Stellar Industries 5521 User's Manual
Contents
1. 552 1 TELESCOPIC CRANE OWNERS MANUAL Installation Assembly Drawings Parts AEN i gt SIELLAR EQUIPPED Stellar Industries Inc 190 State Street 169 Garner IA 50438 800 321 3741 641 923 2811 www stellarindustries com Last Revision 09 06 12 Subject to Change without Notification 2012 Stellar Industries Inc _ 292 Manual Revisions 2 Manual Revisions Section Revised Table of Contents Table of Contents Chapter 1 Specifications Model Stellar 5521 Crane Specifications Sheet Stellar 5521 Geometric Measurements Capacity Chart Decal PN 57598 Chapter 2 Installation Installation Overview Control Kit Flip Sheave CDT Boost PN 57913 Control Kit Flip Sheave CDT Non Boost PN 59154 Control Kit Flip Sheave 12V CDT Boost PN 58276 Control Kit Flip Sheave 12V CDT Non Boost PN 59522 Control Kit Cradle A2B CDT Boost PN 59138 Control Kit Cradle A2B CDT Non Boost PN 59155 Control Kit Cradle A2B 12V CDT Boost PN 59523 Control Kit Cradle A2B 12V CDT Non Boost PN 59524 Wiring Diagram Electrical Version Hydraulic Kit PN 58277 Hydraulic Kit 12 Volt Version PN 58279 Valve Bank PN 44530 Hydraulic Installation Hydraulic System Stability Procedure Decal Kit Placement PN 57304 Chapter 3 Assembly Drawings Base Assembly PN 50364 Mast Assembly PN 57577 Main Boom Assembly PN 5758 Extensio2. 6620 6 75 DIA 3IR L94THK 2 9 12824 PINHITCH1 00x4 50 30 5521 Owner s Manual Main Cylinder Assembly 54942 Manifold Assembly PN 41910 DESCRIPTION MANIFOLD CBAL DOUBLE TI 1A WITH RELIEF VALVE CHECK CXED XCN VALVE RDDA LAN 800 PSI Valve C SUN CBBD LJN 3500 PLUG STR HOLLOW HEX 0 38 6 Cylinder Serial Tag Location PN 54942 ITEM PART DESCRIPTION 50918 CYLINDER INNER 4 00X21 38 NEW MAST 2 41910 ASM DUAL IO ICBAL RLE CHK 1 8 44066 TUBE ASM 0 38X8 25 MAIN 10628 12628 0279 ADAPT 6 F5OLO S Note Main Cylinder uses Stellar Seal Kit PN 17724 Assembly Drawings 31 Extension Cylinder Assembly 49316 Holding Jam Nut Center Screw Holding Valve Removal Procedure Locate Holding Valve to be removed Unlock Jam Nut as shown Turn center screw as shown ClockWise Direction Important Count the turns it takes until stopping Holding valve can now be removed from manifold Important Before replacing valve reset by turning the center srew the same amount of turns Counter ClockWise as in previous step Reset Jam Nut yA Valve is now removed and set at Factory Specifications Cylinder Serial Tag Location PN 49316 37548 3 4 6 14443 TUBE ASM 0 38 102 25 EXT CYL 6620 1 20655 Extension Cylinder Uses Upper Seal Kit
3. Assembly Drawings 35 CDT Radio Transmitter Assembly 56647 SEE NOTE NOTE 1 P N S 25999 amp 24958 ARE OPTIONAL COVERS FOR THE SWITCHES AND TRIGGER PN 56647 2 56657 CONTROL HANDLE FACE PLT W LABEL 6 1 3 24385 GUARDRADIOSWIICHAFCIN 4 35447 CONTROLHANDLE GRIP W TRIGGERHTH2 5 24958 RUBBERBOOTTRIGGER GUARD HET 6 22600 _ SWITCH TOGGLE HET RADIO 63019300 6 7 35441 BATTERYTUBE AA 11 8 4 856 SWITCHESTOPNOVAXL Y 36 5521 Owner s Manual Replacement Parts 37 Chapter 4 Replacement Parts PARTA 6069 25367 25368 24960 25569 25571 SOLENOID VALVE TAND 604571 25573 44532 9803 25485 2027 2028 2029 01245 01246 01247 17724 54778 20310 44066 14442 14443 55827 55829 55830 4381 0068 BUSHING 1 00 X 1 50 44553 9363 6252 9320 PIN CAP 44 X 2 50 X 25 9142 PIN CAP 56 X 2 50 X 0 25 SS 10172 9543 6353 0790 11545 9610 12824 57937 13436 5758 53493 11938 LIMIT SWITCH CHAIN amp WEIGHT ANTI 2 BLOCK 31670 WEIGHT amp CHAIN ASSY ANTI 2 BLOCK 35105 13488 61048 27710 11544 56647 35441 BATTERY TUBE HOLDER HETRONIC RADIO 47856 E STOP SWITCH HETRONIC RADIO 0 8 z U 5 m gt 2 U 0 mo gt E gt N 2 N lt 5 lt 22600 35447 35916 18468 24956 17771 25
4. 10 11 15 WINCH EXTEND gt WINCH RETRACT WINCH 15 NOTE USE 12 OF HOSE PROTECTOR P N 17288 OVER THE 2 WINCH HOSES PN 58279 28465 TRANSDUCER PRESSURE 5000 Psi Fo 8 5005 1 HOSE PROTECTOR 1 00 85 8 27 4 17 39780 GAUGE OL LF 25 0 5000 COM sE 1 os ws Fi Deseos farer 19 sm eros eem Los 19029 Hose Hvo 38 x 2250 9 12 116 ADAPT 90 6 10 0500 5 2 ITEM PART No DESCRIPTION ITEM PART No DESCRIPTION 18 5521 Owner s Manual Valve Bank PN 44530 o HYDRAULIC SCHEMATIC o Alp Alpi TE us Xini t Ke N lt 2 V A ZA MX NA 4 55 5 NA PN 44530 DESCRIPTION RELIEF VALVE 24685 24690 25368 SEAL KIT 25367 VALVE FLW CTRL PRP JP04C3150N 0 8 SEAL KIT 24960 25381 05373 SEAL KIT 2537425372 5 44592 2VDCDUETSCHCAPOUH o Installation Hydraulic Installation 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 Install hydraulic lines per diagram below Note Stabilizer valve supplies oil to crane using the Power Beyond feature Install hydraulic reservoir with return filte
5. 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 PIO 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 Important When installing welder units to the service bodies it is highly recommended that a surge protector is installed on the chassis batteries lo 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 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
6. crane under partial load to assure operator proficiency and proper machine function Put the radio into Stability Test Mode A Push the bottom four switches up and hold until all lights come on approximately 5 seconds B At this point the crane will have enough capacity to handle the weight for the stability test C The radio will timeout of stability mode after 30 minutes or when the E Stop button is pushed Note The radio can only be put into stability mode five times After that the radio would have to be returned to Stellar to be reprogrammed to allow additional stability testing All other radio functions will work properly even if stability mode is not avail able 552 Stability Data Max Horizontal Reach 252 From the center of rotation to boom fip Boost Stability Test Weight 1650 lbs Non Boost Stability Test Weight 1400 lbs Test Procedure 1 Rotate the crane into Zone 1 position 2 With the crane fully retracted and the boom horizontal winch the test weight off the ground Note Keep 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
7. fo ENG STOP o POWER 9 GROUND 9 E STOP 5 wow kam B SPD CTRL ON OFF Idd BASE END 4 CYL 8 E MANIFOLD J END GONHIXH NOISN amp SIXS _ NIVIA E an NIM 0 2 00 26 00 57913 08 9756 CONTACTM TERMSHROUD Ov 8384 CABLESBAL 06 9752 CONNECT2PINSHROUD 05 10965 CABLEGROMMET 46307 WIRE HARNESS 12621 12628 LMI TRANSMITTER RADIO PART OF 1 REF 2 RECEIVER RADIO PART OF 1 57914 RADIO CONTROLLER ASSEMBLY a PART No DESCRIPTION 8 5521 Owner s Manual Control Kit Flip Sheave CDT Non Boosl 59154 INCLINOMETER 6 7 8 CPRSR ON OFF A m 4 n 8 c 8 o Es EAN 1 1 PN 59154 08 9756 CONTACTM TERMSHROUD 2 0v 8384 CA
8. CRANE 6 0343 WASHER 0 31 USS FLATZINC 5 7 C6353 WASHERO 38SAEFLATYELLOW GR8 8 8 27813 COLLAROS8X075X038UHMW 2 9 44530 VB4SECTW PROPSTERBGPM DEUTSCH 1 Assembly Drawings 25 Boom Assembly 57581 NOTE INCLINOMETER MOUNTS INSIDE THE BOOM VIEW SHOWS POSITION OF INCLINOMETER PN 57581 4 9142 0 56 2 50 019 6 19 C6106 JNUTO S0 ISHHGRBNYLOC 2 6 97121 PINT OOX amp 38D amp T 1 21 9843 CAP SCRO 38 16X0 75HHGRE 2 7 DII94PC PLATEANGLEINDICATOR 2 22 C6353 jWASHEROJ38SAEFLATYELOW GR8 6 8 9363 1 12 2 00 RNDNYLATRON 2 23 10172 CAPSCRO SC3XI00HHGRB 1 14 9 9545PC PLATE WEAR PAD SUPPORT 12 24 12168 CAPSCROS3816 X900HHGRb 2 5521 Owner s Manual Extension Boom Assembly Flip Sheave 57593 2 PN 57593 DESCRIPTION 50341 EXT BOOM IST 5521 EXT BOOM 2ND 6621 FLIP SHEAVE 12929PC PLATE SHEAVE MOUNTING 12824 PIN HITCH 1 00X4 50 9545PC PLATE WEAR PAD SUPPORT SHEAVE 6620 6 75 DIA 31R 1 94 THK PIN TEAR DROP 1 00X4 38 PIN TEAR DROP 1 00X3 81 SPACER BOOM TIP 6620 UHMW CAP SCR 0 50 13X1 00 HHGR8 CAP SCR 0 31 18X3 50 HHGR5 CAP SCR 0 31 18X0 75 HHGR5 WASHER 0 50 SAE FLAT YELLOW GR8 0343 WASHER 0 75 SAE FLAT YELLOW GR8 WASHER 0 31 USS FLAT ZINC 0342 NUT 0 31 18 H
9. Stellar does not participate in or obligate itself to any such warranty Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products theretofore manufactured This warranty will apply to all Stellar Cranes Stellar Hooklift Hoists Stellar Cable Hoists Stellar Container Carriers Stellar Service Trucks Stellar X Tra Lift Systems and Stellar Tarper Systems shipped from Stellar s factory after January 151 2010 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 Revision Date February 2010 Document Number 37040
10. the Stellar product registration card provided with the product If the owner is not sure 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 owner will pay the cost of labor and supplies associated with routine maintenance 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 products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only
11. 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 Stable horizontal reach divided by Maximum horizontal reach multiplied by 100 equals the percentage of rated capacity for this zone Use the following formula to determine the percentage of rated capacity Stable Horizontal Reach x 100 Percentage of Rated Capacity Max Horizontal Reach 6 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 8 This is the revised capacity based on stability of this package 22 5521 Owner s Manual Decal Kit Placement PN 57304 30 22 33 d _ Li G 1 lt 28 25 9 26 29 57304 THESE DECALS NOT INCLUDED WITH THE DECAL KIT USE THESE DECALS WITH BODY PACKAGE 33 54588 DECAL CDT 2 00 2 00 2 16 12451 DECAL HOISTING PERSONNEL 32 25159 DECAL WARNINC MANUAL OVERRIDES 15 D1197 DECAL ANGLE INDICATOR SS 3 41068 DECAL VB CONTROL MECH CRANE 1 14 01196 DECAL ANGLE INDICATOR CS 2077 35234 DECAL STELLAR MADE IN THE USA 3 1179 DECAL ELECTROCUTION 4 5x7 5 2 29 38472 DECAL SNATCH BLOCK CAP 5 TON 12 5918 DECAL DANGER MOVING 2 28 28256 D
12. 831 19501 SAFETY LATCH FOR 5 TON SWIVELHOOK 01593 4460 GEAR BEARING GREASE MOLUBE Open Teeth 42 gt TI m x gt TI A 2 r I GREASE ZERK STELLAR INDUSTRIES INC Limited Warranty Statement 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 capacities This warranty shall cover the following Stellar Cranes Stellar Hooklift Hoists Stellar Cable Hoists Stellar Container Carriers Stellar Service Trucks and Stellar X Tra Lift Systems Twelve 12 month warranty on parts from the date recorded by Stellar as the in service date not to extend beyond twenty four 24 months from date of manufacture Twelve 12 month repair labor from the date recorded by Stellar as the in service date not to extend beyond twenty four 24 month from date of manufacture and Thirty six 36 month warranty on all Stellar Manufactured structural parts from the date recorded by Stellar as the in service date not to extend beyond forty eight 48 months from date of manufacture Stellar Tarper Systems Twelve 12 month warranty on parts from the date recorded by Stellar as the in service date not to extend bey
13. BLESEAL 06 9752 CONNECT2PNSHROUD 1 05 10965 CABLEGROMMET 1 04 46307 WIREHARNESSI262VI2OIMI 1 o gt TRANSMITTER RADIO PART OF 1 02 RECEIVER RADIO PART OF 1 01 59148 RADIO CONTROLLER ASSEMBLY 1 ITEM PART No DESCRIPTION QTY Installation 9 Control Kit Flip Sheave 12V CDT Boost PN 58276 NOTE 1 SHRINK TO CUT PIECES 2 FOR SHIP OUT CABLE CONNECTORS AND HEAT SHRINK FOR BATTERY END TO BE LOOSE PN 58276 59518 TERML 1 38 COPPER LUG EE E 5 06 9752 CONNECT2PINSHROUD 03 TRANSMIITER RADIO PARTOFi O2 RECEIVER RADIOCARTOF REF TEM PART No DESCRIPTION 10 5521 Owner s Manual Control Kit Flip Sheave 12V CDT Non Boost PN 59522 NOTE 1 HEAT SHRINK TO BE CUT TO 3 PIECES 2 FOR SHIP OUT CABLE CONNECTORS AND HEAT SHRINK FOR BATTERY END TO BE LOOSE PN 59522 59518 WIRE HARNESS BATTERY CABLE 20 32523 FUSE HOLDER FUSE 200 AMP HEAT SHRINK 0 50 BLK 15219 HEATSHRINKOSORED G 09 20466 CABLEQ2WRE 832 5 CONTACT M TERM SHROUD ES CABLE SEAL 9752 CONNECT 2 PIN SHROUD CABLE GROMMET 1 TRANSMITTER RADIO PARTOF1 REF O2 RECEIVER RADIO ARTOF1 ITEM PART No DESCRIPTION QTY Installation 11 Control Kit Cradle A2B CDT Boost PN 59138 A2B SWITCH INCLINOMETER 5 6 7 CPRSR ON OFF m wi 1 E
14. ECAL WARNING OVERLOAD DEVICE 11 4795 DECAL DANGER 2 27 24712 DECAL CAUTION STOW HOOK 10 41920 DECAL DANGER 1 26 15172 DECAL ASME ANSI B30 22 B30 5 09 2188 DECAL ROTATE GREASE 1 25 15171 DECAL GREASE WORM DRIVE BEARINGS 08 4189 DECAL DANGER 24 4188 DECAL ROTATION ALIGNMENT 1 07 4186 DECAL ELECTROCUTION 22 75 1 729 C454 DECAL CRANE STOWING 06 4544 DECAL DANGER 22 12300 DECAL TWO BLOCKING 05 C4540 DECAL DANGER 21 4214 DECAL SERVICE 04 4545 DECAL ELECTROCUTION 5x13 4 20 568 DECAL DIESEL 2 03 57598 DECAL CAPACITY 5521 2 19 12452 DECAL MANUAL EXT 02 57306 DECAL 5521 IDENTIFICATION 2 18 5911 DECAL STELLAR 2x4 5 3 01 52681 DECAL STELLAR 060 6 00 X 16 50 2 17 C5910 DECAL STELLAR 4x9 5 ITEM PART No DESCRIPTION QTY ITEM PART DESCRIPTION QTY Assembly Drawings 23 Chapter 3 Assembly Drawings Assembly 50364 GASKET SHOWN AS REFERENCE PN 50364 DESCRIPTION BEARING SWING DRIVE CAST 6620 GEARTEK 2 11542 3820 400 SLIDE 3 6069 MOTOR HYD ROSS MK080613AAAB 21151 GASKET MOTOR 008 10056 1 5 01345 FIGCPRSNOI2NPI 2BTUBE L 2 6 01810 5 44 25 RM 8 56589 ZERK 1 8 NPTSTRAIGHTLONG THREAD 1 9 53495 CAPSCROSO3X200SH NOTE ITEMS 1 INCLUDE CUARD amp CUARD FASTENERS 24 5521 Owner s Manual Assembly 57577 57577 DESCRIPTION MAST 5521 WINCH 2500 5520
15. HGR5 NYLOC 0425 MACHY WASHER 1 25ID 10GA 19 20 49316 CYLINDER EXT ASM 6620 2 0 2 0 2 34354PC 33749 ANTI 2 BLOCK COVER LH 1 22 11938 SWITCH LIMIT A2B FURNAS 3SE3170 23 CAP SCR 10 24 1 75 2 18454 C4956 CHAIN 0 105X21 50 4 25 01711 ICAP SCR 10 24 0 50 BTNHD SS 26 NUT 10 24 HH NYLOC 55 2 37850 0530 CONNECTOR QUICK LINK 0 13 7 28 35264 WEIGHT ANTI 2 BLOCK 29 CAP SCR 0 38 16X2 75 HHGR5 30 0347 NUT 0 38 16 HHGR5 NYLOC WEAR PAD 0 34X2 50 RND NYLATRON CAP SCR 0 75 10X2 50 HHGR8 RED PATCH Assembly Drawings 27 Extension Boom Assembly Cradle 2 58290 PN 58290 TEM 51903 CRADDLE 6620 6628 30 C1000 5 0 50 13X5 00 HHGR5 2 1 28 5521 Owner s Manual Extension Boom Assembly Flip Sheave 1 1 Manual 57935 57935 PLATE SHEAVE MOUNTING PIN HITCH 1 00X4 50 7 10 133997P PINTEAR DROP 1 00X3 81 0 18 0425 WASHER 1 2510 CAP SCR 0 50 13X1 75 HHGR8 PIN HITCH 0 75X8 00 Assembly Drawings 29 Extension Boom Assembly Cradle A2B 1 Hyd 1 Manual 59146 59146 29 5 3 9363 WEARPAD 1 12X2 00 NYLATRON 2 6 10172 5 0 50 13 1 00 HHGRBZY 8 8 11545 5
16. NG START gt i lt ENG STOP m POWER Op CES gt GROUND E J Ei J SPD CTRL ON OFF BASE END PN 59138 8384 06 9752 cONNECT2PINSHROUD 2 05 9756 CONTACTMITERMSHROUD 4 03 TRANSMITTER RADIO PART OF 1 REF 02 RECEIVER RADIO PART OF 1 57914 RADIO CONTROLLER ASSEMBLY ITEM PART No DESCRIPTION 12 5521 Owner s Manual Control Kit Cradle A2B CDT Non Boost PN 59155 5 6 7 INCLINOMETER 5 6 7 A m 1 BB 111 SB EE PN 59155 8884 CABLESEAL 04 06 9752 CONNECT2PINSHROUD 2 05 9756 CONTACTM TERMSHROUD 4 03 TRANSMITTER RADIO PARTOFI 02 RECHVER RADIO PARTOF E 57914 RADIO CONTROLLER ASSEMBLY 1 4 EF EF ITEM PART No DESCRIPTION Installation 13 Control Kit Cradle A2B 12V CDT Boost PN 59523 6 7 8 INCLINOMETER Low A mg 4 alg 11111 a US SPD ON OFF JA NOTE 1 SHRINK TO BE CUT TO 3 PIBCES 2 FOR SHIP OUT CABLB CONNECTORS AND HEAT SHRINK FOR BATTERY END TO BE SHIPPED LOOSE PN 59523 59518 12 15218 HRATSHRINKOSOBLK 6 11 15219 HEATSHRINEOSURED 6 20466 CABLEW 2WRE 325 TRANSMITTER RADIO PART OF 1 RECEIVER RADIO PARTOF1 00000 DESCRIPTION 14 5521
17. Owner s Manual Control Kit Cradle A2B 12V CDT Non Boost PN 59524 NOTE 1 SHRINK TO BE CUT TO 3 PIECES 2 FOR SHIP OUT CABLE CONNECTORS AND HEAT SHRINK FOR BATTERY END TO BE SHIPPED LOOSE PN 59524 59518 09 20466 5 08 9756 CONTACTMTERMSHROUD 4 06 9752 CONNECT2PINSHROUD O3 TRANSMITTER RADIO PARTOFI O2 RECEVER RADIOQARTOF 00000 TEM PART No DESCRIPTION QTY Installation 15 Wiring Diagram Electrical Version M mm n a Hr P ism Nn Ng s FUSE 200 AMP ieee SWITCH STELLAR SUPPLIED 200 AMP NOT SUPPLIED TRUCK BATTERY UNDERHOOD START MOTOR 1 CRANE HARNESS SOLENOID FUSE 200 AMP OPT 1 STELLAR SUPPLIED 911 Torque Spec Large Nuts 35 in Ibs RN QY Small Nuts 15 in Ibs 2 GROUND POWER AUX BATTERY LOCATE AUX BATTERY AS puce 1 CLOSE TO CRANE AS POSSIBLE POWER SOURCE FOR RADIO REMOTE SWITCH POWER 10 AMP COMPARTMENT MINIMUM WIRE E SIZE 2 GA CUSTOMER SUPPLIED NOTE CAB OR CRANE 16 5521 Owner s Manual Hydraulic 58277 12 ROTATION CW ROTATION ROTATION CCW IP WINCH UP WINCH DOWN 12 NOTE USE 32 OF HOSE PROTECTOR P N 17288 OVER THE ROTATION HOSES EX
18. PN 54778 Lower Seal Kit PN 20310 32 5521 Owner s Manual Extension Cylinder Assembly 1 Hyd 1 Manual 57936 Holding Jom Nut Center Screw Holding Valve Removal Procedure Locate Holding Valve to be removed Unlock Jam Nut as shown Turn center screw as shown ClockWise Direction Important Count the turns it takes until stopping Holding valve can now be removed from manifold Important Before replacing valve reset by turning the center srew the same amount of turns Counter ClockWise as in previous step Reset Jam Valve is now removed and set at Factory Specifications PN 57936 ITEM PART DESCRIPTION 57932 2 00 60 00 5521 MANUAL 14115 MANIFOLD ASM 6620 EXT CBBD LJN XVN 11882 SCR 0 38 16X1 75 SH ZC 14401 CAP SCR 0 38 16X2 25 SH ZC Assembly Drawings 33 Cable amp Hook Assembly PN 57597 PN 57597 PART DESCRIPTION 1 11545 5 6620 6 75 DIA 31R 1 94 THK PLATE SNATCH BLOCK 5521 6 398747 PIN 1 00 4 06 COTER 8 44643 COLLARO 44X0 75X200 2 9 0347 NUTO 38 16HHGRSNYLOC 2 34 5521 Owner s Manual Power Unit Assembly 57939 57939 5 0840 WASHER 0 25 USS FLATZINC 2 6 C6353 WASHER 0 38 SAE FLAT YELLOW GRB 16 8 56673 0 38 16 HHGR8 NYLOC 8 9 59136 BRACKET POWER UNIT 55211 1 10 16962 CAPSCROS amp l6XIS0HHGRB
19. TENSION EXTEND EXTENSION RETRACT EXTENSION RETRACT MAIN DOWN EXTENSION ROTATION CW EXTENSION MAIN UP ROTATION CCW BOOM DOWN BOOM UP 9 10 11 19 15 H RETURN LINE TO TANK 18 WINCH RETRACT 4 WINCH PRESSURE FROM PUMP 15 NOTE USE 12 OF HOSE PROTECTOR P N 17288 OVER THE 3 WINCH HOSES PN 58277 1o re wer wemyesm 8 81 01 12 To 28485 TRANSDUCER PRESSURE 5000 Psi 19 12172 FIG SWNEL 050 FS FS PSB1 JWAI S 8 17 17288 PROTECTOR 1 00 8 27 iz 18 FTG SWWEL 0 38 FS FS Pset AWM G 6 1 ov 45439 wostcwvo 38x0 f tret 17 39780 GAUGE OL LF 25 0 5000 com 1 45439 so x8 FIG ELL amp eno s 38 x 15 0279 FIG ADAPT 6 Fsorocs m 13030 HOSE HYD 38 X 39 2ref 14 01193 FTG ADAPT 6 5010 5 13028 HOSE HYD X 17 ret 12 D1302 FTG ADAPT 90 6 10 5010 5 58278 HOSE KIT 5521 2 7 3861 FTG 90 MSTR FSTR 6 Installation 17 Hydraulic 12 Volt Version 58279 12 ROTATION CW ROTATION ROTATION CCW IC WINCH DOWN le NOTE USE 32 OF HOSE PROTECTOR P N 17288 OVER THE ROTATION HOSES EXTENSION RETRACT EXTENSION RETRACT MAIN DOWN EXTENSION EXTEND ROTATION CW EXTENSION BOOM DOWN BOOM UP 9
20. d freight collect returns will be refused Freight reimbursement of returned parts will be considered as part of the warranty claim 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 by the Stellar factory in the event of a direct sale 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 obligations of Stellar and its 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 a 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 The owner operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question Warranty registration is ultimate responsibility of the owner and may be accomplished by the completion and return of
21. n Boom Assembly Flip Sheave PN 57593 Extension Boom Assembly Cradle A2B PN 58290 Extension Boom Assembly Flip Sheave 1 Hyd 1 Manual PN 57935 Extension Boom Assembly Cradle A2B 1 Hyd 1 Manual PN 59146 Main Cylinder Assembly PN 54942 Extension Cylinder Assembly PN 49316 Extension Cylinder Assembly 1 Hyd 1 Manual PN 57936 Cable amp Hook Assembly PN 57597 Power Unit Assembly PN 57939 CDT Radio Transmitter Assembly PN 56647 Chapter 4 Replacement Parts OO l 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 service stellarindustries com Order Parts partsestellarindustries com Warranty Information warranty stellarindustries com 5521 Owner s Manual Specifications 1 Chapter 1 Specifications Model Stellar 5521 Crane Specifications Sheet Crane Rating 29 500 ft lb 4 1 ton m Standard Boom Length 11 0 3 35 m from CL of Crane Boom Extension 151 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 fo 80 deg
22. 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 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 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 6 9 5521 Owner s Manual Installation Overview Determine that the mounting location for the 5521 crane is at least 18 x 20 45 7 x 50 8 cm Use the detail below to drill 1 06 diameter holes into the mounting plate Run tap on the threads of the base fo be sure They are clean Use crane or lifting device capable of lifting the weight of the Stellar crane The Stellar 5521weighs approximately 1400 Ibs 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 Connect straps or chain from the liffing device to the lifting rings on the Stellar 5521 Use four 4 1 x 3 8 bolts and four 4 8 flat washers Install a washer on each bol
23. ond twenty four 24 months from date of manufacture and Three 3 month repair labor from the date recorded by Stellar as the in service date not to extend beyond fifteen 15 month from date of manufacture The in service 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 unaltered part and or component in question Stellar after sales service personnel must be notified by telephone fax or letter of any warranty applicable damage within fourteen 14 days of ils 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 after sales 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 prepai
24. r Attach pump pressure line to valve return link to tank Fill system with hydraulic oil See Stellar Lubrication Recommendations for fluid details Route Thru Return Filter Tank Return Stabilizer Functions Pump Pressure Power Beyond Stabilizer Functions 4411 Typical Stabilizer Valve with Power Beyond Capabilities 19 20 5521 Owner s Manual Hydraulic System Rotation Main Extension Winch IK N A 91 2 A A4 B4 Crane Valve 2 Yo p Installation 21 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 8576 tipping Set Up Locate the truck on a test course in position for loading and engage travel brakes Set stabilizers so that they make contact with firm level footing Operate
25. rees Stowed Height 32 81 3 cm crane only Mounting Space Required 20 x 21 50 8 x 53 3 Approximate Crane Weight 1400 Ibs 635 kg Controls Radio control standard for all functions Winch Specifications Rope Diameter 5 16 8 mm 2210 Line pull speed 70 ft min 21 34 m min 6 95m 20 ft min 6 09 m min Electric Version Max single part line 2500 16 1130 kg Max double part line 5000 Ibs 2265 kg Rotation 400 degree power worm gear Liffing Capacities 5000 Ibs 5710 2265 kg 1 78 1400 Ibs 21 635 kg 6 40 1710 Power Supply Required PTO amp Pump 5 45m 8 0 gom 2500 psi 30 31 173 bar 12 volt power unit 2 0 gom 2500 psi 7 57 172 bar Crane rating in Boost Mode Normal crane rating is 25 000 ft lbs 3 46 ton m Maximum capacities in Boost Mode 3 e d ke IF e 18 41 0 47m f T 10 69 1 1 0 3 34 160 4 87 2170 6 39 2 5521 Owner s Manual Stellar 5521 Geometric Measurements E 0 lt ng pn Serr 25 70 s oi oO 0 65m 0 56m 3 12V HYD SO lt T m 0 40m 0 32m 35 13 0 89m 1100 3 34 123 3 72m HYD 1211 3 95m 12V Specifications 3 Capacity Chart Decal PN 57598 Reach in Feet Meter
26. s 5000 Ibs Capacity in Pounds Kilograms 2265 kg 93 4755 Ibs NE EX 4030 Ibs If Equipped EL rre E Standard 21 5000 Ibs 2265 kg 6 40 m SN 2260 Ibs 1025 kg 1945 Ibs 880 kg 5 49 m 2265 kg 3445 16 1650 Ibs lt 1560 kg 745 kg 2920 5 BEN 1320 kg 15 4 57 1620 Ibs 730 kg 1375 Ibs 42 1 X 620kg 3 66m 2120 155 960 kg 1800 165 815 kg 9 1475 Ibs 2 75 m 665 kg 1250 Ibs 565 kg 4865 Ibs 2205 kg a 1945 Ibs 880 kg 1650 Ibs 745 kg NZ 2680 Ibs 1840 165 1400 Ibs 1215 kg 830 kg 635 kg 2275 Ibs 1560 Ibs 1190 Ibs 1030 kg 705 kg 535 kg 0 3 6 9 11 16 21 914 1 83 m 2 4m 3 35 4 88 m 6 40 m Weight of load handling devices are Maximum 1 part line capacity is part of the load lifted and must be 2500 Ibs 1130 kg For greater deducted from the capacity loads use 2 part line PN 57598 4 5521 Owner s Manual Installation 5 Chapter 2 Installation Notice Read this Before Installation of the Crane General installation This chapter is designed to serve as q 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
27. t Apply Loctite Thread locker 277 to the bolts Using the liffing 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 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 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 WARNING use of this crane on body not capable of handling the loads imposed on it may result in serious injury or 01 063 4 Places Hole Mounting Detail ITEM PART DESCRIPTION 5199 CAP SCR 1 00 8 3 00 8 ZY 6538 WASHER 1 00 SAE FLAT YELLOW GR8 Installation 7 Control Kit Flip Sheave CDT Boost PN 57913 INCLINOMETER 6 7 8 CPRSR ON OFF ENG START
Download Pdf Manuals
Related Search