stellar labs 5520 User manual

UPDATED 01/23/03
CRANE
MODEL 5520
280 W. 3rd St., Box 169 •Garner, IA 50438 •Phone: [phone] •Fax: [phone]

2
TABLE OF CONTENTS
STELLAR CRANE 5520
PAGE DESCRIPTION
3.) SPECIFICATION SHEET
4.) CAPACITY CHART
5.) CRANE OPERATION
6.) MANUAL OPERATION
7.) BASE ASSEMBLY
8.) MAST ASSEMBLY
9.) MAIN BOOM ASSEMBLY
10.) EXTENSION BOOM ASSEMBLY
11.) HOOK AND CABLE ASSEMBLY
12.) CONTROL KIT
13.) HYRAULIC KIT
14.) INSTALLATION KIT
15.) DECAL KIT
16.) STABILITY PROCEDURE
17.) STABILITY CHART
18.) WARRANTY

3
Model 5520 Crane
SPECIFICATION SHEET
Crane Rating 25,000 ft-lbs (3.46 ton-meters)
Standard Boom Length 10’(3.05 m) from CL of Crane
Boom Extension 1st stage: Hydraulic 60”(152.4 cm)
2
nd stage: Manual 60”(152.4 cm)
Maximum Horizontal Reach 20’(6.10 m) from CL of Crane
Maximum Vertical Lift 21’ 4”(6.50 m)
(from crane base)
Boom Elevation -8 to +80 degree
Winch Specification
Rope Diameter 5/16”(.794 cm)
Line pull speed 40 ft/min (12.19 m/min)
Max. single part line 2500 lbs (1135 kg)
Max. double part line 5000 lbs (2270 kg)
Rotation 385 degree power
(worm gear)
Lifting Capacities 2500 lbs @ 10’(1135 kg @ 3.05 m)
1670 lbs @ 15’(760 kg @ 4.57 m)
1250 lbs @ 20’(565 kg @ 6.10 m)
Power Supply Required PTO & Pump
(4.00 gpm @ 2500 psi)
(15.14 lpm @ 172 bars)
Controls Radio control standard
for all functions.
Stowed Height 31.50 inches (80.0 cm)
(crane only)
Mounting Space Required 18 x 20 inches (45.7 x 50.8 cm)
Approximate Shipping Weight 1400 lbs (635 kg)

4
CAPACITY CHART
STELLAR 5520
be deducted from the capacity.
Maximum 1−part line capacity is
For greater loads, use 2−part line.
Weight of load handling devices
are part of the load lifted and must
2500 lbs(1135 kg). CAPACITY IN POUNDS/KILOGRAMS
REACH IN FEET/METERS

5
CRANE OPERATION
THIS CRANE IS OPERATED BY A RADIO CONTROL SYSTEM
WHICH OPERATES AN ELECTRONIC VALVE BANK. THE
CONTROLLER (AS SHOWN) OPERATES THE FOLLOWING
FUNCTIONS:
MAIN BOOM UP & DOWN
EXTENSION BOOM IN & OUT
WINCH UP & DOWN
ROTATION CW & CCW
THIS CONTROLLER CAN ALSO BE UTILIZED TO OPERATE THE FOLLOWING
OPTIONAL FUNCTIONS:
ENGINE START & STOP
SPEED CONTROL ON & OFF
COMPRESSOR ON & OFF
TWO OPTIONAL FUNCTIONS ARE ALSO AVAILABLE FOR OTHER CUSTOMER
NEEDS. OPTION TWO AND OPTION FOUR ARE BOTH MOMENTARY 12 VOLT
FUNCTIONS AND WILL REQUIRE A LATCHING RELAY FOR MOST
INSTALLATIONS.
E−stop
boom ext winch rot
Start/Stop
Engine

6
MANUAL OPERATION
IN CASE OF RADIO FAILURE THE CRANE CAN BE OPERATED USING THE
MANUAL OVERRIDES LOCATED ON THE VALVE BANK. USE THE MANUAL
OVERRIDES ONLY TO GET THE CRANE INTO A STOWED POSITION FOR
TRAVEL. HAVE THE EQUIPMENT SERVICED FOR NORMAL RADIO USE.
WARNING
PROLONGED MANUAL OPERATION WILL CAUSE SEVERE
DAMAGE TO THE HYDRAULIC SYSTEM.
TO OPERATE CRANE MANUALLY:
1.) LOOSEN JAM NUT ON MANUAL OVERRIDE VALVE
2.) TURN THE HANDKNOB FULLY COUNTER CLOCKWISE
3.) OPERATE FUNCTIONS AS NEEDED TO STOW CRANE BY
PUSHING ON THE END OF THE SOLENOID
4.) TURN THE HANDKNOB FULLY CLOCKWISE
5.) HAVE UNIT SERVICED
EXT OUT
MAIN UP
ROT CCW
WINCH UP
ROT CW
EXT IN
MAIN DN
WINCH DN
OVERRIDE
MANUAL

7
BASE ASSEMBLY
P/N 18164
ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY.
1 12857 BEARING SWING DRIVE WR170A-60:1ASK 1 9 D0790 WASHER 0.50 FLAT GR8 2
2 12141 BASE 5520 1 10 D1307 CAP SCR 0.50-13X1.25 SH 2
3 10668 GEAR GUARD WELDMENT 2200 1 11 C4808 CAP PLASTIC (RED) 1
4 12152 WASHER 0.63 FLAT SP 16 12 c1592 ZERK 1/8 NPT STRAIGHT 1
5 D1312 CAP SCR 0.63-11X3.50 HHGR8 16 13 C2256 FTG COUPLER PIPE 0.13 1
6 0343 WASHER 0.31 FLAT 3 14 D1345 FTG CPRSN 0.12NPT/0.25 TUBE 2
7 0484 CAP SCR 0.31-18 X 0.50 HHGR5 3 15 D1810 TBE AIR SAEJ844 TYPE A .25 1
8 D1204 ROTATION MOTOR 5520 1

8
MAST ASSEMBLY
P/N 18165
ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY.
1 11699 MAST 5520 1 10 C6353 WASHER 0.38 FLAT GR8 8
2 11362 WINCH KINEMATIC'S 3000# 1 11 12167 CAP SCR 0.38-16X1.75 HHGR8 4
3 12810 VB 4 SECT ELECT W/PROP VLV HYDAK 1 12 0347 NUT 0.38-16 HH NYLOC 7
4 11847 RADIO RECEIVER 1ref 13 0343 WASHER 0.31 FLAT 4
5 0067 BUSHING QSI-2426-24 4 14 0484 CAP SCR 0.31-18 X 0.50 HHGR5 4
6 12137 COVER MAST 5520 1 15 10976 CAP SCR 6MMX12MM HHGR8 4
7 C5902 WASHER 0.63 FLAT GR8 12 16 0346 WASHER 0.38 FLAT 3
8 D1312 CAP SCR 0.63-11X3.50 HHGR8 3 17 0531 CAP SCR 0.38-16X3.50 HHGR5 3
9 C1026 CAP SCR 0.63-11X2.50 HHGR8 ZY 9

9
MAIN BOOM ASSEMBLY
P/N 18226
ITEM NO. PART NO. DESCRIPTION QTY. ITEM NO. PART NO. DESCRIPTION QTY.
1 12014 INNER BOOM 5520 1 22 7403 PIN CAP 0.44X2.50X.252 10
2 13754 CYLINDER 3.50X21.00 1 23 C6353 WASHER 0.38 FLAT GR8 28
3 0279 FTG ADAPT 6-F5OLO-S 8 24 9843 CAP SCR 0.38-16X0.75 HHGR8 6
4 15173 TUBE ASM 0.38X7.81 MAIN CYL 5520 2 25 13573 CAP SCR 0.38-16X1.00 HHGR8 14
5 11544 CORD REEL 6620 1 26 16962 CAP SCR 0.38-16X1.50 HHGR8 4
6 12040 WEAR PAD 3.00X4.50X1.00 1 27 C0987 CAP SCR 0.38-16X7.00 HHGR5 1
7 13642 WEAR PAD 2.00X3.50X0.97 2 28 0347 NUT 0.38-16 HH NYLOC 3
8 13643 PLATE WEAR PAD COVER 5520 1 29 0335 CAP SCR 0.38-16X1.25 HHGR5 2
9 13644 PLATE WEAR PAD COVER 5520 1 30 0337 HOSE CLAMP LN 4190 PP 2
10 13441 CYLINDER 2.00 X 60.00 1 31 0220 CAP SCR 0.25-20 X 1.50 HHGR5 2
11 13757 BRKT ROPE GUIDE 6620 2 32 C1033 WASHER 0.25 USS FLAT ZINC 2
12 13759 SPACER ROPE GUIDE 5520 1 33 0478 CAP SCR 0.25-20X0.50 HHGR5 2
13 13760 PIPE 0.75X6.00 PVC 1 34 14929 CLAMP 0.38 PORT TUBE 1
14 13811 PIN 1.50X9.75 D&T 2 35 14494 WEAR PAD COVER W\CLAMP 5520 1
15 0067 BUSHING QSI-2426-24 8 36 14491 CLAMP ASM CYL 5520(HRS4S65PPUNC) 1
16 13812 PIN 1.50X7.88 D&T 1 37 12158 TUBE ASM 0.38X8.88 MAIN CYL 6620 1
17 13813 PIN 1.25X4.50 D&T 1 38 13575 TUBE ASM 0.38X45.00 EXT CYL 5520 1
18 13814 PIN 1.25X3.50 D&T 1 39 15110 VALVE CHECK SINGLE W/ ORIFICE 1
19 D0790 WASHER 0.50 FLAT GR8 4 40 15111 FTG ADAPT MSTH/FSTH 6-4-F50G5 1
20 13815 PLATE ANGLE INDICATOR 2 41 13080 MANIFOLD ASM 6620 INNER HOLDING 2
21 C6106 NUT 0.50-13 HHGR5 NYLOC 2
27 12
13
31 30
31 30
25 9
7
1
26
23
35
8
6
23
25
10
25
23
22
18
24
23
22
16
24
23
22
14
15
2
33
524 23
22
15
21
19
20
19
14
3
4
7
15
28
29
23
28
17
22
23
25
23
29
11
3
34
3
37
25
23
22
25 23
22
324
23
22
324
23 22
24
23
22
21
19
32
36
39
40
41
15
38
23
23
1

10
EXTENSION BOOMS ASSEMBLY
P/N 18227
6
7
1
2
11 10
459
18
15 14
16
17
38
12
13
19
15
14
ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY.
1 12023 EXT BOOM 1ST 552
0
1 11 022
0
CAP SCR 0.25-20 X 1.50 HHGR5
2
2
12013 EXT BOOM 2ND 552
0
1 12 0343 WASHER 0.31 FLAT
2
3 11545 SHEAVE 6620 6.75 DIA .31R/1.94 TH
K
2
13 048
4
CAP SCR 0.31-18 X 0.50 HHGR5
2
4
13642 WEAR PAD 2.00X3.50X0.97 1 1
4
1193
6
SPACER BOOM TIP 382
0
2
5 1364
4
PLATE WEAR PAD COVER 552
0
1 15 12178 CAP SCR 0.31-18X3.25 HHGR5
2
6
13645 WEAR PAD 3.00X4.50X.63 1 16 1282
4
PIN HITCH 1.00X4.5
0
1
7 13646 WEAR PAD 2.00X3.50X.63 1 17 5753 PIN 0.19X1.56 LYNCH 1
8 9706 PIN TEAR DROP 1.00X3.25
2
18 13573 CAP SCR 0.38-16X1.00 HHGR8
4
9
C6353 WASHER 0.38 FLAT GR8
4
19 D1298 PIN HITCH 0.63X6.25 1
1
0
0337 HOSE CLAMP LN 4190 PP
2