Stellar Industries Telescopic Crane 7621 Users Manual

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Model 7621
Telescopic crane
owners’ Manual

installation • assembly drawings • parts

®

TM

Stellar Industries, Inc.

Subject to Change without Notification.
© 2012 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

7621 Manual Revisions
Date of Revision

Section Revised

Description of Revision

September 15th, 2011

Chapter 2: Installation
Chapter 3: Assembly
Drawings

New Flip Sheave Design Implemented. Updated Extention
Boom Assembly Drawings.

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
Hydraulic System................................................................................11
Stability Procedure.............................................................................12
Decal Placement - PN 54957 ...........................................................13
Chapter 3 - Assembly Drawings...........................................................15
Base Assembly - PN 50364 ................................................................15
Mast Assembly - PN 54790 ................................................................16
Main Boom - PN 54941 ......................................................................17
Extension Boom Assembly - PN 61824 .............................................18
Extension Boom Assembly - PN 61824 (Expanded) .......................19
Main Cylinder Assembly - PN 54942 ................................................20
Extension Cylinder Assembly - PN 49316.........................................21
Snatch Block Assembly - PN 56266..................................................22
CDT™ Radio Transmitter Assembly - PN 56647...............................23
Chapter 4 - Replacement Parts............................................................25

Find a Dealer Near You:
http://www.stellarindustries.com/pages/dist/distsearch.htm
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

service@stellarindustries.com
parts@stellarindustries.com
warranty@stellarindustries.com

i

ii

7621 Owner’s Manual

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’ 0” (6.40 m) from CL of Crane

Maximum Vertical Lift:
(from crane base)

23’ (7.01 m)

Boom Elevation:

-5 to +80 degrees

Stowed Height:
(crane only)

35.5” (90.2 cm)

Mounting Space Required:

20” x 21” (50.8 x 53.3 cm)

Approximate Crane Weight:

1625 lbs (735 kg)

Controls:

Radio control standard
for all functions.

Winch Specifications
Rope Diameter:
Line pull speed:
Max. single part line:
Max. double part line:

3/8" (.952 cm)
60 ft/min (18.29 m/min)
3750 lbs (1700 kg)
7500 lbs (3400 kg)

Rotation:
(worm gear)

400 degree power

Lifting Capacities:

3455 lbs @ 11’ (1565 kg @ 3.35 m)
2375 lbs @ 16’ (1075 kg @ 4.88 m)
1810 lbs @ 21’ (820 kg @ 6.40 m)

Power Supply Required:

PTO & Pump
(8.0 gpm @ 3000 psi)
(30.31 lpm @ 207 bar)

*Subject to change without notification

1

2

7621 Owner’s Manual

Capacity Chart - Decal PN 54958
Reach in Feet/Meters
Capacity in Pounds/Kilograms

7500
lbs
9000#
3400 kgs
kg
4080
7470 lbs
3385 kg
6330 lbs
2870 kg

23'
7.01 m

Boost

(If Equipped)

4050 lbs
1835 kg
3435 lbs
1555 kg

21'
6.40 m

Standard

7500
lbs
9000#
3400kgs
kg
4080
7500
9000#lbs
3400kgs
kg
4080

5230 lbs
2370 kg
4435 lbs
2010 kg

7500
lbs
9000#
3400kgs
kg
4080
9000#
7500
lbs
4080
3400 kgs
kg

80º

45º

4700 lbs
2130 kg
3985 lbs
1805 kg

30º

15º

4405 lbs
1995 kg
3735 lbs
1695 kg

4075 lbs
1845 kg
3455 lbs
1565 kg

0'
0m

3'
.914 m

6'
1.83 m

9'
11'
2.74 m 3.35 m

Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.

2465 lbs
1115 kg
2090 lbs
945 kg
3230 lbs
1465 kg
2735 lbs
1240 kg

5545 lbs
2515 kg
4700 lbs
2130 kg

60º

15'
4.57 m

3855 lbs
1745 kg
3270 lbs
1480 kg

7390 lbs
3350 kg
6265 lbs
2840 kg

75º

18'
5.49 m

2955 lbs
1340 kg
2505 lbs
1135 kg

2950 lbs
1335 kg
2500 lbs
1130 kg

2240 lbs
1015 kg
1900 lbs
860 kg

12'
3.66 m

9'
2.75 m

6'
1.83 m

3'
.914 m

2800 lbs
1270 kg
2375 lbs
1075 kg

2135 lbs
965 kg
1810 lbs
820 kg

16'
4.88 m

21'
6.40 m

Maximum 1 - part line capacity is
3750 lbs (1700 kg). For greater
loads, use 2 - part line.

PN 54958

Installation

3

Chapter 2 - Installation
Notice: Read this Page Before Installation of the Crane
General Installation
Installation Notice
This chapter is designed to serve as a
general guide for the installation of a Stellar
7621 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.

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
Important: When installing welder units to the service
5 (400-999), for further information, or visit
bodies, it is highly recommended that a surge
protector is installed on the chassis batteries to protect http://www.gpoaccess.gov/nara/index.html
the crane radio receiver, wiring and other electronic for the full text of Code of Federal
devices from an unexpected electrical spike or surge. Regulations.
Failure to do so could result in extensive damage to
the service body and crane electrical circuit.

4

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.
3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 7621 weighs
approximately 1625 lbs (735 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 7621.
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 7621 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.

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.

FRONT
Motor

Ø1.063
4 Places

14.75

2

Ø6.00

7.38

1
7.38
14.75

Hole Mounting Detail

ITEM NO.
1
2

PART NO.
5199
6538

QTY.
DESCRIPTION
CAP SCR 1.00X8X3.00 HHGR8 ZY
4
WASHER 1.00 SAE FLAT YELLOW GR8 4

Installation

Control Kit - PN 54952

PN 54952

5

6

7621 Owner’s Manual

Control Kit (Non-Boost) - PN 55823

PN 55823

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

7

8

7621 Owner’s Manual

Valve Bank - PN 52265

HYDRAULIC SCHEMATIC

4

2

1

3

4

3

4

3

PN 52265
ITEM PART
1
25367
25368
2
24960
25369
3
25371
25373
4
44532

DESCRIPTION
RELIEF VALVE 24685/24690
SEAL KIT 25367
VALVE FLW CTRL PRP/JP04C3150N 0-8
SEAL KIT 24960/25381
VALVE SOLND 3 POS 4 WAY TAND G04571
SEAL KIT 25371/25372
COIL 12VDC DUETSCH CAP012H

QTY
1
1
4
9

Installation

Hydraulic Installation

1. After mounting, locate the pressure and return
lines. Note: Pressure line is 3/8” hose; Winch
Case Drain Line is 3/8” hose; Return line is 1/2”
hose. Hoses are terminated using swivel fittings.
2. Install hydraulic lines per diagram below. See
next page for Case Drain Installation. Note:
Stabilizer valve supplies oil to crane using the
Power Beyond feature.
3. Install hydraulic reservoir with return filter. Attach
pump pressure line to valve, return link to tank.
4. Fill system with hydraulic oil (See Stellar®
Lubrication Recommendations for fluid details).
(Blue)

Stabilizer Functions

Stabilizer Functions

Typical Stabilizer Valve
with Power Beyond Capabilities

9

7621 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. 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.
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

(Blue)

10

Installation

Hydraulic System

11

12

7621 Owner’s Manual

Stability Procedure
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 available.

7621 Stability Data
Max Horizontal Reach: 252” (From the center of
rotation to boom tip)
Boost Stability Test Weight: 2520 lbs.
Non-Boost Stability Test Weight: 2135 lbs.

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.

Installation

13

Decal Placement - PN 54957
30
14,15

®

Indicator

Angle

80 70

60
50

3

40

30

20

10

7621

22

0

2
27

33

1
28

9

25

26

29

PN 54957

**THESE DECALS NOT INCLUDED WITH THE DECAL KIT
*USE THESE DECALS WITH BODY PACKAGE

33

54588

DECAL CDT 2.00X2.00

2

*16

12451

DECAL HOISTING PERSONNEL

1

32

25159

DECAL WARNING MANUAL OVERRIDES

1

15

D1197

DECAL-ANGLE INDICATOR SS

1

31

52270

DECAL VB CONTROL MECH CRANE

1

14

D1196

DECAL ANGLE INDICATOR CS

1

30**

35234

DECAL STELLAR MADE IN THE USA

1

*13

C1179

DECAL-ELECTROCUTION 4.5x7.5

2

29

38472

DECAL SNATCH BLOCK CAP 5 TON

1

*12

C5918

DECAL-DANGER MOVING O.R.

2

28

28256

DECAL WARNING OVERLOAD DEVICE

1

*11

C4795

DECAL-DANGER O.R.

2

27

24712

DECAL CAUTION STOW HOOK

1

*10

4190

DECAL-DANGER

1

26

15172

DECAL ASME/ANSI B30.22/B30.5

1

09

9188

DECAL-ROTATE/GREASE

1

25

15171

DECAL GREASE WORM DRIVE BEARINGS

1

*08

4189

DECAL-DANGER

1

24

4188

DECAL-ROTATION ALIGNMENT

1

*07

4186

DECAL-ELECTROCUTION 2x2.75

1

*23

C4541

DECAL-CRANE STOWING

1

*06

C4544

DECAL-DANGER

1

22

12300

DECAL-TWO BLOCKING

1

*05

C4540

DECAL-DANGER

1

*21

4214

*04

C4545

DECAL-ELECTROCUTION 5x13

4

*20

*03

54958

DECAL CAPACITY

2

02

54959

DECAL 7621 IDENTIFICATION

2

52681

DECAL STELLAR LOGO 6.5 x 18

2

*17
ITEM

01
ITEM

PART No.

DESCRIPTION

QTY

DECAL-SERVICE

1

C0568

DECAL-DIESEL

2

*19

12452

DECAL MANUAL EXT

1

*18

C5911

DECAL-STELLAR 2x4.5

3

C5910
PART No.

DECAL-STELLAR 4x9.5
DESCRIPTION

1
QTY

14

7621 Owner’s Manual

Assembly Drawings

15

Chapter 3 - Assembly Drawings
Base Assembly - PN 50364

2

5

4
3

1

5
9

8

6

GASKET SHOWN AS REFERENCE

7

PN 50364
ITEM
1
2
3
4
5
6
7
8
9

PART
47869
11542
C6069
21151
D1345
D1810
C2256
56589
5 34 95

DESCRIPTION
BEARING SWING DRIVE CAST 6620 GEARTEK
STOP 3820 400 SLIDE
MOTOR HYD ROSS MK080613AAAB
GASKET MOTOR 008-10056-1
FTG CPRSN 0.12NPT/0.25 TUBE
TBE AIR SAEJ844 TYPE A .25 (RM)
F T G C O U P L E R P I PE 0 . 1 3
ZERK 1/8 NPT STRAIGHT LONG THREAD
CAP S CR 0 .5 0-13 X2 .0 0 SH

QTY.
1
1
1
1
2
1
1
1
2

NOTE: ITEMS 1 INCLUDE GUARD & GUARD FASTENERS

16

7621 Owner’s Manual

Mast Assembly - PN 54790
11

9

3
12

7

5
2
5

1

6
10
4
3

8

DO NOT GREASE
THESE BUSHINGS

PN 54790
ITEM
1
2
3
4
5
6
7
8
9
10
11
12

PART
43483
27813
C5902
D1034
0343
C0933
0342
44533
11693
52265
63516
52490

DESCRIPTION
MAST 10621/12621
COLLAR 0.38X0.75X0.38 UHMW
WASHER 0.63 SAE FLAT YELLOW GR8
CAP SCR 0.63-11X3.00 HHGR8 RED PATCH
W A S HE R 0 . 31 US S FL A T ZI N C
CAP SCR 0.31-18X4.50 HHGR5
NUT 0.31-18 HHGR5 NYLOC
BUSHING HSG3235012S 2.00X0.75
CAP SCR 0.63-11X1.75 HHGR8
VB 4 SECT W/PROP STER8GPM DEUTSCH
WINCH 3750 TH2CC230246 W/100 FT ROPE
CAP SCR 6MMX30MM HH 8.8(GR5)

QTY.
1
2
18
14
4
2
2
4
4
1
1
4

Assembly Drawings

17

Main Boom - PN 54941
11

13

10

24

16

15

3

26

4
25

26

20
29 28

22
12

30
18

27

6

33
19
20
1

8
31

9

16 17

32

23

14

21
4

20

23

22
3
4
20

2

7
5

4

23

23
20 23

PN 54941
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

PART
48018
54942
9 70 9 Z P
9142
9 7 1 1Z P
9 71 2 Z P
D1194PC
9363
9545PC
13435PC
27720
11544
c1592
9320
0068

DESCRIPTION
INNER BOOM 6620
CYLINDER ASM 6620 INNER CDT
P I N 2 . 00 X 10 . 1 9 D & T
PIN CAP 0.56X2.50X0.19
P I N 2 . 00 X 8 . 8 8 D & T
P I N 1 .0 0 X 8 . 3 8 D & T
PLATE ANGLE INDICATOR
WEAR PAD 1.12X2.00 RND NYLATRON
PLATE WEAR PAD SUPPORT
BRKT ROPE GUIDE 9620
SPACER ROPE GUIDE 6620 UHMW
CORD REEL 6620
ZERK 1/8 NPT STRAIGHT
PIN CAP 0.44X1.75X0.19 SS
BUSHING BPC16DXR24 1.00X1.50

NOTE: INCLINOMETER MOUNTS
INSIDE THE BOOM. VIEW SHOWS
POSITION OF INCLINOMETER

QTY.
1
1
2
6
1
1
2
2
2
1
2
1
1
2
2

ITEM
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

PART
4381
0340
0478
C6106
D0790
9843
C6353
10172
12168
0335
0347
53493
18765
D 0 07 6
18618
0425
0437
C5606

DESCRIPTION
BUSHING BPC32DXR32 2.00X2.00
WASHER 0.25 USS FLAT ZINC
CAP SCR 0.25-20X0.50 HHGR5
NUT 0.50-13 HHGR5 NYLOC
WASHER 0.50 SAE FLAT YELLOW GR8
CAP SCR 0.38-16X0.75 HHGR8
WASHER 0.38 SAE FLAT YELLOW GR8
CAP SCR 0.50-13X1.00 HHGR8
CAP SCR 0.38-16X9.00 HHGR5
CAP SCR 0.38-16X1.25 HHGR5
NUT 0.38-16 HHGR5 NYLOC
INCLINOMETER 60 DEG
WASHER #6 SAE FLAT ZINC
N U T #6 - 3 2 H H N Y L OC S S
SCREW #6-32X1.00 PHMS PH
MACHY WASHER 1.25ID 10GA
CAP SCR 0.25-20X1.25 HHGR5
CLAMP 0.25 BLK VINYL

QTY.
4
2
1
2
18
2
6
14
2
2
4
1
4
2
2
2
1
1

18

7621 Owner’s Manual

Extension Boom Assembly - PN 61824
3
4

24

30

4

1

9

25 31

39

13

47

46
40

2
8

8

5

6 48
16

32

23
40

12
18

12

7

17

28

14

44 29
38

45

42
15
41

23

43

26
33
21
27
34

23
38

19 44

25
25

10

11

37

36

See Next Page for
Expanded View.

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

PART
3 4 73 9
61825
49316
9991
13400ZP
27719
13339
5753
9363
9 54 5 P C
0425
61050
12824
61051
61048
61049
35105
61054
3 76 8 0 Z P
27710
C0 078
3 127 9
C6353
C6219
D0790
0343
0340
D0178
0867
58681
10666
0490
0420
0478
0484
C1000
C1002
9843
0489
0342
C6106
31132
61053
9320
6 15 4 8 PC
61549
45125
6 5 93 8

PN 61824
D ES C R I P T I O N
QTY.
EXT BOOM 1ST 6620
1
EXT BOOM 2ND 7621 FS/CRADLE A2B
1
CYLINDER EXT ASM 6620 2.0/2.0
1
WEAR PAD 0.19X2.50 RND NYLATRON
4
P IN TEAR DROP 1.00X4.38
1
SPACER BOOM TIP 6620 UHMW
2
SHEAVE 7621 8.00 DIA .38R/1.88THK
2
PI N 0.19X1.56 LYNCH
2
WEAR PAD 1.12X2.00 RND NYLATRON
2
P L A TE W EA R P A D SU P P OR T
2
MACHY WASHER 1.25ID 10GA
2
PLATE SHEAVE MOUNTING FS/CRADLE 106/126
2
PIN HITCH 1.00X4.50
1
MNT CRADLE LH FS/CRADLE A2B 106/126
1
CRADLE FS/CRADLE A2B 106/126
1
LINK FS/CRADLE A2B 106/126 W/HOLES
1
SWITCH LIMIT E1117-B9111-6C
1
MNT CRADLE RH FS/CRADLE A2B 106/126
1
P I N 1 . 0 0 X4 .1 9 S R
1
SPRING ANTI 2 BLOCK CRADLE A2B
2
CLA MP 0. 38 BLK V INYL
2
CLA M P 0.31 B LK VI NYL
1
WASHER 0.38 SAE FLAT YELLOW GR8
6
WASHER 0.75 SAE FLAT YELLOW GR8
1
WASHER 0.50 SAE FLAT YELLOW GR8
18
W AS H E R 0. 3 1 U SS F L A T Z I N C
2
W A S H E R 0. 2 5 U S S F L A T Z IN C
2
WASHER #10 SAE FLAT ZINC
2
MACHY WASHER 1.00ID 14GA
2
CAP SCR 0.75-10X2.50 HHGR8
1
CAP SCR 0.50-13X1.25 HHGR8
8
CAP SCR 0.31-18X3.50 HHGR5
2
CAP SCR 0.31-18X0.75 HHGR5
1
CAP SCR 0.25-20X0.50 HHGR5
2
CAP SCR 0.31-18X0.50 HHGR5
1
CAP SCR 0.50-13X5.00 HHGR5
2
CAP SCR 0.50-13X6.00 HHGR5
1
CAP SCR 0.38-16X0.75 HHGR8
2
CAP SCR 0.31-18X2.50 HHGR5
1
NUT 0.31-18 HHGR5 NYLOC
3
N UT 0.50-13 HHGR5 NYLOC
3
CAP SCR #10-24X0.550 SH SS 18-8
2
BOLT SHOULDER 0.38X0.50 0.31-18X0.50
4
PIN CAP 0.56X3.50X.25
2
P IPE 0. 50X 3 .1 3 S C H4 0
1
COLLAR 1.13X2.00X1.13 W/HOLE
1
PIN HITCH 1.00 FORK KPCC
1
LI NK F S/C R AD LE A2 B 10 6 / 12 6
1

Assembly Drawings

19

Extension Boom Assembly - PN 61824 (Expanded)
47
See Parts Breakdown
on Previous Page.

39

8

8

46
12

6

5

13 40

26

32

33

21
27

16

34

43

23
38

6

23
7

44

40

18

41
12

17
14

25
26

29

19

44

23
38

22

45
28

35
42 20
25

PN 61824
Assembled View
25

15
41

25
36

37

20

7621 Owner’s Manual

Main Cylinder Assembly - PN 54942

2
5

4

3

4
3

4

1

4

2
Manifold Assembly
PN 41910
ITEM
1
2
3
4
5

PART
39425
41908
419 07
9803
C4961

DESCRIPTION
MANIFOLD CBAL DOUBLE T11A WITH RELIEF
VALVE CHECK CXED-XCN
V ALV E R DDA- LAN 800 P SI
Valve C- SUN CBBD-LJN-3500
PLUG STR HOLLOW HEX 0.38 6-HP5ON

4

QTY.
1
1
1
2
1

3
4

Cylinder
Serial Tag
Location

1

PN 54942
I TE M
1
2
3
4

PART
50918
41910
44066
0279

DESCRIPTION
CYLINDER INNER 4.00X21.38 NEW MAST
MANIFOLD ASM DUAL 10-1CBAL-RLF-CHK
TUBE ASM 0.38X8.25 MAIN 10628/12628
FTG AD APT 6-F5OLO-S

Note: Main Cylinder uses
Stellar Seal Kit PN 17724

QTY.
1
1
2
4

Assembly Drawings

21

Extension Cylinder Assembly - PN 49316

9

Cylinder
Serial Tag
Location

7

6

8
5

PN 49316
1
2

3

4

I TE M
1
2
3
4
5
6
7
8
9

P A RT
37548
14115
11882
14601
14442
14443
24729
18701
D0655

DESCRIPTION
CYLINDER EXT 2 STAGE 2.0/2.0 PTD 60
MANIFOLD ASM 6620 EXT CBBD-LJN-XVN
CAP SCR 0.38-16X1.75 SH ZC
CAP SCR 0.38-16X2.25 SH ZC
TUBE ASM 0.38X23.25 EXT CYL 6620
TUBE ASM 0.38X102.25 EXT CYL 6620
HOSE CLAMP #52 3.00 - 3.75
CLAMP PORT TUBE ZR518
HOSE CLAMP #36 WRM GEAR

Extension Cylinder Uses:
Upper Seal Kit - PN 54778
Lower Seal Kit - PN 20310

QTY.
1
1
2
1
1
1
1
1
1

22

7621 Owner’s Manual

Snatch Block Assembly - PN 56266
5

2

12

1
4

6

2

10
7
4

9

7

3

12

13

11

10

14
8

2

9

PN 56266
ITEM

PART

1
2
3
4
5
6
7
8
9
10
11
12
13
14

13339
53263PC
39874ZP
44643
0347
C0538
0532
5841
C6219
0867
3 9 84 4 Z P
5753
25831
13436

DESCRIPTION
SHEAVE 7621 8.00 DIA .38R/1.88THK
PLATE SNATCH BLOCK 76/96/106/126
P I N 1 . 0 0 X 4 .0 6 CO T T E R
COLLAR 0.44X0.75X2.00
NUT 0.38-16 HHGR5 NYLOC
NUT 0.75-10 HHGR8 NYLOC
CAP SCR 0.38-16X3.75 HHGR5
CAP SCR 0.75-10X4.50 HHGR8
WASHER 0.75 SAE FLAT YELLOW GR8
MACHY WASHER 1.00ID 14GA
BUSHING V HOOK SS
PIN 0.19X 1. 56 LYNCH
HOOK 5 TON SWIVEL CROSBY 1028623
PIN .38X4.00 QUICK RELEASE

Defau
lt
1
2
1
2
2
1
2
1
2
2
1
2
1
1

Assembly Drawings

23

CDT™ Radio Transmitter Assembly - PN 56647
1

2

8

3

5
6
SEE NOTE
4

7
NOTE: 1) P/N'S 25999 & 24958 ARE OPTIONAL COVERS
FOR THE SWITCHES AND TRIGGER

PN 56647
ITEM
1
2
3
4
5
6
7
8

PART
20088
56657
24385
35447
24958
22600
35441
4 7 85 6

DESCRIPTION
CONTROL HANDLE HOUSING 4 FCTN HET
CONTROL HANDLE FACE PLT W/LABEL 6 FCTN CDT
GUARD RADIO SWITCH 4 FCTN
CONTROL HANDLE GRIP W/TRIGGER HT H2
RUBBER BOOT TRIGGER GUARD HET
SWITCH TOGGLE HET RADIO 63019300
BATTERY TUBE AA HETRONIC RADIO
S W I T C H E S T O P N OV A X L

QTY.
1
1
1
1
1
6
1
1

24

7621 Owner’s Manual

Replacement Parts

Chapter 4 - Replacement Parts
PART#
C6069
25367
25368
24960
25369
25371
25373
44532
39425
41907
41908
28485
9803
6397
C2027
C2028
C2029
D1245
D1246
D1247
44066
14442
14443
17724
54778
20310
55827
55829
55830
0068
4381
44533
13403
9363
9991
12824
5753
13339
53493
11938
31670
35105
43488PC
61048
27710
11544
56647
34557
47856
35441
35916
25831
19501
C1592
4460

DESCRIPTION
HYDRAULIC SWING MOTOR
RELIEF VALVE
SEAL KIT - RELIEF VALVE (25367)
FLOW CONTROL VALVE
SEAL KIT - FLOW VALVE (24960)
SOLENOID VALVE TAND G04571
SEAL KIT - SOLENOID VALVE (25371)
COIL - 12VDC
MANIFOLD - MAIN LIFT CYLINDER
RELIEF VALVE - MAIN LIFT CYLINDER
CHECK VALVE - MAIN LIFT CYLINDER
PRESSURE TRANSDUCER
C-BALANCE VALVE - MAIN LIFT & EXTENSION CYLINDER
HYD PRESSURE GUAGE
O'RING - # 4 FACE SEAL
O'RING - # 6 FACE SEAL
O'RING - # 8 FACE SEAL
O'RING - # 4 SAE
O'RING - # 6 SAE
O'RING - # 8 SAE
HYD TUBE ASSY - MAIN LIFT CYLINDER
HYD TUBE ASSY - EXTENSION CYLINDER
HYD TUBE ASSY - EXTENSION CYLINDER
SEAL KIT (MAIN LIFT CYLINDER)
SEAL KIT - EXTENSION CYLINDER (UPPER)
SEAL KIT - EXTENSION CYLINDER (LOWER)
WORM GEAR - BEARING SWING DRIVE
BEARING & SEAL KIT - BEARING SWING DRIVE
WORM GEAR / BEARING & SEAL KIT - BEARING SWING DRIVE
BUSHING 1.00" X 1.50"
BUSHING 2.00" X 2.00"
BUSHING 2.00" X 0.75"
WIRE ROPE
WEAR PAD - 2.00" RND
WEAR PAD - 2.50" RND
HITCH PIN - 1.00" X 4.50"
LYNCH PIN - 0.19" X 1.56"
SHEAVE 8.00"
INCLINOMETER 60 DEGREE
LIMIT SWITCH - FLIP SHEAVE
CHAIN & WEIGHT KIT - LIMIT SWITCH (FLIP SHEAVE)
LIMIT SWITCH - CRADLE / BASKET
CRADLE PLATE - ANTI-2-BLOCK (CRADLE/BASKET STYLE)
CRADLE FS/CRADLE A2B (After 8/1/2011)
SPRING - LIMIT SWITCH CRADLE / BASKET
CORD REEL
RADIO TRANSMITTER (HETRONIC RADIO)
HANDLE ASM - TRANSMITTER
E-STOP SWITCH (HETRONIC RADIO)
BATTERY TUBE (AA) HOLDER (HETRONIC RADIO)
BACK UP CORD 25FT (RADIO REMOTE SYSTEM)
5-TON HOOK
SAFETY LATCH ASM - 5 TON HOOK
GREASE ZERK
GEAR BEARING GREASE - MOLUBE (Open Teeth)

25

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
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.
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 warrantyapplicable 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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