Stellar Industries 5521 User Manual

Model 5521

Telescopic crane

owners’ Manual

installation • assembly drawings • parts

605040					5521
Angle	Indicator			®
80
70
	30	20	10
				0

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

®

TM

Last Revision: 09/06/12

5521 Manual Revisions

Date of Revision	Section Revised	Description of Revision

Table of Contents i

Table of Contents

Chapter 1 - Specifications	1
Model Stellar® 5521 Crane Specifications Sheet	1
Stellar® 5521 Geometric Measurements	2
Capacity Chart - Decal PN 57598	3
Chapter 2 - Installation	5
Installation Overview	6
Control Kit (Flip Sheave/CDT Boost) - PN 57913	7
Control Kit (Flip Sheave/CDT Non-Boost) - PN 59154	8
Control Kit (Flip Sheave/12V/CDT Boost) - PN 58276	9
Control Kit (Flip Sheave/12V/CDT Non-Boost) - PN 59522	10
Control Kit (Cradle A2B/CDT Boost) - PN 59138	11
Control Kit (Cradle A2B/CDT Non-Boost) - PN 59155	12
Control Kit (Cradle A2B/12V/CDT Boost) - PN 59523	13
Control Kit (Cradle A2B/12V/CDT Non-Boost) - PN 59524	14
Wiring Diagram (Electrical Version)	15
Hydraulic Kit - PN 58277	16
Hydraulic Kit (12 Volt Version) - PN 58279	17
Valve Bank - PN 44530	18
Hydraulic Installation	19
Hydraulic System	20
Stability Procedure	21
Decal Kit Placement - PN 57304	22
Chapter 3 - Assembly Drawings	23
Base Assembly - PN 50364	23
Mast Assembly - PN 57577	24
Main Boom Assembly - PN 57581	25
Extension Boom Assembly (Flip Sheave) - PN 57593	26
Extension Boom Assembly (Cradle A2B) - PN 58290	27
Extension Boom Assembly (Flip Sheave - 1 Hyd/1 Manual) - PN 57935	28
Extension Boom Assembly (Cradle A2B - 1 Hyd/1 Manual) - PN 59146	29
Main Cylinder Assembly - PN 54942	30
Extension Cylinder Assembly - PN 49316	31
Extension Cylinder Assembly (1 Hyd/1 Manual) - PN 57936	32
Cable & Hook Assembly - PN 57597	33
Power Unit Assembly - PN 57939	34
CDT™ Radio Transmitter Assembly - PN 56647	35
Chapter 4 - Replacement Parts	37

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 5521 Owner’s Manual

Specifications 1

Chapter 1 - Specifications

Model Stellar® 5521 Crane Specifications Sheet

	4'7"	Crane Rating:	29,500 ft-lb (4.1 ton-m)*
	(1.40m)
		Standard Boom Length:	11’ 0” (3.35 m) from CL of Crane
		Boom Extension:	1st stage: Hydraulic 60” (152.4 cm)
			2nd stage: Manual 60” (152.4 cm)
			Optional: 2nd stage: Hydraulic 60” (152.4 cm)
		Maximum Horizontal Reach:	21’ 0” (6.39 m) from CL of Crane
		Maximum Vertical Lift:	22’ 10” (6.95 m)
	3'9"	(from crane base)
	(1.14m)	Boom Elevation:	-5 to +80 degrees
		Stowed Height:	32” (81.3 cm)
		(crane only)
		Mounting Space Required:	20” x 21” (50.8 x 53.3 cm)
		Approximate Crane Weight:	1400 lbs (635 kg)
	2'10"	Controls:	Radio control standard for all
			functions.
	(0.87m)
		Winch Specifications
	22'10"	Rope Diameter:	5/16" (8 mm)
		Line pull speed:	70 ft/min (21.34 m/min)
	(6.95m)		20 ft/min (6.09 m/min) - Electric Version
		Max. single part line:	2500 lbs (1130 kg)
		Max. double part line:	5000 lbs (2265 kg)
		Rotation:	400 degree power
		(worm gear)
		Lifting Capacities:	5000 lbs @ 5’10” (2265 kg @ 1.78 m)**
			1400 lbs @ 21’ (635 kg @ 6.40 m)**
	17'10"	Power Supply Required:	PTO & Pump
	(5.45m)		(8.0 gpm @ 2500 psi)
			(30.31 lpm @ 173 bar)
	12'11"		12 volt power unit
			(2.0 gpm @ 2500 psi)
	(3.93m)
			(7.57 lpm @ 172 bar)
		*Crane rating in Boost Mode. Normal crane rating is 25,000 ft-lbs (3.46 ton-m)
		**Maximum capacities in Boost Mode.

18.41”

(0.47m)

10.69”

(0.27m)

11’0”

(3.34m)

16’0”

(4.87m)

21’0”

(6.39m)

25521 Owner’s Manual

Stellar® 5521 Geometric Measurements

56.47	33.80
[1.43m]	[0.86m]
12V	HYD

25.7022.11

[0.65m]

[0.56m]

12V

HYD

32.15

[0.82m]

CG

15.75	12.61
[0.40m]	[0.32m]

35.13 [0.89m]

11'0"

3.34m 12'3"

3.72m HYD

12'11"

3.95m

12V

Specifications 3

Capacity Chart - Decal PN 57598

80º

0' 0 m

5000 lbs			Reach in Feet/Meters
			Capacity in Pounds/Kilograms
2265 kg					23'
	4755 lbs
	2155 kg			Boost	7.01 m
	4030 lbs
			2665 lbs	(If Equipped)
	1825 kg			Standard	21'
			1205 kg
					6.40 m
			2260 lbs
			1025 kg
5000 lbs
2265 kg					18'
				1945 lbs
					5.49 m
5000 lbs				880 kg
2265 kg		3445 lbs		1650 lbs
		1560 kg		745 kg
		2920 lbs			15'
		1320 kg
5000 lbs			2535 lbs		4.57 m
2265 kg			1150 kg	1620 lbs
5000 lbs			2150 lbs
	4865 lbs			730 kg
1870 kg			975 kg	1375 lbs	12'
	2205 kg
	4125 lbs			620 kg	3.66 m
	2840 kg			2120 lbs
	3650 lbs			960 kg
	1655 kg			1800 lbs	9'
	3095 lbs			815 kg
	1400 kg			1475 lbs	2.75 m
				665 kg
	45º	3090 lbs		1250 lbs
				565 kg
		1400 kg
					6'
		2620 lbs		1945 lbs
					1.83 m
	30º	1185 kg		880 kg
			2905 lbs	1650 lbs
				745 kg
			1315 kg
	15º		2465 lbs		3'
			1115 kg
					.914 m

		2680 lbs		1840 lbs	1400 lbs
			1215 kg	830 kg	635 kg
		2275 lbs		1560 lbs	1190 lbs
			1030 kg	705 kg	535 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 2500 lbs (1130 kg). For greater loads, use 2 - part line.

PN 57598

45521 Owner’s Manual

Installation 5

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
	5521 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.

65521 Owner’s Manual

Installation Overview

1.Determine that the mounting location for the 5521 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 5521weighs approximately 1400 lbs (635 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 5521.

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 5521 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.

2

1

Motor

Ø1.063

4 Places

14.75

Ø6.00

7.38

7.38

14.75

Hole Mounting Detail

ITEM	PART	DESCRIPTION	QTY.
1	5199	CAP SCR 1.00X8X3.00 HHGR8 ZY	4
2	6538	WASHER 1.00 SAE FLAT YELLOW GR8	4

Installation 7

Control Kit (Flip Sheave/CDT Boost) - PN 57913

PN 57913

85521 Owner’s Manual

Control Kit (Flip Sheave/CDT Non-Boost) - PN 59154

PN 59154

Installation 9

Control Kit (Flip Sheave/12V/CDT Boost) - PN 58276

PN 58276