stellar labs 7621 Owner's Manual

Heavy-duty telescopic cranes

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Owner's manual (38 pages)

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Models:

7621

8621

9621

10621 10630

12621 12630

Notice: A copy of this manual must remain with the equipment at all times.

For a printable download copy, please visit: www.stellarindustries.com

Subject to Change without Notification.

Safety • Operation • Maintenance • Troubleshooting

7630

8630

9630

Stellar Industries, Inc.

190 State Street

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Heavy-Duty

Telescopic Cranes

Owner's Manual

PO Box 169

Rev 1

PN 115278

Courtesy of CraneMarket.com

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Do you have a question about the 7621 and is the answer not in the manual?

Questions and answers

Tom Hiser

March 6, 2025

what if I have a boom stuck in the air and the manual override doesn't work?

1 comments:

Mr. Anderson

March 6, 2025

If the boom on your Stellar Labs 7621 is stuck in the air and the manual override is not functioning, follow these steps:

1. Check the Parking Brake – Ensure that the parking brake is engaged.
2. Verify PTO Engagement – Confirm that the Power Take-Off (PTO) is engaged.
3. Check Radio Receiver Power – Ensure there is 12V power going to the radio receiver. If not, trace back to the power source and check for a blown fuse or a loose ground connection.
4. Inspect Transmitter Batteries – Make sure the transmitter batteries are fully charged.
5. Evaluate Hydraulic Pump Performance – Verify that the hydraulic pump is operating at its rated flow (GPMs). Use a flow meter to determine if the pump is weakening. If suspected, contact Stellar Customer Service.

If these steps do not resolve the issue, further inspection of the hydraulic circuit may be necessary.

This answer is automatically generated

Duane Beckwith

June 25, 2025

We have a customers truck in the shop with a stellar 7621 crane on it. They had a fire under the dash I’m looking for a wiring diagram The truck is a 2016 Ford F550. Thanks

Summary of Contents for stellar labs 7621

Page 1 Heavy-Duty Telescopic Cranes Owner’s Manual Safety • Operation • Maintenance • Troubleshooting Models: 7621 7630 8621 8630 9621 9630 10621 10630 12621 12630 Notice: A copy of this manual must remain with the equipment at all times. For a printable download copy, please visit: www.stellarindustries.com Stellar Industries, Inc.
Page 2 Heavy-Duty Manual Revisions Date of Revision Section Revised Description of Revision WARNING Operating, maintaining, and servicing a Stellar product may expose you to chemicals including, but not limited to, engine exhaust, carbon monoxide, phthalates, and lead. These chemicals are known to the State of California to cause cancer and birth defects (or other reproductive harm).
Page 3: Table Of Contents
Table of Contents Introduction ..........................................iv Chapter 1 - Operation ........................................1 General Operation ........................................1 Pre-Operation Inspection ......................................1 Job Site Setup..........................................2 Step 1: Disengage drive axle and set the parking brake..........................3 Step 2: Engage the hydraulic power source..............................3 Step 3: Position the stabilizers.
Page 4: Introduction
Introduction Cranes are designed to provide safe and dependable service for a variety of operations. Stellar ® With proper use and maintenance, these cranes will operate at peak performance for many years. To promote this longevity, carefully study the information contained in this manual before putting the equipment into service.
Page 5: Chapter 1 - Operation
Chapter 1 - Operation Safety should be the n umber one thought on every operator’s mind. Three factors should exist for safe operation: a qualified operator, well-maintained equipment, and the proper use of this equipment. This chapter contains information regarding the safety and operation of Stellar® manufactured EC Series Telescopic Cranes and should be read and understood completely by everyone working with or near the crane before putting the unit into operation.
Page 6: Job Site Setup
Replace/repair as necessary prior to operation. For a more detailed checklist of scheduled inspection points, refer to the Stellar® Crane Inspection Log. This document is an essential guide for the daily, monthly, quarterly and annual inspection tasks that will help maintain the quality of your Stellar® product.
Page 7: Step 1: Disengage Drive Axle And Set The Parking Brake
Step 1: Disengage drive axle and set the parking brake. The drive axle must be disengaged and the parking brake must be set before operating any of the equipment. Step 2: Engage the hydraulic power source. 1. Make certain that the transmission is in neutral/park and that the PTO switch is in the ‘off’ position.
Page 8: Step 4: Operate The Crane
Step 4: Operate the crane. Operators should have a firm understanding of ANSI B30.5 - Section 5-3.2 Operating Practices and AEM Safety Manual (Form C-70-2) prior to operating of the crane. Prevent booms from contacting hard or sharp objects which could damage WARNING the boom and lessen structural integrity of the boom.
Page 9: Step 5: Stow The Crane
Never exceed manufacturer’s load charts and ratings. These ratings are • WARNING based on the machine’s hydraulic, mechanical, and structural design rather than stability. • Never perform a lift that can induce a dynamic force greater than the capacity of the crane. •...
Page 10: Step 6: Stow The Stabilizers. (Only After Stowing The Crane.)
Step 6: Stow the stabilizers. (Only after stowing the crane.) Stow vertical leg(s). Hydraulic applications - Return to the stabilizer controls and pull up on the CS and SS levers and fully retract the stabilizers. Note: Both levers can be used at the same time. Manual applications - Ensure the leg is returned to the stowed position by using crank/ pin retainers.
Page 11: Radio System Components
Radio System Components RADIO TRANSMITTER PAIRING MAGNET RADIO RECEIVER RECHARGEABLE NiMH DOCKING/CHARGING STATION AA BATTERIES (x4) Stellar ® Heavy-Duty Telescopic Crane Owner’s Manual | Page 7 Courtesy of CraneMarket.com...
Page 12: Radio Remote Control Functions
Radio Remote Control Functions Page 8 | Stellar ® Heavy-Duty Telescopic Crane Owner’s Manual Courtesy of CraneMarket.com...
Page 13: Radio Remote Control Functions
Radio Remote Control Functions on back light preferences.) 1. Rotate Clockwise/Counterclockwise Push up to rotate the boom clockwise. Push down to rotate the boom counterclockwise. 10. Boost/Re-Link Button Push and hold for 2 seconds to engage boost The screen will continue to display Load % while mode (See page 18 for details on ‘Boost pressed.
Page 14: Stop Mode
Stop Mode The radio remote control is equipped with an “all functions” stop button. If a situation arises that requires the immediate stoppage of crane functionality (or just to simply turn the remote off after finishing a job), push in the RED Stop Button at the bottom of the handle.
Page 15: Unlinked Mode
Unlinked Mode Immediately after waking up by twisting the UNLINKED Stop Button, the controller will go into Unlinked Mode. You cannot control the crane, but the controller can receive information from the transmitter about the crane, such as position Link and load weight, etc.
Page 16: Crane Operating Mode - Static
Crane Operating Mode - Static With the crane stationary during Crane Operating mode, the LED feedback screen can return a number of key statistical readouts. To cycle through the different readout screens, use the Crane Info Scroll Button Current percentage of max load capacity Current Load Weight Remaining Load Weight Maximum Radius...
Page 17: Crane Operating Mode - Dynamic
Crane Operating Mode - Dynamic While operating crane functions with the toggle switches, the LED screen will switch to a live and continuously-updating feedback screen relative to the function being used. Boom Up/Down Toggle - Boom Angle Extension In/Out Toggle - Radius Winch Up/Down Toggle - Load Weight Default No Toggle/Rotate Toggle - Load Percentage Stellar...
Page 18 Shift Function Mode Pressing the Shift Function Screen Down Button allows you to access additional screens with more functions tied to the four main toggle switches. The new functions of the switches will be dis- played on the screen. Continue pressing the Down Button to access the next Shift Function Screen or press the Shift Function Screen Up Button to go to the previous Shift Function Screen.
Page 19: Optional Function Controls
Optional Function Controls Far-Left Toggle Switch - Air Compressor Start/Stop & Speed Control On/Off TOGGLE UP TOGGLE DOWN Press up to activate Press down to acti- compressor. vate Speed Control. AIR will appear in the SPD will appear in the lower left corner of lower left corner of the feedback screen...
Page 20: Operation And System Preferences
Operation and System Preferences Far-Left Toggle Switch - RPM Mode Configuration TOGGLE UP TOGGLE DOWN Press up to select the Press down to select HI-LO option of RPM the DMD (Power on Mode. (See page 19 Demand) option of for more information.) RPM Mode.
Page 21: Information And Diagnostics
Information and Diagnostics Far-Left Toggle Switch TOGGLE UP TOGGLE DOWN In this current program Press down to cycle configuration this tog- through LED backlight gle action does not settings: always on, al- ways off, or automatic have connected function. with light sensor. •...
Page 22: Capacity Feedback And Boost Mode
Capacity Feedback and Boost Mode CDTpro Remote Feedback If the crane starts to approach full capacity or an overload situation, the Stellar CDTpro sensory feedback system will respond: Vibration Visual System Function Normal Normal 0-79% Load Capacity None Normal Normal 80-89% Load Capacity Short Pulsing Normal...
Page 23: Rpm Mode
RPM Mode This allows your Speed Control function to act in Shift Function Screen 1 Turn Speed Control On or Off. different ways depending on your preferences. Speed control can either be activated in the Shift Function Screen or programmed as the quick function button.
Page 24: Range Finder™ Mode
Range Finder™ Mode The Range Finder™ feature allows the opera- tor to create a lift plan without ever needing UNLINKED to unstow the crane. This world-first technology estimates distance and calculates crane ca- pacities where the operator is holding the radio remote.
Page 25: Test Mode
Test Mode The CDTpro™ has a built in feature for internal system information called Test Mode. While speaking with a Stellar Customer Service Representative, you might be asked to put your remote into Test Mode to diagnose your system. When entering Test Mode all crane communication is stopped, preventing link-up with the receiver.
Page 26: Safe Mode
Safe Mode Various sensors are mounted on the crane to monitor the crane's lifting capacity. If any encounter a fault, the crane will put itself into Safe Mode. Safe Mode will allow the operator to work with the crane at a reduced speed until the current lift is complete and the crane is properly stowed. The crane should not be used again until the malfunctioning safety device is repaired.
Page 27: System Error Notifications
System Error Notifications Some of the system notifications below might be displayed after startup. Others can appear during operation if the condition develops. Critically Low Battery Critically Low Battery If the state of Transmitter battery is so low it does not have enough charge to power up and op- erate the transmitter, an empty battery icon Link...
Page 28: Radio Transmitter/Receiver Pair Procedure
Radio Transmitter/Receiver Pair Procedure Start with both Transmitter and Receiver turned off. To activate pairing the Transmitter, release RED Stop button, then press Boom Up and Winch Down and hold for at least 6 seconds. Do not release either during this period. The feedback screen will in- dicate it is searching for a Receiver to pair with.
Page 29: Charging And Battery Features
Charging and Battery Features Charging Station/Docking/Undocking The radio remote docking station also serves as a charger for the rechargeable battery. It is Docking Transmitter important to return the remote to the docking station to keep the battery charged between jobs. Follow the instructions below to correctly mount the transmitter in the docking station.
Page 30: Low Battery Indicator
Low Battery Indicator A battery level indicator in the lower right corner of the feedback screen will notify you when the battery power is draining and in need of recharging. Recharge your remote or replace Link the batteries as soon as you can. Actual battery power level can be checked at any time in Screen 2 of Test Mode (see page 21 for more information).
Page 31: Tethering Features
Tethering Features Radio Remote Tethered Extension Cable If the handheld transmitter has a system problem that makes the wireless function unusable, use of a back-up tethered extension cable may be necessary. While tethered, the extension cable will also supply power to recharge the remote's NiMH batteries.
Page 32: Wire Rope/Sheave Configurations
Wire Rope/Sheave Configurations PIN "A" Standard 2-Part Line Sheave Flipped Down PIN "B" Capacities as shown on load chart. Single Part Line Sheave Flipped Down 1) Remove PIN “A” from boom tip. PIN "B" 2) Route wire rope through snatch block. 3) Pin wire rope to snatch block as shown with PIN “A”...
Page 33: Personal Fall Protection With Stellar Equipment
® Personal Fall Protection with Stellar Equipment OSHA Provisions Before proceeding, all users must read, understand, and follow the provisions located in OSHA 29 CFR 1926.1423, specifically paragraphs (g) Anchorage criteria, (j) Anchoring to the load line, and (k) Training. Please note that OSHA sections 1926.502(d)(15) and 1926.502(e)(2) are cross-referenced in this section and need to be read, understood, and followed by each user.
Page 34: Safety Decals Of Note
Safety Decals of Note Safety decals serve to inform the viewer of the hazard type, how to avoid the hazard, and the consequences of not avoiding the hazard. Decals are considered safety equipment. They must be maintained, as would other safety devices. All safety instruction plates, notices, capacity charts and any other decal applied to the crane or service body must be kept legible and in good condition.
Page 35: Crane Compartment
Crane Compartment DANGER Decal Part Number: 4186 Decal Location: Crane Compartment Electrocution Hazard Hazard Type: Electrocution Hazard Death or serious injury will result from touching tethered Consequences: Will result in death or serious injury. remote if crane, load, or vehicle Avoidance: Maintain safe clearance from high becomes electrically charged.
Page 36: Main Boom
Main Boom WARNING Decal Part Number: 12451 Decal Location: Main Boom Fall Hazard Hazard Type: Fall Hazard Hoisting personnel on boom, hook, load, or loadline can result Consequences: Can result in death or serious injury. in death or serious injury. Avoidance: Never use the crane to hoist •...
Page 37: Crane Horse Head
Crane Horse Head WARNING Decal Part Number: 12300 Decal Location: Crane Horse Head Boom Hazard Type: Misuse Hazard Down Consequences: Can result in death or serious injury. Avoidance: Never allow the hook block to contact the boom tip by hoisting up, extending or lowering the boom.
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Page 39: Chapter 2 - Maintenance
Chapter 2 - Maintenance Maintenance is an important part of extending the life of any Stellar Telescopic Crane. Performing ® key maintenance items on a scheduled program will prevent unnecessary downtime. General Maintenance Guidelines Before performing any maintenance to the •...
Page 40: Maintenance Procedures
Maintenance Procedures Hydraulic Oil/Filter Maintenance Stellar Industries recommends the first filter change to occur after the first 250 hours of service. The second, and every subsequent change, should occur after every 1,000 hours of service. By following these guidelines, the hydraulic oil should last up to 6,500 hours. Note: These recommendations are based on normal working parameters.
Page 41: Winch Maintenance
Winch Maintenance Refer to winch manual supplied with crane. Extension Boom Maintenance While operating the crane, extend and retract the extension booms If the extension weldments are noisy during operation, it is necessary to lubricate the booms. Stellar Model Cranes feature a metal ®...
Page 42: Rotation Gear Bearing Maintenance
Rotation Gear Bearing Maintenance Rotation Worm Gear and Open Gear Teeth Use a heavy Moly Lube grease (Stellar PN 4460) ® to lubricate the worm gear and open gear teeth of the rotation bearing. Slowly rotate the crane while pumping the grease between the worm and rotation gear.
Page 43: Gear-Bearing Bolt Maintenance
Gear-Bearing Bolt Maintenance Once a bolt has been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same as when the bolt was new thus giving indeterminate damp loads after torquing. Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of WARNING the identical grade and size.
Page 44: Rotation Gear Bearing Thread Tightening Procedure
Rotation Gear Bearing Thread Tightening Procedure GRADE 5 GRADE 8 GRADE 9 Size Bolt DIA Plain Plated Plain Plated Plated (DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) 5/16-18 0.3125 3/8-16 0.3750 7/16-14 0.4375 1/2-13 0.5000 9/16-12 0.5625 5/8-11 0.6250 3/4-10 0.7500 7/8-9 0.8750...
Page 45: Rotation Gear Bearing Tilt Test
It should not exceed the following tilt measurements: • Stellar Models 7621 - 12630 = 0.060” (1.524 mm) • Stellar Model 14530 = 0.070” (1.778 mm) Step 6: Return the crane to vertical position. The dial indicator should return to calibration.
Page 46: Rotation Gear Bearing Worm End Play & Backlash
Rotation Gear Bearing Worm End Play & Backlash Telescopic Cranes have an integral base and worm drive rotation system. ® Stellar Backlash is the shortest distance between non-driving tooth surfaces in mating gears. Measure backlash using a feeler gauge at or near the pitch diameter and tangent to the gear. Locate High Tooth To set both Worm End Play and Backlash, first locate the high tooth on the gear.
Page 47: Face Seal/O-Ring Size Chart
Face Seal/O-Ring Size Chart Hose Fitting Face Seal (A) O-ring Boss (B) Size Size ® ® Stellar Stellar C2027 D1245 1/4” 3/8” C2028 D1246 C2029 D1247 1/2” 32223 D1248 5/8” D1244 D1249 3/4” D1250 1” Lubrication Recommendations Crane Lubrication Component Location Recommendation Reservoir...
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Page 49: Chapter 3 - Troubleshooting
Chapter 3 - Troubleshooting This chapter will list a number of potential problems that may occur while operating the crane. Most problems are easily solved using the solutions portion of this chapter. If problems persist, please contact Customer Service at Stellar Industries 1-800-321-3741. Serial Tag Location ®...
Page 50 Problem: Crane will operate manually but will not operate by radio remote. Solutions: • Make sure that there is 12V power going to the radio receiver. If there is no power going to the receiver, trace back to the power source and check for a blown fuse or loose ground connection.
Page 51 Do not over tighten. If the problem persists, replace the proportional valve. • Check to see if the manual override on the proportional valve is turned out. Turn the manual override on the flow valve in (7621 through 12630 models only). Problem: Crane operates slowly.
Page 52 Problem: Winch “Up”, Main Cylinder “Down”, and Extension Cylinder “Out” are the only functions that don’t operate. Solutions: • Make sure that the anti-two block weight and chain on the end of the boom are straight so they slide easily along the wire rope cable. •...
Page 53: Manual Crane Operation
Manual Crane Operation If the remote control malfunctions, follow the steps on this and the following page to operate the crane manually. Firstly, determine which type of valve bank you have and follow only the instructions on that page. Valve Bank Style 1 (Rectangular Coils) 1.
Page 54: Valve Bank Style 2 (Cylindrical Coils)
Valve Bank Style 2 (Cylindrical Coils) 1. Activate Flow Control. Turn the override screw on proportional flow control CW (clockwise) until it stops - between three and five full turns. Coils 2. Operate Solenoids. Using the identification decal as a guide, slide the locking collar out to the knurled plunger knob and then push or pull to operate the desired function.
Page 55 Courtesy of CraneMarket.com...

This manual is also suitable for:

7630 8621 8630 9621 9630 10621 ... Show all

stellar labs 7621 Owner's Manual

Chapter 1 - Operation

Chapter 2 - Maintenance

Chapter 3 - Troubleshooting

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