Model 5521 Telescopic crane owners’ Manual installation • assembly drawings • parts Indicator Angle ® 80 70 60 50 40 30 20 10 5521 0 ® 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.
5521 Manual Revisions Date of Revision Section Revised Description of Revision
Table of Contents Table of Contents Chapter 1 - Specifications Model Stellar® 5521 Crane Specifications Sheet Stellar® 5521 Geometric Measurements Capacity Chart - Decal PN 57598 Chapter 2 - Installation Installation Overview Control Kit (Flip Sheave/CDT Boost) - PN 57913 Control Kit (Flip Sheave/CDT Non-Boost) - PN 59154 Control Kit (Flip Sheave/12V/CDT Boost) - PN 58276 Control Kit (Flip Sheave/12V/CDT Non-Boost) - PN 59522 Control Kit (Cradle A2B/CDT Boost) - PN 59138 Control Kit (Cradle A2B/CDT Non-Boo
ii 5521 Owner’s Manual
Specifications Chapter 1 - Specifications Model Stellar® 5521 Crane Specifications Sheet 4'7" (1.40m) 3'9" (1.14m) 2'10" (0.87m) Crane Rating: 29,500 ft-lb (4.1 ton-m)* 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: (from crane base) 22’ 10” (6.
2 5521 Owner’s Manual Stellar® 5521 Geometric Measurements 33.80 [0.86m] HYD 56.47 [1.43m] 12V 25.70 [0.65m] 12V 22.11 [0.56m] HYD 32.15 [0.82m] CG 15.75 [0.40m] 35.13 [0.89m] 11'0" 3.34m 12'3" 3.72m HYD 12'11" 3.95m 12V 12.61 [0.
Specifications Capacity Chart - Decal PN 57598 Reach in Feet/Meters Capacity in Pounds/Kilograms 5000 lbs 9000# 2265 kgs kg 4080 4755 lbs 2155 kg 4030 lbs 1825 kg 23' 7.01 m Boost (If Equipped) 2665 lbs 1205 kg 2260 lbs 1025 kg 21' 6.
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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 general guide for the installation of a Stellar 5521 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.
6 5521 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).
Installation Control Kit (Flip Sheave/CDT Boost) - PN 57913 PN 57913 7
8 5521 Owner’s Manual Control Kit (Flip Sheave/CDT Non-Boost) - PN 59154 PN 59154
Installation Control Kit (Flip Sheave/12V/CDT Boost) - PN 58276 PN 58276 9
10 5521 Owner’s Manual Control Kit (Flip Sheave/12V/CDT Non-Boost) - PN 59522 PN 59522
Installation Control Kit (Cradle A2B/CDT Boost) - PN 59138 PN 59138 11
12 5521 Owner’s Manual Control Kit (Cradle A2B/CDT Non-Boost) - PN 59155 PN 59155
Installation Control Kit (Cradle A2B/12V/CDT Boost) - PN 59523 PN 59523 13
14 5521 Owner’s Manual Control Kit (Cradle A2B/12V/CDT Non-Boost) - PN 59524 PN 59524
Installation Wiring Diagram (Electrical Version) FUSE 200 AMP MASTER SWITCH 200 AMP (STELLAR SUPPLIED) - + (NOT SUPPLIED) TRUCK BATTERY UNDERHOOD CRANE HARNESS CRANE START MOTOR SOLENOID FUSE 200 AMP OPT1 Torque Spec Large Nuts: 35 in-lbs Small Nuts: 15 in-lbs OPT2 (STELLAR SUPPLIED) GROUND GROUND GROUND POST POWER - + AUX BATTERY GROUND LOCATE AUX BATTERY AS CLOSE TO CRANE AS POSSIBLE SWITCH POWER 10 AMP POWER SOURCE FOR RADIO REMOTE CAB OR CRANE COMPARTMENT NOTE: MINIMUM WIRE SIZE
16 5521 Owner’s Manual Hydraulic Kit - PN 58277 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 58277
Installation Hydraulic Kit (12 Volt Version) - PN 58279 NOTE: USE 32" OF HOSE PROTECTOR P/N 17288 OVER THE ROTATION HOSES NOTE: USE 12" OF HOSE PROTECTOR P/N 17288 OVER THE 2 WINCH HOSES PN 58279 17
18 5521 Owner’s Manual Valve Bank - PN 44530 5 HYDRAULIC SCHEMATIC 2 1 3 5 3 5 4 PN 44530 ITEM PART 1 25367 25368 2 24960 25369 3 25371 4 25372 25373 5 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 VALVE SOLND 3 POS 4 WAY OPEN G04591 SEAL KIT 25371/25372 COIL 12VDC DUETSCH CAP012H QTY 1 1 3 1 9
Installation Hydraulic Installation 1. After mounting, locate the pressure and return lines. Note: Pressure line is 3/8” hose; Return line is 1/2” hose. Hoses are terminated using swivel fittings. 2. Install hydraulic lines per diagram below. 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.
20 5521 Owner’s Manual Hydraulic System
Installation 21 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.
22 5521 Owner’s Manual Decal Kit Placement - PN 57304 30 14,15 22 Indicator Angle ® 80 70 60 50 3 40 30 20 10 5521 0 2 33 27 1 28 26 9 25 29 PN 57304 **THESE DECALS NOT INCLUDED WITH THE DECAL KIT *USE THESE DECALS WITH BODY PACKAGE 33 54588 DECAL CDT 2.00X2.
Assembly Drawings 23 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 .
24 5521 Owner’s Manual Mast Assembly - PN 57577 2 4 15 10 7 6 11 9 6 14 8 3 5 12 PN 57577 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 14 15 PA R T 57296 21528 C1026 C1006 C5902 0343 C6353 27813 44530 0342 56673 57594 0491 47425 DESCRIPTION M AST 5521 WINCH 2500 5520 CRANE CAP SCR 0.63-11X2.50 HHGR8 CAP SCR 0.38-16X2.00 HHGR8 WASHER 0.63 SAE FLAT YELLOW GR8 WASHER 0.31 USS FLAT ZINC WASHER 0.38 SAE FLAT YELLOW GR8 COLLAR 0.38X0.75X0.38 UHMW VB 4 SECT W/PROP STER8GPM DEUTSCH NUT 0.31-18 HHGR5 NYLOC NUT 0.
Assembly Drawings 25 Main Boom Assembly - PN 57581 4 16 23 11 10 20 24 13 3 15 26 25 29 28 26 22 18 16 12 33 19 30 17 32 14 27 6 20 22 21 4 3 23 4 1 8 20 7 31 5 9 20 2 23 4 23 23 NOTE: INCLINOMETER MOUNTS INSIDE THE BOOM.
26 5521 Owner’s Manual Extension Boom Assembly (Flip Sheave) - PN 57593 PN 57593 20 32 16 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 31 31 1 19 6 7 12 15 2 3 8 PART 57307 50341 12929PC 12 8 2 4 5753 9363 9545PC 11545 13400 13399 27719 10172 0490 0420 D0790 C6219 0343 0342 0425 49316 34354PC 11938 33749 18454 D1711 C4956 37850 3 5 264 P C 0530 0347 6252 4974 DESCRIPTION QTY.
Assembly Drawings 27 Extension Boom Assembly (Cradle A2B) - PN 58290 PN 58290 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 27 3 4 9 1 28 5 7 2 6 11 18 12 8 17 16 26 24 23 7 22 29 7 7 19 21 14 20 PART 5 7 3 07 51117 C6219 4974 9363 9545PC D0790 10172 9991 11545 12824 5753 9706ZP 0343 0420 0484 27719 12178 03 42 27710 C6106 0506 31132 D0178 31279 35105 49316 0425 51903PC C1000 DESCRIPTION EXT BOOM 1ST 5521 EXT BOOM 6620 2ND CRADLE A2B WASHER 0.
28 5521 Owner’s Manual Extension Boom Assembly (Flip Sheave - 1 Hyd/1 Manual) - PN 57935 30 PN 57935 32 IT E M P A RT D E S C R I P T I O N 1 5 7 9 2 5 E X T B O O M 1 S T 5 5 2 1 1 H1 M 2 57930 EXT BOOM 2ND 5521 FLIP SHEAVE 1H1M 3 1 2 9 2 9 P C PL A T E S H E A V E M O U N T I N G 4 12824 PIN HITCH 1.00X4.50 5 57 53 PIN 0. 1 9X1.56 LYNCH 6 9363 WEAR PAD 1.12X2.00 RND NYLATRON 7 9 5 4 5 P C P L A T E W E A R P A D S U PP O R T 8 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK 9 13400ZP PIN TEAR DROP 1.00X4.
Assembly Drawings 29 Extension Boom Assembly (Cradle A2B - 1 Hyd/1 Manual) - PN 59146 PN 59146 29 5 7 28 30 7 10 1 25 3 5 2 4 9 16 10 6 15 14 24 22 21 5 20 26 5 5 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 P AR T 57925 59147 9363 9545PC D0790 10172 9991 11545 12824 5753 9706ZP 0343 0420 0484 27719 12178 0342 27710 C6106 0506 31132 D0178 3 127 9 35105 0425 51903PC C1000 57936 9004 57937 DESCRIPTION EXT BOOM 1ST 5521 1H1M EXT BOOM 6620 2ND CRADLE A2B
30 5521 Owner’s Manual Main Cylinder Assembly - PN 54942 2 5 4 3 4 3 4 1 4 2 Manifold Assembly PN 41910 ITEM 1 2 3 4 5 PART 39425 41908 419 07 9803 C4961 DESCRIPTION MANIFOLD CBAL DOUBLE T11A WITH RELIEF VALVE CHECK CXED-XCN V ALV E R DDA- LAN 800 P SI Valve C- SUN CBBD-LJN-3500 PLUG STR HOLLOW HEX 0.38 6-HP5ON 4 QTY. 1 1 1 2 1 3 4 Cylinder Serial Tag Location 1 PN 54942 I TE M 1 2 3 4 PART 50918 41910 44066 0279 DESCRIPTION CYLINDER INNER 4.00X21.
Assembly Drawings 31 Extension Cylinder Assembly - PN 49316 9 Cylinder Serial Tag Location 7 6 8 5 PN 49316 1 2 3 4 I TE M 1 2 3 4 5 6 7 8 9 P A RT 37548 14115 11882 14601 14442 14443 24729 18701 D0655 DESCRIPTION CYLINDER EXT 2 STAGE 2.0/2.0 PTD 60 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 0.38X23.25 EXT CYL 6620 TUBE ASM 0.38X102.25 EXT CYL 6620 HOSE CLAMP #52 3.00 - 3.
32 5521 Owner’s Manual Extension Cylinder Assembly (1 Hyd/1 Manual) - PN 57936 1 PN 57936 2 3 4 ITEM 1 2 3 4 PART 57932 14115 11882 14601 DESCRIPTION CYLINDER 2.00X60.00 5521 MANUAL MANIFOLD ASM 6620 EXT CBBD-LJN-XVN CAP SCR 0.38-16X1.75 SH ZC CAP SCR 0.38-16X2.25 SH ZC QTY.
Assembly Drawings Cable & Hook Assembly - PN 57597 5 9 2 10 1 7 14 2 12 8 15 11 3 7 4 12 13 PN 57597 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART 11545 57596PC 13436 25831 9610 39874ZP 0867 44643PC 0347 5753 39844 C6219 5841 C0538 0531 DESCRIPTION SHEAVE 6620 6.75 DIA .31R/1.94 THK PLATE SNATCH BLOCK 5521 PIN .38X4.00 QUICK RELEASE HOOK 5 TON SWIVEL CROSBY 1028623 WIRE ROPE 0.31 6X19 IWRC-XIP 90FT P I N 1 . 0 0 X 4 .0 6 CO T T E R MACHY WASHER 1.00ID 14GA COLLAR 0.44X0.75X2.00 NUT 0.
34 5521 Owner’s Manual Power Unit Assembly - PN 57939 4 3 1 10 6 6 5 8 10 9 8 7 PN 57939 ITEM 1 2 3 4 5 6 7 8 9 10 PART 19997PC 16994 17771 18472 0340 C6353 0479 56673 59136 16962 DESCRIPTION COVER POWER UNIT 5520 POWER UNIT 12V 5520 HORZ SWITCH PUSH BUTTON 9216-03 DECAL MANUAL OPERATION 5520 WASHER 0.25 USS FLAT ZINC WASHER 0.38 SAE FLAT YELLOW GR8 CAP SCR 0.25-20X0.75 HHGR5 NUT 0.38-16 HHGR8 NYLOC BRACKET POWER UNIT 5521 CAP SCR 0.38-16X1.50 HHGR8 QTY.
Assembly Drawings 35 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
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Replacement Parts Chapter 4 - Replacement Parts PART# C6069 25367 25368 24960 25369 25371 25373 44532 9803 28485 C2027 C2028 C2029 D1245 D1246 D1247 17724 54778 20310 44066 14442 14443 55827 55829 55830 4381 0068 44533 9363 6252 9320 9142 10172 9843 C6353 D0790 11545 9610 12824 57937 13436 5753 53493 11938 31670 35105 43488PC 61048 27710 11544 56647 35441 47856 22600 35447 35916 18468 24956 17771 25831 19501 C1592 4460 DESCRIPTION HYDRAULIC SWING MOTOR RELIEF VALVE SEAL KIT - RELIEF VALVE FLOW CONTROL VAL
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.
