Stellar Industries 7621 User Manual

Model 7621

Telescopic crane

owners’ Manual

installation • assembly drawings • parts

®

TM

	Stellar Industries, Inc.
	190 State Street
	PO Box 169
	Garner, IA 50438
	800-321-3741
Subject to Change without Notification.	Fax: [phone]
	www.stellarindustries.com
© 2012 Stellar Industries, Inc.		Last Revision: 09/17/12

7621 Manual Revisions

Date of Revision	Section Revised	Description of Revision
	Chapter 2: Installation	New Flip Sheave Design Implemented. Updated Extention
September 15th, 2011	Chapter 3: Assembly	Boom Assembly Drawings.
	Drawings

	Table of Contents i
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	[e-mail]
Order Parts	[e-mail]
Warranty Information	[e-mail]

ii 7621 Owner’s Manual

Specifications 1

Chapter 1 - Specifications

Model 7621 Crane

SPECIFICATION SHEET

Crane Rating:

Standard Boom Length:

Boom Extension:

Maximum Horizontal Reach:

Maximum Vertical Lift:

(from crane base)

Boom Elevation:

Stowed Height:

(crane only)

Mounting Space Required:

Approximate Crane Weight:

Controls:

Winch Specifications

Rope Diameter: Line pull speed: Max. single part line:

Max. double part line:

Rotation:

(worm gear)

Lifting Capacities:

38,000 ft-lb (5.25 TM)

11’ 0” (3.35 m) from CL of Crane

1st stage: Hydraulic 60” (152.4 cm)

2nd stage: Hydraulic 60” (152.4 cm)

21’ 0” (6.40 m) from CL of Crane

23’ (7.01 m)

-5 to +80 degrees

35.5” (90.2 cm)

20” x 21” (50.8 x 53.3 cm)

1625 lbs (735 kg)

Radio control standard for all functions.

3/8" (.952 cm)

60 ft/min (18.29 m/min)

3750 lbs (1700 kg)

7500 lbs (3400 kg)

400 degree power

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

27621 Owner’s Manual

Capacity Chart - Decal PN 54958

80º

0' 0 m

7500 lbs		Reach in Feet/Meters
		Capacity in Pounds/Kilograms
3400 kg				23'
	7470 lbs
	3385 kg		Boost	7.01 m
	6330 lbs
		4050 lbs	(If Equipped)
	2870 kg		Standard	21'
		1835 kg
				6.40 m
		3435 lbs
		1555 kg
7500 lbs
3400 kg				18'
			2955 lbs
	7500 lbs			5.49 m
			1340 kg
	3400 kg	5230 lbs
			2505 lbs
		2370 kg
			1135 kg
		4435 lbs
		2010 kg		15'
7500 lbs		3855 lbs		4.57 m
3400 kg
		1745 kg	2465 lbs
7500 lbs
		3270 lbs
			1115 kg
3400 kg	7390 lbs	1480 kg	2090 lbs	12'
	3350 kg
	6265 lbs		945 kg	3.66 m
	2840 kg		3230 lbs
		5545 lbs
			1465 kg
		2515 kg	2735 lbs
		4700 lbs		9'
60			1240 kg
		2130 kg	2240 lbs	2.75 m
			1015 kg
	45º	4700 lbs	1900 lbs
			860 kg
		2130 kg		6'
		3985 lbs
	30º	1805 kg	2950 lbs	1.83 m
		4405 lbs	1335 kg
			2500 lbs
		1995 kg
	15º	3735 lbs	1130 kg	3'
		1695 kg
				.914 m

		4075 lbs		2800 lbs	2135 lbs
			1845 kg	1270 kg	965 kg
		3455 lbs		2375 lbs	1810 lbs
			1565 kg	1075 kg	820 kg
3'	6'	9'	11'	16'	21'
.914 m	1.83 m	2.74 m	3.35 m	4.88 m	6.40 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 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	According to Federal Law (49 cfr part 571),
	general guide for the installation of a Stellar	each final-stage manufacturer shall
	7621 Telescopic Crane on a Stellar Service	complete the vehicle in such a manner that
	Body. Each installation is considered unique	it conforms to the standards in effect on the
	so certain portions of this chapter may or	date of manufacture of the incomplete
	may not apply to your direct application. If	vehicle, the date of final completion, or a
	a question should arise during the installation	date between those two dates. This
	process, please contact Stellar Customer	requirement shall, however, be superseded
	Service at [phone].	by any conflicting provisions of a standard
		that applies by its terms to vehicles
	This crane is designed for use with a Stellar	manufactured in two or more stages.
	Service Body installed on a vehicle that
	meets the minimum chassis requirements of	Therefore, the installer of Stellar cranes and
	the crane. It is the installer’s responsibility to	bodies is considered one of the
	assure that the crane is mounted on a	manufacturers of the vehicle. As such a
	platform that will support the maximum	manufacturer, the installer is responsible for
	crane rating of this crane.	compliance with all applicable federal and
		state regulations. They are required to
	Notice:	certify that the vehicle is in compliance with
	PTO and Pump installation instructions are	the Federal Motor Vehicle Safety Standards
	provided by the corresponding	and other regulations issued under the
	manufacturers. For more information on	National Traffic and Motor Vehicle Safety
	which PTO and Pump fit your application,	Act.
	please contact your local Stellar Distributor
	or Stellar Customer Service.	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	http://www.gpoaccess.gov/nara/index.html
	protector is installed on the chassis batteries to protect
	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.

47621 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 [phone].

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.	PART NO.	DESCRIPTION	QTY.
1	5199	CAP SCR 1.00X8X3.00 HHGR8 ZY	4
2	6538	WASHER 1.00 SAE FLAT YELLOW GR8	4

Installation 5

Control Kit - PN 54952

PN 54952