stellar labs 5521 User manual

Model 5521
Telescopic Crane
Owner’s Manual
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Subject to Change without Notication.
© 2016 Stellar Industries, Inc. Last Revision: 10/27/16
Installation • Assembly Drawings • Parts
Notice: A copy of this manual must remain with the equipment at all times.
For a printable download copy, please visit: www.stellarindustries.com

Page ii | Stellar®5521 Telescopic Crane Owner’s Manual
Model 5521 Manual Revisions
MODELNO.SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PNC5942
®
PATENTINFORMATION
http://www.stellarindustries.com/ip
MODEL NO.SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENT INFORMATION
http://www.stellarindustries.com/ip
Serial Tag
Location
Date of Revsion Section Revised Description of Revision

Stellar®5521 Telescopic Crane Owner’s Manual | Page iii
Table of Contents
Introduction .........................................................................................................iv
Chapter 1 - Specications..................................................................................... 1
Model 5521 Specications .................................................................................1
Capacity Chart - Decal PN 72816 .....................................................................2
Dimensional Drawing 1 .......................................................................................3
Dimensional Drawing 2 .......................................................................................4
Chapter 2 - Installation .......................................................................................... 5
General Installation .............................................................................................5
Installer Notice ...................................................................................................5
Torque Data Chart ............................................................................................6
Installation Overview ........................................................................................7
Control Kit (Cradle CDT Boost) - PN 59138 ........................................................8
Control Kit (Cradle CDT Non-Boost) - PN 59155 ...............................................9
Control Kit (Cradle 12V CDT Boost) - PN 59523 ..............................................10
Control Kit (Cradle 12V CDT Non-Boost) - PN 59524 ......................................11
Wiring Diagram (Electrical Version) .................................................................12
Hydraulic Kit (CDT) - PN 72837 ..........................................................................13
Hydraulic Kit (12V CDT) - PN 72839 ..................................................................14
Valve Bank - PN 44530 .......................................................................................15
Hydraulic Installation .........................................................................................16
Hydraulic System ...............................................................................................17
Face Seal/O-Ring Size Chart ............................................................................18
Stability Procedure ............................................................................................19
Crane Load Level Indicator .............................................................................20
Decal Placement - PN 72815 ...........................................................................21
Chapter 3 - Assembly Drawings ......................................................................... 23
Base Assembly - PN 50364 ................................................................................23
Gear Bearing - PN 47869 ..................................................................................24
Mast Assembly - PN 72819 ................................................................................25
Main Boom Assembly - PN 72833 .....................................................................26
Extension Boom Assembly (2 Hyd) - PN 58290 ................................................27
Extension Boom Assembly (1 Hyd/1 Manual) - PN 59146 ..............................28
Main Cylinder Assembly - PN 78434 ................................................................29
Extension Cylinder Assembly (2 Hyd) - PN 49316 ...........................................30
Extension Cylinder Assembly (1 Hyd/1 Manual) - PN 57936 .........................31
Cable & Hook Assembly - PN 57597 ................................................................32
Power Unit Assembly - PN 57939 ......................................................................33
CDT™ Radio Transmitter Assembly - PN 56647 ...............................................34

Page iv | Stellar®5521 Telescopic Crane Owner’s Manual
Introduction
A copy of this manual is provided with every crane and can be found in the hard plastic
manual case that is installed on the chassis. A copy of this manual shall remain with the
crane at all times.
Throughout the manual, three signal words will be used to bring attention to important
items:
A NOTICE signal word indicates a practice not related to physical injury.
A WARNING signal word indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
A DANGER signal word indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Information contained within this manual does not cover operation, maintenance, or
troubleshooting. Please refer to the General Light Duty Crane Manual for details on these
items.
This manual is not binding. Stellar Industries, Inc. reserves the right to change, at any
time, any or all of the items, components, and parts deemed necessary for product
improvement or commercial/production purposes. This right is kept with no requirement or
obligation for immediate mandatory updating of this manual.
In closing:
If more information is required or technical assistance is needed, or if you feel that any
part of this manual is unclear or incorrect, please contact the Stellar Customer Service
Department by phone at 800-321-3741 or email at [email protected].
WARNING
NOTICE
DANGER
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]

Stellar®5521 Telescopic Crane Owner’s Manual | Page 1
Model 5521 Crane
Specifications Sheet Page: 1of4
Crane Rating*: 29,500 ft-lbs (4.1 TM)
Standard Boom Length: 11'0" (3.35 m) from CL of Crane
Boom Extension: Hydraulic 60" (152.4 cm)
Hydraulic 60" (152.4 cm)
Maximum Horizontal Reach: 21' 0" (6.40 m) from CL of Crane
Maximum Vertical Lift: 22' 11" (6.99 m) from Crane Base
Stowed Height (Crane Only): 33" (83.8 cm)
Required Mounting Space: 20" x 21" (50.8cmx53.3 cm)
Approximate Crane Weight:
Controls: Radio control standard for all functions.
Wire Rope: 5/16" (0.79 cm) 6X19 IWRC-DGXIP X 90' (27.73 m)
Boom Elevation: -10º to +80º
Line Pull Speed: 70 ft/min (21.34 m/min)
Max. Single Part Line: 2,500 lbs (1,135 kg)
Max. Double Part Line: 5,000 lbs (2,265 kg)
Rotation (Worm Gear): 400º Power
Lifting Capacity**: 5,000 lbs @ 5'10" (3,400 kg @ 1.78 m)
1,400 lbs @ 21' (635 kg @ 6.40 m)
Power Supply:
2H: 1480 lbs (671 kg)
1H1M: 1365 lbs (619 kg)
5521 (Electric)
2H: 1390 lbs (631 kg)
1H1M: 1275 lbs (578 kg)
5521 (Hydraulic)
1st Stage:
2nd Stage:
12V Power Unit: 2 gpm @ 2,500 psi
(7.6 lpm @ 172 bar)
PTO & Pump: 8 gpm @ 2,500 psi
(30.3 lpm @ 172 bar)
Winch Specifications
*Crane rating in Boost Mode. Normal crane rating is 25,000 ft-lbs (3.46 TM).
**Maximum capacities in Boost Mode.
Chapter 1 - Specications
Model 5521 Specications

Page 2 | Stellar®5521 Telescopic Crane Owner’s Manual
Model 5521 Crane
Specifications Sheet
Page: 2 of 4
Crane Rating*:
Standard Boom Length:
Boom Extension:
Maximum Horizontal Reach:
Maximum Vertical Lift:
Stowed Height (Crane Only):
Required Mounting Space:
Approximate Crane Weight:
Controls:
Wire Rope:
Boom Elevation:
Line Pull Speed:
Max. Single Part Line:
Max. Double Part Line:
Rotation (Worm Gear):
Lifting Capacity**:
Power Supply:
1st Stage:
2nd Stage:
Winch Specifications
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 (1135 kg). For greater loads,
use 2 - part line.
PN 72816
-10º
80º
0º
15º
30º
45º
60º
0’
1’
4’
6’
8’
10’
12’
14’
16’
18’
20’
22’
24’
2’ 4’ 6’ 8’ 10’ 12’ 14’ 15’ 16’ 18’ 20’ 22’
0’
11’
3.35m
16’
4.88m
21’
6.40m
5.5 m 4.3 m2.4 m1.8 m1.2 m0.6 m
7.3 m
6.7 m
6.1 m
5.5 m
4.9 m
4.3 m
4.3 m
3.7 m
3.7 m
3.1 m
3.1 m
2.4 m
1.8 m
1.2 m
4080 kgs
4080 kgs
4080 kgs
9000#
9000#
9000#
5000 lbs
2265 kg
5000 lbs
2265 kg
5000 lbs
2265 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
2720 lbs
1235 kg
2305 lbs
1045 kg
1870 lbs
850 kg
1585 lbs
720 kg
1425 lbs
645 kg
1205 lbs
545 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
Boost
(If Equipped)
Standard
2905 lbs
1315 kg
2465 lbs
1115 kg
Capacity Chart - Decal PN 72816

Stellar®5521 Telescopic Crane Owner’s Manual | Page 3
Model 5521 Crane
Specifications Sheet
Page: 3 of 4
Crane Rating*:
Standard Boom Length:
Boom Extension:
Maximum Horizontal Reach:
Maximum Vertical Lift:
Stowed Height (Crane Only):
Required Mounting Space:
Approximate Crane Weight:
Controls:
Wire Rope:
Boom Elevation:
Line Pull Speed:
Max. Single Part Line:
Max. Double Part Line:
Rotation (Worm Gear):
Lifting Capacity**:
Power Supply:
1st Stage:
2nd Stage:
Winch Specifications
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)
Dimensional Drawing 1

Page 4 | Stellar®5521 Telescopic Crane Owner’s Manual
Model 5521 Crane
Specifications Sheet
Page: 4 of 4
Crane Rating*:
Standard Boom Length:
Boom Extension:
Maximum Horizontal Reach:
Maximum Vertical Lift:
Stowed Height (Crane Only):
Required Mounting Space:
Approximate Crane Weight:
Controls:
Wire Rope:
Boom Elevation:
Line Pull Speed:
Max. Single Part Line:
Max. Double Part Line:
Rotation (Worm Gear):
Lifting Capacity**:
Power Supply:
1st Stage:
2nd Stage:
Winch Specifications
33.80
[0.86m]
HYD
56.47
[1.43m]
12V
35.13
[0.89m]
15.75
[0.40m]
CG
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
Dimensional Drawing 2

Stellar®5521 Telescopic Crane Owner’s Manual | Page 5
Installer Notice
According to Federal Law (49 cfr part 571), each nal-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 nal completion, or a date between
those two dates. This requirement shall, however, be superseded by any conicting
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 Trafc 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.
Chapter 2 - Installation
General Installation
This chapter is designed to serve as a general guide for the installation of a Stellar®5521
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 [phone].
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.
Do not install this crane on a body not capable of handling the loads
imposed on it. Failure to do so may result in serious injury or death.
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.
WARNING
NOTICE

Page 6 | Stellar®5521 Telescopic Crane Owner’s Manual
When using the torque data in the
chart, the following rules should be
observed:
• Bolt manufacturer’s particular
specications should be consulted
when provided.
• Flat washers of equal strength
must be used.
• All torque measurements are
given in foot-pounds. To convert
to inch-pounds, multiply by 12.
• Torque values specied are for
bolts with residual oils or no special
lubricants applied. If special
lubricants of high stress ability,
such as Never-Seez compound
graphite and oil, molybdenum
disulphite, colloidal copper or white lead are applied, multiply the torque values in the
charts by the factor .90. The use of Loctite does not affect the torque values listed above.
• Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
• Do not use these values if a different torque value or tightening procedure is given for
a specic application. Torque values listed are for general use only. Check tightness of
fasteners periodically.
• Sheer bolts are designed to fail under predetermined loads. Always replace shear bolts
with identical grade.
• Fasteners should be replaced with the same or higher grade. If higher grade fasteners
are used, these should only be tightened to the strength of the original.
• Tighten plastic insert or crimped steel-type lock nuts to approximately 110 percent of the
dry torque values shown in the chart below, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full torque value. Note: “Lubricated”
means coated with a lubricant such as engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without lubrication. Tighten lubricated bolts
to approximately 80% of dry bolts.
Size Bolt DIA Plain Plated Plain Plated Plated
(DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb)
5/16-18 0.3125 17 13 25 18 22
3/8-16 0.3750 31 23 44 33 39
7/16-14 0.4375 49 37 70 52 63
1/2-13 0.5000 75 57 105 80 96
9/16-12 0.5625 110 82 155 115 139
5/8-11 0.6250 150 115 220 160 192
3/4-10 0.7500 265 200 375 280 340
7/8-9 0.8750 395 295 605 455 549
1-8 1.000 590 445 910 680 823
1 1/8-7 1.1250 795 595 1290 965 1167
1 1/4-7 1.2500 1120 840 1815 1360 1646
1 3/8-6 1.3750 1470 1100 2380 1780 2158
1 1/2-6 1.500 1950 1460 3160 2370 2865
GRADE 5 GRADE 8 GRADE 9
Torque Data Chart

Stellar®5521 Telescopic Crane Owner’s Manual | Page 7
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 5521.
5. Use four (4) 1” x 3” #8 bolts and four (4) #8 at washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the 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.
Installation Overview
1
2
.YTQNOITPIRCSEDTRAPMETI
15199CAP SCR 1.00X8X3.00 HHGR8 ZY 4
26538WASHER 1.00 SAE FLAT YELLOW GR8 4
Motor
Hole Mounting Detail
Ø1.063
7.38
14.75
7.38
14.75
Ø6.00
4 Places

Page 8 | Stellar®5521 Telescopic Crane Owner’s Manual
RECEIVER - RADIO (PART OF 1)
RADIO CONTROLLER ASSEMBLY
WIRE HARNESS 12621/12628 LMI TRANSMITTER - RADIO (PART OF 1)
PD1
PD2
ROTROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH
DOWN
WINCH
UP
AB
MAIN CYL
MANIFOLD
PD1
PD2
BASE END
ROD END
B
AB
AB
AB
AB
A
ABABABAB
INCLINOMETER
4
2
3
A2B
SWITCH
CORD REEL
FB
D
ECA
POWER
PWR UNIT SIGNAL
GROUND
ENG START
ENG STOP
CPRSR ON/OFF
SPEED CTRL
PWR ON DEMAND MODE
SPEED CTRL
ON / OFF MODE
8
6
7
5
TRANSMITTER
RECEIVER
CABLE BACKUP HETRONIC G2 RADIO
INCLINOMETER 60 DEG PENNY AND GILES
SWITCH LIMIT E1161-B9111-6C
CORD REEL ASM 15/20/21 FT CRANE
TRANSDUCER PRESSURE 5000 PSI
ADAPTER REV. POL. TNC M -STANDARD TNC FM
PN 59138
Control Kit (Cradle CDT Boost) - PN 59138

Stellar®5521 Telescopic Crane Owner’s Manual | Page 9
RECEIVER - RADIO (PART OF 1)
RADIO CONTROLLER ASSEMBLY
WIRE HARNESS 12621/12628 LMI TRANSMITTER - RADIO (PART OF 1)
PD1
PD2
ROTROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH
DOWN
WINCH
UP
AB
MAIN CYL
MANIFOLD
PD1
PD2
BASE END
ROD END
B
AB
AB
AB
AB
A
ABABABAB
INCLINOMETER
4
2
3
A2B
SWITCH
CORD REEL
FB D ECA
POWER
PWR UNIT SIGNAL
GROUND
ENG START
ENG STOP
CPRSR ON/OFF
SPEED CTRL
PWR ON DEMAND MODE
SPEED CTRL
ON / OFF MODE
RECEIVER
TRANSMITTER
7
6
8
5
CABLE BACKUP HETRONIC G2 RADIO
INCLINOMETER 60 DEG PENNY AND GILES
SWITCH LIMIT E1161-B9111-6C
CORD REEL ASM 15/20/21 FT CRANE
TRANSDUCER PRESSURE 5000 PSI
ADAPTER REV. POL. TNC M -STANDARD TNC FM
PN 59155
Control Kit (Cradle CDT Non-Boost) - PN 59155

Page 10 | Stellar®5521 Telescopic Crane Owner’s Manual
RECEIVER - RADIO (PART OF 1)
RADIO CONTROLLER ASSEMBLY WIRE HARNESS 5521 12V TRANSMITTER - RADIO (PART OF 1)
CABLE #2 2 WIRE TERML #1X.38 COPPER LUG
HEAT SHRINK 0.50 BLK HEAT SHRINK 0.50 RED FUSE HOLDER
FUSE 200 AMP
WIRE HARNESS BATTERY CABLE 20"
ROT
ROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH
DOWN
WINCH
UP
AB
ROD END
B
AB
AB
AB
AB
A
ABABABAB
INCLINOMETER
A2B
SWITCH
4
30"
BLK
10
BLKRED
10 10
05 06
SOLENOID
05
RED
30"
9
SIGNAL
GROUND
OVERRIDE
11
12V POWER UNIT
PT
10 06
PUSH BUTTON
08
07
SIGNAL
OVERRIDE
NOTE:
1. HEAT SHRINK TO BE CUT TO 3" PIECES
2. FOR SHIP OUT CABLE, CONNECTORS AND HEAT SHRINK FOR
BATTERY END TO BE SHIPPED LOOSE.
BATTERY
+
FB D
ECA
PD1
PD2
MAIN CYL
MANIFOLD
PD1
PD2
+ POWER
CTRL OUTPUT
- GROUND
ENG START
ENG STOP
CPRSR ON/OFF
SPD CTRL ON/OFF
BASE END
2
RECEIVER
3
TRANSMITTER
14
13
12
15
CABLE BACKUP HETRONIC G2 RADIO
INCLINOMETER 60 DEG PENNY AND GILES
SWITCH LIMIT E1161-B9111-6C
CORD REEL ASM 15/20/21 FT CRANE
TRANSDUCER PRESSURE 5000 PSI
CORD REEL
ADAPTER REV. POL. TNC M -STANDARD TNC FM
PN 59523
Control Kit (Cradle 12V CDT Boost) - PN 59523

Stellar®5521 Telescopic Crane Owner’s Manual | Page 11
FB D ECA
PD1
PD2
RECEIVER - RADIO (PART OF 1)
RADIO CONTROLLER ASSEMBLY
WIRE HARNESS 5521 12V
TRANSMITTER - RADIO (PART OF 1)
ROTROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH
DOWN
WINCH
UP
AB
MAIN CYL
MANIFOLD
PD1
PD2
+ POWER
CTRL OUTPUT
- GROUND
ENG START
ENG STOP
CPRSR ON/OFF
SPD CTRL ON/OFF
BASE ENDROD END
B
AB
AB
AB
AB
A
ABABABAB
INCLINOMETER
CABLE #2 2 WIRE TERML #1X.38 COPPER LUG
A2B
SWITCH
HEAT SHRINK 0.50 BLK HEAT SHRINK 0.50 RED
FUSE HOLDER
FUSE 200 AMP
WIRE HARNESS BATTERY CABLE 20"
30"
BLK
10
BLK
RED
10 10
05 06
SOLENOID
05
RED
30"
9
SIGNAL
GROUND
OVERRIDE
11
12V POWER UNIT
PT
10 06
PUSH BUTTON
08
07
SIGNAL
OVERRIDE
NOTE:
1. HEAT SHRINK TO BE CUT TO 3" PIECES
2. FOR SHIP OUT CABLE, CONNECTORS AND HEAT SHRINK FOR
BATTERY END TO BE SHIPPED LOOSE.
BATTERY
+
RECEIVER
TRANSMITTER
2
3
14
13
15
12
CORD REEL
TRANSDUCER PRESSURE 5000 PSI
SWITCH LIMIT E1161-B9111-6C
CORD REEL ASM 15/20/21 FT CRANE
INCLINOMETER 60 DEG PENNY AND GILES CABLE BACKUP HETRONIC G2 RADIO
4
ADAPTER REV. POL. TNC M -STANDARD TNC FM
PN 59524
Control Kit (Cradle 12V CDT Non-Boost) - PN 59524

Page 12 | Stellar®5521 Telescopic Crane Owner’s Manual
+
-
FUSE 200 AMP
(STELLAR SUPPLIED)
UNDERHOOD
TRUCK BATTERY
MASTER
200 AMP
AUX BATTERY
-+
CRANE
COMPARTMENT
CAB OR CRANE
10 AMP
POWER
SWITCH
NOTE:
MINIMUM WIRE
SIZE - 2 GA
LOCATE AUX BATTERY AS
CLOSE TO CRANE AS POSSIBLE
SWITCH
(NOT SUPPLIED)
POWER SOURCE FOR
RADIO REMOTE
FUSE 200 AMP
(STELLAR SUPPLIED)
OPTION WIRES
POWER
GROUND
CRANE
HARNESS POWER
UNIT
SOLENOID
-
+
RELAY
Operating the crane without
the truck engine running could allow the truck
battery to be discharged below levels required
for starter cranking power.
SAFETY BRAKE
87A
30
86 85
87
NOTICE
Wiring Diagram (Electrical Version)

Stellar®5521 Telescopic Crane Owner’s Manual | Page 13
NOTE: USE 12" OF HOSE PROTECTOR
P/N 17288 OVER THE 2 WINCH HOSES
NOTE: USE 32" OF HOSE PROTECTOR
P/N 17288 OVER THE ROTATION HOSES
PN 72837
Hydraulic Kit (CDT) - PN 72837

Page 14 | Stellar®5521 Telescopic Crane Owner’s Manual
NOTE: USE 12" OF HOSE PROTECTOR
P/N 17288 OVER THE 2 WINCH HOSES
NOTE: USE 32" OF HOSE PROTECTOR
P/N 17288 OVER THE ROTATION HOSES
PN 72839
Hydraulic Kit (12V CDT) - PN 72839

Stellar®5521 Telescopic Crane Owner’s Manual | Page 15
5
3
1
5
4
5
3
2
HYDRAULIC SCHEMATIC
EUQROTYTQNOITPIRCSEDTRAPMETI
125367 RELIEF VALVE 24685/24690137 FT LBS
25368SEAL KIT 25367
224960 VALVE FLW CTRL PRP/JP04C3150N 0-8 120-22 FT LBS
25369SEAL KIT 24960/25381
325371 VALVE SOLND 3 POS 4 WAY TAND G045713 25 FT LBS
425372 VALVE SOLND 3 POS 4 WAY OPEN G04591 125 FT LBS
25373SEAL KIT 25371/25372
544532 COIL 12VDC DUETSCH CAP012H93 FT LBS
PN 44530
Valve Bank - PN 44530

Page 16 | Stellar®5521 Telescopic Crane Owner’s Manual
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. Fill system with hydraulic oil (See Stellar®
Lubrication Recommendations for fluid details).
Stabilizer Functions
Stabilizer Functions
Typical Stabilizer Valve
with Power Beyond Capabilities
Hydraulic Installation