Model 7628 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.
7628 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 55114 .....................................................2 Chapter 2 - Installation ...........................................................................3 Installation Overview ...........................................................................4 Control Kit - PN 54968 .................................................................
ii 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: (from crane base) 30’4” (9.24 m) Boom Elevation: -5 to +80 degrees Stowed Height (crane only) 35.50” (90.2 cm) Mounting Space Required 20 x 21 inches (50.
2 7628 Owner’s Manual Capacity Chart - Decal PN 55114 7470 lbs 3385 kg Reach in Feet/Meters Capacity in Pounds/Kilograms 5330 lbs 2415 kg 6330 lbs 2870 kg 4685 lbs 2125 kg Boost (If Equipped) 3015 lbs 1365 kg 2555 lbs 1155 kg 7430 lbs 3370 kg 6300 lbs 2855 kg 7500 lbs 3400 kg 30' 4” 9.25 m Standard 24' 7.01 m 2220 lbs 995 kg 1880 lbs 850 kg 4130 lbs 1870 kg 21' 6.
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 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.
4 7628 Owner’s Manual 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).
Installation Control Kit - PN 54968 PN 54968 5
6 7628 Owner’s Manual Control Kit (Non-Boost) - PN 56490 PN 56490
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 7628 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.
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. 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.
Installation Hydraulic System 11
12 7628 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.
Installation 13 Decal Placement - 54970 30 14,15 ® Indicator Angle 80 70 60 50 3 40 30 20 10 7628 22 0 2 27 33 1 28 9 25 26 29 PN 54970 **THESE DECALS NOT INCLUDED WITH THE DECAL KIT *USE THESE DECALS WITH BODY PACKAGE 33 54588 DECAL CDT 2.00X2.
14 7628 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 .
16 7628 Owner’s Manual Mast Assembly - PN 62795 5 6 3 13 10 8 7 8 9 1 2 4 3 DO NOT GREASE 11 THESE BUSHINGS PN 62795 ITEM 1 2 3 4 5 6 7 8 9 10 11 13 PART 434 83 52265 C5902 D1034 63517 11693 27813 0343 C0933 0342 44533 52490 DESCRIPTION MAST 10621/12621 VB 4 SECT W/PROP STER8GPM DEUTSCH WASHER 0.63 SAE FLAT YELLOW GR8 CAP SCR 0.63-11X3.00 HHGR8 RED PATCH WINCH 3750 TH2CC230246 W/120 FT ROPE CAP SCR 0.63-11X1.75 HHGR8 COLLAR 0.38X0.75X0.38 UHMW W A S H E R 0 . 3 1 U S S FLA T Z IN C CAP SCR 0.
Assembly Drawings 17 Main Boom - PN 54960 14 25 19 20 15 26 16 21 3 28 32 19 23 13 26 33 18 27 1 9 31 29 30 4 5 17 12 7 8 22 16 19 5 17 12 17 2 6 5 17 10 24 11 12 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 12 PN 54960 PART 50346 54961 0 0 68 97 0 9 Z P 9142 9711ZP 9712ZP 9320 D1194PC 9363 9545PC 10172 0478 12168 DESCRIPTION INNER BOOM 6628 CYLINDER ASM 7628 INNER BUSHING QSI-1618-24 P I N 2. 0 0 X 1 0. 1 9 D & T PIN CAP 0.56X2.50X0.19 PIN 2.00X8.88 D&T PIN 1.00X8.
18 7628 Owner’s Manual Extension Boom Assembly - PN 61831 4 3 4 24 30 1 3 11 9 13 47 46 39 31 40 8 8 5 6 48 16 32 26 21 33 23 12 18 12 17 7 28 14 45 42 15 41 27 40 43 44 29 34 23 38 38 23 19 44 25 25 PN 61831 10 25 37 36 See Next Page for Expanded View.
Assembly Drawings Extension Boom Assembly - PN 61831 (Expanded) 47 39 8 See Parts Breakdown on Previous Page.
20 7628 Owner’s Manual Main Cylinder Assembly - PN 54961 2 5 3 4 2 1 4 4 Manifold Assembly PN 41910 ITEM 1 2 3 4 5 PART 39425 41908 41 907 41906 C4961 DESCRIPTION MANIFOLD CBAL DOUBLE T11A WITH RELIEF VALVE CHECK CXED-XCN VA L VE R DDA -LAN 80 0 PSI VALVE C-BAL SUN CBCH-LJN 3500 PLUG STR HOLLOW HEX 0.38 6-HP5ON QTY. 1 1 1 2 1 2 3 2 Cylinder Serial Tag Location 4 2 1 PN 54961 ITEM 1 2 3 4 PART 50928 0279 41910 44066 DESCRIPTION CYLINDER 4.50X21.
Assembly Drawings 21 Extension Cylinder Assembly - PN 50929 Cylinder Serial Tag Location 7 6 1 7 5 2 3 4 PN 50929 ITEM 1 2 3 4 5 6 7 PART 50919 14115 11882 14601 31652 31651 24729 DESCRIPTION CYLINDER EXT 6628 2 STAGE 2.0/2.0 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 0.38X 72.86 EXT CYL 6628 TUBE ASM 0.38X 119.75 EXT CYL 6628 HOSE CLAMP #52 3.00 - 3.75 Extension Cylinder Uses: Upper Seal Kit - PN 54778 Lower Seal Kit - PN 20310 QTY.
22 7628 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.
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
24 7628 Owner’s Manual
Replacement Parts Chapter 4 - Replacement Parts PART# C6069 25367 25368 24960 25369 25371 25373 44532 39425 9803 41907 41908 28485 9803 6397 C2027 C2028 C2029 D1245 D1246 D1247 44066 14442 14443 35655 54778 20310 55827 55829 55830 0068 4381 44533 23454 9363 9991 12824 5753 13339 53493 11938 31670 35105 43488PC 61048 27710 19166 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)
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.
