Stellar Industries 5521 User manual

Brand: Stellar Industries

Model: 5521

Type: User manual

Stellar Industries 5521 is a telescopic crane with a crane rating of 29,500 ft-lb (4.1 ton-m) in Boost Mode. Normal crane rating is 25,000 ft-lbs (3.46 ton-m). The standard boom length is 11’ 0” (3.35 m) from CL of Crane. It has a maximum horizontal reach of 21’ 0” (6.39 m) from CL of Crane and a maximum vertical lift of 22’ 10” (6.95 m) from the crane base. The boom elevation ranges from -5 to +80 degrees. The crane has a stowed height of 32” (81.3 cm) and weighs approximately 1400 lbs (635 kg). The controls are radio controlled standard for all functions. It comes with a winch that has

®®

5521

Angle

Indicator

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Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Last Revision: 09/06/12

Subject to Change without Notification.

5521 Manual Revisions

Date of Revision Description of Revision

Section Revised

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 [email protected]

Order Parts [email protected]

Warranty Information [email protected]

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

Table of Contents 

 5521 Owner’s Manual

4'7"

(1.40m)

3'9"

(1.14m)

2'10"

(0.87m)

22'10"

(6.95m)

17'10"

(5.45m)

12'11"

(3.93m)

10.69”

(0.27m)

18.41”

(0.47m)

11’0”

(3.34m)

16’0”

(4.87m)

21’0”

(6.39m)

Specifications 

Chapter 1 - Specifications

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: 22’ 10” (6.95 m)

(from crane base)

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)

Controls: Radio control standard for all

functions.

Winch Specifications

Rope Diameter: 5/16" (8 mm)

Line pull speed: 70 ft/min (21.34 m/min)

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)**

Power Supply Required: PTO & Pump

(8.0 gpm @ 2500 psi)

(30.31 lpm @ 173 bar)

12 volt power unit

(2.0 gpm @ 2500 psi)

(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.

Model Stellar® 5521 Crane Specifications Sheet

Stellar® 5521 Geometric Measurements

33.80

[0.86m]

HYD

56.47

[1.43m]

12V

35.13

[0.89m]

15.75

[0.40m]

32.15

[0.82m]

12'3"

11'0"

3.34m

[0.32m]

12.61

3.72m

HYD

12'11"

12V

3.95m

[0.65m]

12V

25.70 22.11

[0.56m]

HYD

 5521 Owner’s Manual

Reach in Feet/Meters

Capacity in Pounds/Kilograms

Weight of load handling devices are

part of the load lifted and must be

deducted from the capacity.

PN 57598

Maximum 1 - part line capacity is

2500 lbs (1130 kg). For greater

loads, use 2 - part line.

4080 kgs

9000#

4755 lbs

2155 kg

5000 lbs

2265 kg

5000 lbs

2265 kg

5000 lbs

2265 kg

5000 lbs

1870 kg

5000 lbs

2265 kg

4030 lbs

1825 kg

2665 lbs

1205 kg

2260 lbs

1025 kg

3445 lbs

1560 kg

2920 lbs

1320 kg

4865 lbs

2205 kg

4125 lbs

2840 kg

3650 lbs

1655 kg

3095 lbs

1400 kg

3090 lbs

1400 kg

2620 lbs

1185 kg

2120 lbs

960 kg

1800 lbs

815 kg

1620 lbs

730 kg

1375 lbs

620 kg

1945 lbs

880 kg

1650 lbs

745 kg

2680 lbs

1215 kg

2275 lbs

1030 kg

1840 lbs

830 kg

1560 lbs

705 kg

1400 lbs

635 kg

1190 lbs

535 kg

1475 lbs

665 kg

1250 lbs

565 kg

2535 lbs

1150 kg

2150 lbs

975 kg

1945 lbs

880 kg

1650 lbs

745 kg

0 m

.914 m

1.83 m

2.74 m

11'

3.35 m

21'

6.40 m

16'

4.88 m

12'

3.66 m

.914 m

1.83 m

2.75 m

15'

4.57 m

18'

5.49 m

21'

6.40 m

23'

7.01 m

Boost

(If Equipped)

Standard

2905 lbs

1315 kg

2465 lbs

1115 kg

Capacity Chart - Decal PN 57598

Specifications 

 5521 Owner’s Manual

Installation 

Chapter 2 - Installation

General Installation

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. If

a question should arise during the installation

process, please contact Stellar Customer

Service at (800) 321 3741.

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.

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.

Notice: Read this Page Before Installation of the Crane

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.



.YTQNOITPIRCSEDTRAPMETI

1 5199 CAP SCR 1.00X8X3.00 HHGR8 ZY4

2 6538 WASHER 1.00 SAE FLAT YELLOW GR84

Motor

Hole Mounting Detail

Ø1.063

7.38

14.75

7.38

14.75

Ø6.00

4 Places

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.

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 (800) 321-3741.

 5521 Owner’s Manual

Installation 

PN 57913

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



 5521 Owner’s Manual

PN 59154

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

Installation 

PN 58276

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

 5521 Owner’s Manual

PN 59522

Control Kit (Flip Sheave/12V/CDT Non-Boost) - PN 59522

Installation 

PN 59138

Control Kit (Cradle A2B/CDT Boost) - PN 59138

 5521 Owner’s Manual

PN 59155

Control Kit (Cradle A2B/CDT Non-Boost) - PN 59155

Installation 

PN 59523

Control Kit (Cradle A2B/12V/CDT Boost) - PN 59523

 5521 Owner’s Manual

PN 59524

Control Kit (Cradle A2B/12V/CDT Non-Boost) - PN 59524

Installation 

FUSE 200 AMP

(STELLAR SUPPLIED)

UNDERHOOD

TRUCK BATTERY

MASTER

200 AMP

AUX BATTERY

CRANE

COMPARTMENT

CAB OR CRANE

10 AMP

POWER

SWITCH

START MOTOR

SOLENOID

GROUND POST

NOTE:

MINIMUM WIRE

SIZE - 2 GA

CUSTOMER SUPPLIED

CRANE HARNESS

GROUND

LOCATE AUX BATTERY AS

CLOSE TO CRANE AS POSSIBLE

GROUND

POWER

OPT1

OPT2

SWITCH

(NOT SUPPLIED)

POWER SOURCE FOR

RADIO REMOTE

Torque Spec

Large Nuts: 35 in-lbs

Small Nuts: 15 in-lbs

FUSE 200 AMP

(STELLAR SUPPLIED)

Wiring Diagram (Electrical Version)

 5521 Owner’s Manual

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

Hydraulic Kit - PN 58277

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Stellar Industries 5521 User manual

Brand: Stellar Industries

Model: 5521

Type: User manual

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Stellar Industries 5521 User manual

Stellar Industries 5521 User manual

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