stellar labs Model 5521 User manual

!$%%"!($$ '#&!$(#%$
 
)
 
Stellar Industries, Inc.
190 State Street
P Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com Last Revision: 04/17/13
Subject to Change without Notification.
© 2013 Stellar Industries, Inc.
®
TM

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
ours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST
Or email at the following addresses:
Technical Questions, and Information [email protected]
rder 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
ydraulic Kit - PN 58277 16
ydraulic Kit (12 Volt Version) - PN 58279 17
Valve Bank - PN 44530 18
ydraulic Installation 19
ydraulic 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 yd/1 Manual) - PN 57935 28
Extension Boom Assembly (Cradle A2B - 1 yd/1 Manual) - PN 59146 29
Main Cylinder Assembly - PN 54942 30
Extension Cylinder Assembly - PN 49316 31
Extension Cylinder Assembly (1 yd/1 Manual) - PN 57936 32
Cable & ook 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: ydraulic 60” (152.4 cm)
2nd stage: Manual 60” (152.4 cm)
Optional: 2nd stage: ydraulic 60” (152.4 cm)
Maximum orizontal 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 eight: 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]
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
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
4080 kgs
4080 kgs
4080 kgs
4080 kgs
80º
45º
75º
60º
15º
30º
9000#
9000#
9000#
9000#
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'
0 m
3'
.914 m
6'
1.83 m
9'
2.74 m
11'
3.35 m
21'
6.40 m
16'
4.88 m
12'
3.66 m
3'
.914 m
6'
1.83 m
9'
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 [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.
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.


1
2
.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 verview
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.
ave 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. ook-up hydraulics and electrical.
Note: If questions should arise during any portion of this installation,
please contact Stellar Customer Service at [phone].
5521 Owner s Manual

Installation 
PN 57913
PD1
PD2
ROT
ROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH DOWN
WINCH
UP
AB
6
MAIN CYL
MANIFOLD
PD1
PD2
BASE END
ROD END
B AB AB AB
AB
A
A B A B ABAB
INCLINOMETER
4
2
3
78
CORD REEL
FB
D
ECA
POWER
PWR UNIT SIGNAL
GROUND
ENG START
ENG STOP
CPRSR ON/OFF
SWITCH
A2B
32
41
3
4
5
SPEED CTRL OUTPUT 1
PWR ON DEMAND MODE
SPEED CTRL OUPUT 2
ON / OFF MODE
*WIRING OPTIONS FOR REMOTE CONTROL OF ENGINE SPEED:
1. POWER ON DEMAND (POD) MODE- ALLOWS AUTOMATIC
SWITCHING OF HIGH IDLE BASED ON CRANE OPERATION.
- OR -
2. ON/OFF MODE - ALLOWS MANUAL SELECTION OF HIGH IDLE.
Control Kit (Flip Sheave/CDT Boost) - PN 57913


5521 Owner s Manual
PN 59154
PD1
PD2
ROT
ROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH DOWN
WINCH
UP
AB
6
MAIN CYL
MANIFOLD
PD1
PD2
BASE END
ROD END
B AB AB AB
AB
A
A B A B ABAB
INCLINOMETER
4
2
3
78
CORD REEL
FB
D
ECA
POWER
PWR UNIT SIGNAL
GROUND
ENG START
ENG STOP
CPRSR ON/OFF
SWITCH
A2B
32
41
3
4
5
SPEED CTRL OUTPUT 1
PWR ON DEMAND MODE
SPEED CTRL OUPUT 2
ON / OFF MODE
* WIRING OPTIONS FOR REMOTE CONTROL OF ENGINE SPEED:
1. POWER ON DEMAND (POD) MODE- ALLOWS AUTOMATIC
SWITCHING OF HIGH IDLE BASED ON CRANE OPERATION.
-OR -
2. ON/OFF MODE - ALLOWS MANUAL SELECTION OF HIGH IDLE.
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
FB
D
ECA
PD1
PD2
ROT
ROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH DOWN
WINCH
UP
AB
5
MAIN CYL
MANIFOLD
PD1
PD2
POWER
PWR UNIT SIGNAL
GROUND
ENG START
ENG STOP
CPRSR ON/OFF
BASE END
ROD END
B AB AB AB
AB A
ABA B ABAB
INCLINOMETER
4
2
3
A2B
SWITCH
67
5 6 7
CORD REEL
SPEED CTRL OUTPUT 1
PWR ON DEMAND MODE
SPEED CTRL OUPUT 2
ON / OFF MODE
* WIRING OPTIONS FOR REMOTE CONTROL OF ENGINE SPEED:
1. POWER ON DEMAND (POD) MODE- ALLOWS AUTOMATIC
SWITCHING OF HIGH IDLE BASED ON CRANE OPERATION.
- OR -
2. ON/OFF MODE - ALLOWS MANUAL SELECTION OF HIGH IDLE.
Control Kit (Cradle A2B/CDT Boost) - PN 59138

 5521 Owner s Manual
PN 59155
FB
D
ECA
PD1
PD2
ROT
ROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH DOWN
WINCH
UP
AB
5
MAIN CYL
MANIFOLD
PD1
PD2
POWER
PWR UNIT SIGNAL
GROUND
ENG START
ENG STOP
CPRSR ON/OFF
BASE END
ROD END
B AB AB AB AB
A
ABABA B AB
INCLINOMETER
4
2
3
A2B
SWITCH
67
5 6 7
CORD REEL
SPEED CTRL OUTPUT 1
PWR ON DEMAND MODE
SPEED CTRL OUPUT 2
ON / OFF MODE
* WIRING OPTIONS FOR REMOTE CONTROL OF ENGINE SPEED:
1. POWER ON DEMAND (POD) MODE- ALLOWS AUTOMATIC
SWITCHING OF HIGH IDLE BASED ON CRANE OPERATION.
- OR -
2. ON/OFF MODE - ALLOWS MANUAL SELECTION OF HIGH IDLE.
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
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