHSUBPZ4489311
2HCNYL 65.1X91.0 NIP357521
13 25831 HOOK 5 TON SWIVEL CROSBY 10286231
14 13436 PIN .38X4.00 QUICK RELEASE 1
Snatch Block Assembly - PN 56266
Assembly Drawings 
PN 56647
.YTQNOITPIRCSEDTRAPMETI
1 20088 CONTROL HANDLE HOUSING 4 FCTN HET1
2 56657 CONTROL HANDLE FACE PLT W/LABEL 6 FCTN CDT 1
1NTCF 4 HCTIWS OIDAR DRAUG583423
4 35447 CONTROL HANDLE GRIP W/TRIGGER HT H21
524958RUBBER BOOT TRIGGER GUARD HET1
6 22600 SWITCH TOGGLE HET RADIO 630193006
7 35441 BATTERY TUBE AA HETRONIC RADIO1
1LX AVON POTS E HCTIWS658748
3
SEE NOTE
7
5
4
1
2
8
6
NOTE: 1) P/N'S 25999 & 24958 ARE OPTIONAL COVERS
FOR THE SWITCHES AND TRIGGER
CDT™ Radio Transmitter Assembly - PN 56647
 7628 Owner’s Manual
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
39425 MANIFOLD - MAIN LIFT CYLINDER
9803 C-BALANCE VALVE - MAIN LIFT CYLINDER
41907 RELIEF VALVE - MAIN LIFT CYLINDER
41908 CHECK VALVE - MAIN LIFT CYLINDER
28485 PRESSURE TRANSDUCER
9803 C-BALANCE VALVE - EXTENSION CYLINDER
6397 HYD PRESSURE GUAGE
C2027 O'RING - # 4 FACE SEAL
C2028 O'RING - # 6 FACE SEAL
C2029 O'RING - # 8 FACE SEAL
D1245 O'RING - # 4 SAE
D1246 O'RING - # 6 SAE
D1247 O'RING - # 8 SAE
44066 HYD TUBE ASSY - MAIN LIFT CYLINDER
14442 HYD TUBE ASSY - EXTENSION CYLINDER
14443 HYD TUBE ASSY - EXTENSION CYLINDER
35655 SEAL KIT (MAIN LIFT CYLINDER)
54778 SEAL KIT - EXTENSION CYLINDER (UPPER)
20310 SEAL KIT - EXTENSION CYLINDER (LOWER)
55827 WORM GEAR - BEARING SWING DRIVE
55829 BEARING & SEAL KIT - BEARING SWING DRIVE
55830 WORM GEAR / BEARING & SEAL KIT - BEARING SWING DRIVE
0068 BUSHING 1.00" X 1.50"
4381 BUSHING 2.00" X 2.00"
44533 BUSHING 2.00" X 0.75"
23454 WIRE ROPE
9363 WEAR PAD - 2.00" RND
9991 WEAR PAD - 2.50" RND
12824 HITCH PIN - 1.00" X 4.50"
5753 LYNCH PIN - 0.19" X 1.56"
13339 SHEAVE 8.00"
53493 INCLINOMETER 60 DEGREE
11938 LIMIT SWITCH - FLIP SHEAVE
31670 CHAIN & WEIGHT KIT - LIMIT SWITCH (FLIP SHEAVE)
35105 LIMIT SWITCH - CRADLE / BASKET
43488PC CRADLE PLATE - ANTI-2-BLOCK (CRADLE/BASKET STYLE)
61048 CRADLE FS/CRADLE A2B (After 8/1/2011)
27710 SPRING - LIMIT SWITCH CRADLE / BASKET
19166 CORD REEL
56647 RADIO TRANSMITTER (HETRONIC RADIO)
34557 HANDLE ASM - TRANSMITTER
47856 E-STOP SWITCH (HETRONIC RADIO)
35441 BATTERY TUBE (AA) HOLDER (HETRONIC RADIO)
35916 BACK UP CORD 25FT (RADIO REMOTE SYSTEM)
25831 5-TON HOOK
19501 SAFETY LATCH ASM - 5 TON HOOK
C1592 GREASE ZERK
4460 GEAR BEARING GREASE - MOLUBE (Open Teeth)
Limited Warranty Statement
Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under
proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. This warranty
shall cover the following:
Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, and Stellar X-Tra-Lift Systems:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date
ofmanufacture,
Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of
manufacture, and
Thirty-six (36) month warranty on all Stellar Manufactured structural parts from the date recorded by Stellar as the in-service date, not to extend beyond
forty-eight (48) months from date of manufacture.
Stellar Tarper Systems:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date
of manufacture and
Three (3) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond fifteen (15) month from date of
manufacture.
The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, the
factory ship date will be used.
Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option)
of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-
applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24-hours of notification by
the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.
Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service
personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party
prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged parts
must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of
the warranty claim.
Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type
of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence
of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any
field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service
provider.
All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides
other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellar-manufactured
product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any
way not approved, in writing, by Stellar.
The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the
ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the
product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in
question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear,
accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and maintenance
duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such
duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.
The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above.
In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of delay, or for any
special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use,
wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.
All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not
participate in, or obligate itself to, any such warranty.
Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products
theretofore manufactured.
This warranty will apply to all Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, Stellar X-Tra-Lift
Systems, and Stellar Tarper Systems shipped from Stellar’s factory after January 1st, 2010. The warranty is for the use of the original owner only and is not
transferable without prior written permission from Stellar.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR
INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Revision Date: February 2010 Document Number: 37040

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