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

11
CABLE AND HOOK ASSEMBLY
P/N 18228
10
2
823
4
7
6
823
3
5
2
1
8
22
22
8
19
18 16
20
18 21
9
14
13
15
11
12
17
15
ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY.
1 1193
4
SHEAVE 6620 6.50 DIA .31R/1.12 TH
K
1 13 D1711 CAP SCR #10-24X0.50 BTNHD S
S
1
2
9676 PLATE 6620 SNATCH BLOC
K
2
1
4
10972 CHAIN 0.105 (RM) 2607-21201 1
3 3863 HOOK 5 TON 1 15 C4956 NUT #10-24 HH NYLOC S
S
2
4
9706 PIN TEAR DROP 1.00X3.25 1 16 11933 WEIGHT 6620 AT
B
1
5 1166
6
SPACER 5520 SNATCH BLOC
K
3 17 D089
4
CAP SCR #10-24 X 0.75 BTN HD S
S
1
6
0343 WASHER 0.31 FLAT 1 18 C1033 WASHER 0.25 USS FLAT ZINC
4
7 048
4
CAP SCR 0.31-18 X 0.50 HHGR5 1 19 0482 CAP SCR 0.25-20 X 3.00 HHGR5
2
8 C6219 WASHER 0.75 SAE FLAT YELLOW GR8
6
20 12876 FLAT 0.25 X 2.00 X 3.63 1
9 9263 PIN .38X3.00 QUICK RELEASE 1 21 0333 NUT 0.25-20 HHGR5 NYLOC
2
1
0
9610 WIRE ROPE 0.31 6X19 IWRC-XIP 90FT 1 22 C6218 CAP SCR 0.75-10X4.00 HHGR8 ZY 3
11 11938 SWITCH LIMIT A2B FURNAS 3SE3170 1 23 C0538 NUT 0.75-10 HHGR8 NYLOC 3
1
2
12177 CAP SCR #10-24 X 1.50 SHGR5
4

12
CONTROL KIT
Winch
E−stop
Opt
Ext
boom
Opt
Rot
Start/
Stop
Eng

13
HYDRAULIC KIT
ROTATION CW
ROTATION CCW
HOSE-HYD .25 X 23.50
HOSE KIT,5520 CRANE (incl:2-11)
HOSE-HYD .25 X 63.50
HOSE-HYD .25 X 35
HOSE-HYD .38 X 6
HOSE-HYD .50 X 5
HOSE-HYD .25 X 13
HOSE-HYD .25 X 12
FTG O'RING FS 45 DEG 6-8 V5OLO
FTG ADAPT 6-8 F5OLO-S
GAUGE OIL LF 2.5" 0-5000 CBM
FTG SWIVEL 0.50 FS/FS PS81 JMJM-8-8
FTG SWIVEL 0.38 FS/FS PS81 JMJM-6-6
FTG ADAPT MSTR/FNPT 8 - 0.25
FTG ADAPT 4-6 F5OLO-S
FTG ADAPT MSTR/FSTR 10-6 F5OG5
PLUG STR HOLLOW HEX 0.63 10-HP5ON
FTG ADAPT SL LOK 8-10-F5OLO-S
FTG O'RING SL LK TBE 45DG 4 6V5OLO
SWITCH PRES OVERLD 744.6-S03R-2900N
FTG ML FM O'RING 90 DEG
VALVE C-BAL PLUG
VALVE C-BAL
FTG O'RING PLUG
PRESSURE FROM PUMP
RETURN LINE (TO TANK) WINCH EXTEND
WINCH RETRACT
BOOM UP
BOOM DOWN
EXTENSION EXTEND
ROTATION CCW
MAIN UP
WINCH EXTEND
EXTENSION RETRACT
ROTATION CW
MAIN DOWN
EXTENSION EXTEND
EXTENSION RETRACT
WINCH RETRACT
WINCH
MAIN
EXT
ROTATION
PLUG STR HOLLOW HEX 0.50 8-HP5ON

14
INSTALLATION KIT

15
DECAL KIT

16
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. The following procedure will test the truck
package for stability and will provide a stability capacity chart. The load
limit information shown on the stability capacity chart is formulated on 85%
of tipping.
Set Up
-Locate the truck on a test course in position for loading and engage travel
brakes.
-Set outriggers so that they make contact with firm, level footings.
-Operate the crane under partial load to assure operator proficiency and
proper machine function.
Test Data for 5520 Crane
-Maximum Horizontal Reach – 240 inches (center of rotation to boom tip)
- Stability Test Weight – 1475#
Test Procedure
-Rotate the crane into zone 1 position.
-With the crane fully retracted and the boom horizontal, winch the test
weight off the ground. Note: keep the weight within six inches of the ground
at all times.
-Extend the boom outward until full extension has been reached or until the
truck becomes unstable (again, use the winch to keep the weight within six
inches of the ground).
-If the boom goes full extension without becoming unstable, the crane is
termed stable for this zone and 100% can be written in the zone 1 data box.
-If the truck becomes unstable prior to going full extension - retract the
boom until the truck becomes stable and measure the horizontal reach in this
position (center of rotation to boom tip). This is the stable horizontal reach
for this zone. Use the following formula to determine the percentage of
rated capacity.
Stable horizontal reach divided by Maximum horizontal reach multiplied by
100 equals the percentage of rated capacity for this zone. Record this
number in the data box for zone 1. This is the revised capacity due to
stability for this zone.
-Repeat this procedure for each zone until the worksheet is completed.
-This is the revised CAPACITY based on STABILITY of this package.

17
STABILITY CHART
STABILITY CAPACITY CHART

18
Limited Warranty Statement
for Stellar Tire Service Trucks, Truck-mounted Cranes, Truck-mounted Stellarc Welders
& Truck-mounted Compressed Air Systems ONLY
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 stated lifting capacities. The warranty period shall be Twelve (12) month warranty on all
Stellar designed and fabricated parts, and Ninety (90) days repair labor.
The warranty period shall begin from the date recorded by Stellar as the in-service date. This date will be derived from the
completed warranty registration card. In the event a warranty registration card is not received by Stellar, the factory ship
date will be used. Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be,
the repair and/or replacement (at Stellar’s option) of the part and/or component in question. Stellar after-sales service
personnel must be notified by telephone, fax, e-mail, or mail of any warranty-applicable damage within fourteen (14) days
of it’s occurrence. If at all possible, Stellar will ship the replacement part within 24-hours of notification by the most
economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.
Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim
procedure. Stellar Service personnel must be contacted prior to any warranty claim. A return materials authorization
(RMA) account number must be issued to the claiming party prior to the return of any warranty parts. Parts returned
without prior authorization will not be recognized for warranty consideration. All damaged parts must be returned to Stellar
freight prepaid; freight collect returns will be refused.
Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center
authorized to service the type of product involved, or at the Stellar factory. At the time of requesting warranty service, the
owner must present evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor
requested of the servicing company by the owner, any field service call charges, and any towing and/or transportation
charges associated with moving the equipment to the designated repair/service provider.
All obligations of Stellar and it’s authorized dealers and service providers shall be voided if someone other than an
authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar. In the
case repair work is performed on the Stellar-manufactured product, original Stellar parts must be used to keep the
warranty in force. The warranty may also be voided if the product is modified or altered in any way not approved, in
writing, by Stellar engineering.
The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question.
Warranty registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of
the Stellar product registration card provided with the product. If the owner is unsure of registration, he is encouraged to
contact Stellar at the address below to confirm registration of the product in question. This warranty covers only defective
material and workmanship. It does not cover depreciation or damage caused by normal wear and tear, accident, mishap,
untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and
maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting
from owner/operator failure to perform such duties shall void the coverage of this warranty. The cost of labor and supplies
associated with routine maintenance will be paid by the owner.
The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product
specified are those set above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar
be liable for business interruptions, costs of delay, or for any special, indirect, incidental, or consequential costs or
damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use, wages, salaries,
commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.
All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective
manufacturer only. Stellar does not participate in, or obligate itself to, any such warranty.
Hydraulic cylinders used in Stellar products are subject to the same warranty provisions stated above. Should a cylinder
defect develop within the above stated warranty period, notify Stellar immediately. Stellar will ship, freight prepaid, by the
most effective, expedient, means a new or re-manufactured cylinder of the same size and type. An authorization for return
of the original part will be issued at the time the order is placed. The defective cylinder is to be returned to Stellar freight
prepaid by the owner. Cylinders returned freight collect will be refused. Should the defective cylinder not be returned
within 30 days of shipping the replacement cylinder, the owner is responsible to pay Stellar the full purchase price of the
replacement part.
Stellar reserves the right to make changes in design or improvement upon it’s products without imposing upon itself the
same upon it’s products theretofore manufactured.
This warranty will apply to all Stellar Tire Service Trucks, Truck-mounted Cranes, Truck-mounted Stellarc Welders &
Truck-mounted Compressed Air Systems shipped from Stellar’s factory after January 1,1997. The warranty is for the use
of the original owner only and is not transferable without prior written permission from Stellar.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS
WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR
INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Stellar Industries, Inc. • 280 West Third Street • Garner, Iowa 50438 • U.S.A.
E-Mail • [e-mail]
Telephone: [phone] • Fax: [phone]
REVISED 10/05/2000