Stellar Industries 7628 User Manual

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Subject to Change without Notification.
© 2012 Stellar Industries, Inc.

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: [phone]

www.stellarindustries.com

Last Revision: 09/17/12

7628 Manual Revisions

Date of Revision

September 15th, 2011

Section Revised

Chapter 2: Installation
Chapter 3: Assembly
Drawings

Description of Revision

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

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

Table of Contents 

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

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]

 7628 Owner’s Manual

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

Specifications 

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 m3'.914m6'1.83 m9'2.74 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

Chapter 2 - Installation

Notice: Read this Page Before Installation of the Crane

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 [phone].

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.

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.

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.

 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.

15199

QTY.

WASHER 1.00 SAE FLAT YELLOW GR8

CAP SCR 1.00X8X3.00 HHGR8 ZY

DESCRIPTION

4

4

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 [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.

PN 54968

Control Kit - PN 54968

Installation 