Stellar Industries Telescopic Crane 7621 Users Manual

2015-02-02

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 
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
Last Revision: 09/17/12
Subject to Change without Notification.
© 2012 Stellar Industries, Inc.
®
TM
7621 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
Table of Contents
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 service@stellarindustries.com
Order Parts parts@stellarindustries.com
Warranty Information warranty@stellarindustries.com
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
 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: 23’ (7.01 m)
(from crane base)
Boom Elevation: -5 to +80 degrees
Stowed Height: 35.5” (90.2 cm)
(crane only)
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: 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: 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
7621 Owner’s Manual
Reach in Feet/Meters
Capacity in Pounds/Kilograms
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
PN 54958
Maximum 1 - part line capacity is
3750 lbs (1700 kg). For greater
loads, use 2 - part line.
4080 kgs
4080 kgs
4080 kgs
4080 kgs
4080 kgs
80º
45º
75º
60º
15º
30º
9000#
9000#
9000#
9000#
9000#
7470 lbs
3385 kg
7500 lbs
3400 kg
7500 lbs
3400 kg
7500 lbs
3400 kg
7500 lbs
3400 kg
7500 lbs
3400 kg
6330 lbs
2870 kg 4050 lbs
1835 kg
3435 lbs
1555 kg
5230 lbs
2370 kg
4435 lbs
2010 kg
7390 lbs
3350 kg
6265 lbs
2840 kg
5545 lbs
2515 kg
4700 lbs
2130 kg
4700 lbs
2130 kg
3985 lbs
1805 kg
3230 lbs
1465 kg
2735 lbs
1240 kg
2465 lbs
1115 kg
2090 lbs
945 kg
4405 lbs
1995 kg
3735 lbs
1695 kg
2950 lbs
1335 kg
2500 lbs
1130 kg
4075 lbs
1845 kg
3455 lbs
1565 kg
2800 lbs
1270 kg
2375 lbs
1075 kg
2135 lbs
965 kg
1810 lbs
820 kg
2240 lbs
1015 kg
1900 lbs
860 kg
3855 lbs
1745 kg
3270 lbs
1480 kg
2955 lbs
1340 kg
2505 lbs
1135 kg
0'
0 m
3'
.914 m
6'
1.83 m
9'
2.74 m
11'
3.35 m
21'
6.40 m
16'
4.88 m
12'
3.66 m
3'
.914 m
6'
1.83 m
9'
2.75 m
15'
4.57 m
18'
5.49 m
21'
6.40 m
23'
7.01 m
Boost
(If Equipped)
Standard
Capacity Chart - Decal PN 54958
Installation
Chapter 2 - Installation
General Installation
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.
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.
7621 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 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.
Installation
PN 54952
Control Kit - PN 54952
7621 Owner’s Manual
PN 55823
Control Kit (Non-Boost) - PN 55823
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
7621 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
 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.
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
 7621 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.
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.
Stability Procedure
Installation 
PN 54957
*USE THESE DECALS WITH BODY PACKAGE
**THESE DECALS NOT INCLUDED WITH THE DECAL KIT
1
2
®®
7621
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 7621 IDENTIFICATION54959
54958
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 - PN 54957
 7621 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
 7621 Owner’s Manual
DO NOT GREASE
THESE BUSHINGS
6
1
10
4
11
3
9
75
2
5
3
8
12
PN 54790
.YTQNOITPIRCSEDTRAPMETI
112621/12601 TSAM384341
2 27813 COLLAR 0.38X0.75X0.38 UHMW2
3C5902 WASHER 0.63 SAE FLAT YELLOW GR818
4D1034 CAP SCR 0.63-11X3.00 HHGR8 RED PATCH14
4CNIZ TALF SSU 13.0 REHSAW34305
6C0933 CAP SCR 0.31-18X4.50 HHGR52
2COLYN 5RGHH 81-13.0 TUN24307
844533BUSHING HSG3235012S 2.00X0.754
9 11693 CAP SCR 0.63-11X1.75 HHGR8 4
10 52265 VB 4 SECT W/PROP STER8GPM DEUTSCH1
11 63516 WINCH 3750 TH2CC230246 W/100 FT ROPE 1
12 52490 CAP SCR 6MMX30MM HH 8.8(GR5) 4
Mast Assembly - PN 54790
Assembly Drawings 
1CORD REEL 66201154412
2SPACER ROPE GUIDE 6620 UHMW2772011
1BRKT ROPE GUIDE 962013435PC10
2BUSHING BPC16DXR24 1.00X1.50006815
2PIN CAP 0.44X1.75X0.19 SS932014
1ZERK 1/8 NPT STRAIGHTc159213
.YTQNOITPIRCSEDTRAPMETI
10266 MOOB RENNI810841
2 54942CYLINDER ASM 6620 INNER CDT1
2T&D 91.01X00.2 NIPPZ90793
691.0X05.2X65.0 PAC NIP24194
1T&D 88.8X00.2 NIPPZ11795
1T&D 83.8X00.1 NIPPZ21796
7D1194PC PLATE ANGLE INDICATOR 2
8 9363 WEAR PAD 1.12X2.00 RND NYLATRON2
9 9545PC PLATE WEAR PAD SUPPORT2
.YTQNOITPIRCSEDTRAPMETI
16 4381BUSHING BPC32DXR32 2.00X2.00 4
17 0340 WASHER 0.25 USS FLAT ZINC2
18 0478 CAP SCR 0.25-20X0.50 HHGR51
19 C6106 NUT 0.50-13 HHGR5 NYLOC 2
20 D0790 WASHER 0.50 SAE FLAT YELLOW GR818
21 9843 CAP SCR 0.38-16X0.75 HHGR82
22 C6353 WASHER 0.38 SAE FLAT YELLOW GR86
23 10172 CAP SCR 0.50-13X1.00 HHGR814
24 12168 CAP SCR 0.38-16X9.00 HHGR52
25 0335 CAP SCR 0.38-16X1.25 HHGR52
26 0347 NUT 0.38-16 HHGR5 NYLOC 4
1GED 06 RETEMONILCNI3943572
28 18765 WASHER #6 SAE FLAT ZINC4
2SS COLYN HH 23-6# TUN6700D92
30 18618 SCREW #6-32X1.00 PHMS PH2
31 0425 MACHY WASHER 1.25ID 10GA2
32 0437 CAP SCR 0.25-20X1.25 HHGR51
1LYNIV KLB 52.0 PMALC6065C33
NOTE: INCLINOMETER MOUNTS
INSIDE THE BOOM. VIEW SHOWS
POSITION OF INCLINOMETER
33
20
15
19
4
23
17
22
21 14
13
20
23
25
26
24
32
12
7
3
6
5
16
16
10
1
11
2
8
9
23
4
3
4
22
20
23
26
20
27
30
29
18 4
23
31
28
20
PN 54941
Main Boom - PN 54941
 7621 Owner’s Manual
PN 61824
See Next Page for
Expanded View.
36
42
5
7
26
44 29
21
40
31
2
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
.YTQNOITPIRCSEDTRAPMETI
10266 TS1 MOOB TXE937431
2 61825 EXT BOOM 2ND 7621 FS/CRADLE A2B1
3 49316CYLINDER EXT ASM 6620 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
Extension Boom Assembly - PN 61824
Assembly Drawings 
PN 61824
See Parts Breakdown
on Previous Page.
Assembled View
45
6
23
13
8
38
6
42
7
12
21
27
34
40
12
43
18
23
26
33
5
8
16
32
44
19
44
23
38
14
28
17
41
25
35
26
22
20
36
29
37
25
41
25
46
40
39
47
25
15
Extension Boom Assembly - PN 61824 (Expanded)
 7621 Owner’s Manual
PN 54942
.YTQNOITPIRCSEDTRAPMETI
1 50918 CYLINDER INNER 4.00X21.38 NEW MAST1
2 41910 MANIFOLD ASM DUAL 10-1CBAL-RLF-CHK1
3 44066 TUBE ASM 0.38X8.25 MAIN 10628/126282
4S-OLO5F-6 TPADA GTF97204
4
3
1
4
3
4
2
4
Cylinder
Serial Tag
Location
Note: Main Cylinder uses
Stellar Seal Kit PN 17724
Manifold Assembly
PN 41910
2
3
5
4
1
4
.YTQNOITPIRCSEDTRAPMETI
1 39425 MANIFOLD CBAL DOUBLE T11A WITH RELIEF1
1NCX-DEXC KCEHC EVLAV809142
1ISP 008 NAL-ADDR EVLAV709143
4 9803 Valve C- SUN CBBD-LJN-35002
5C4961PLUG STR HOLLOW HEX 0.38 6-HP5ON1
Main Cylinder Assembly - PN 54942
Assembly Drawings 
.YTQNOITPIRCSEDTRAPMETI
137548 CYLINDER EXT 2 STAGE 2.0/2.0 PTD 60 1
214115 MANIFOLD ASM 6620 EXT CBBD-LJN-XVN 1
3 11882 CAP SCR 0.38-16X1.75 SH ZC 2
414601 CAP SCR 0.38-16X2.25 SH ZC 1
514442 TUBE ASM 0.38X23.25 EXT CYL 6620 1
614443 TUBE ASM 0.38X102.25 EXT CYL 6620 1
724729 HOSE CLAMP #52 3.00 - 3.75 1
818701 CLAMP PORT TUBE ZR518 1
1 P #36 WRM GEARMALC ESOHD06559
8
2
4
1
5
6
7
3
9
PN 49316
Cylinder
Serial Tag
Location
Extension Cylinder Uses:
Upper Seal Kit - PN 54778
Lower Seal Kit - PN 20310
Extension Cylinder Assembly - PN 49316
 7621 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
 7621 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
41907 RELIEF VALVE - MAIN LIFT CYLINDER
41908 CHECK VALVE - MAIN LIFT CYLINDER
28485 PRESSURE TRANSDUCER
9803
C-BALANCE VALVE - MAIN LIFT & 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
17724 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"
13403 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
11544 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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