Stellar Industries 5521 Users Manual Telescopic Crane

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®®

5521

60

50

0

20

30

10

40

Angle Indicator

80

70

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 

)

 

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com Last Revision: 09/06/12

Subject to Change without Notification.

© 2012 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

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 parts@stellarindustries.com

Warranty Information warranty@stellarindustries.com

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

Hydraulic Kit - PN 58277 16

Hydraulic Kit (12 Volt Version) - PN 58279 17

Valve Bank - PN 44530 18

Hydraulic Installation 19

Hydraulic 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 Hyd/1 Manual) - PN 57935 28

Extension Boom Assembly (Cradle A2B - 1 Hyd/1 Manual) - PN 59146 29

Main Cylinder Assembly - PN 54942 30

Extension Cylinder Assembly - PN 49316 31

Extension Cylinder Assembly (1 Hyd/1 Manual) - PN 57936 32

Cable & Hook 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: 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 to +80 degrees

Stowed Height: 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 (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:

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 Overview

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.

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.

Note: If questions should arise during any portion of this installation,

please contact Stellar Customer Service at (800) 321-3741.

5521 Owner’s Manual

Installation 

PN 57913

Control Kit (Flip Sheave/CDT Boost) - PN 57913



5521 Owner’s Manual

PN 59154

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

Control Kit (Cradle A2B/CDT Boost) - PN 59138

 5521 Owner’s Manual

PN 59155

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

Installation 

NOTE: USE 32" OF HOSE PROTECTOR

P/N 17288 OVER THE ROTATION HOSES

NOTE: USE 12" OF HOSE PROTECTOR

P/N 17288 OVER THE 2 WINCH HOSES

PN 58279

Hydraulic Kit (12 Volt Version) - PN 58279

 5521 Owner’s Manual

5

3

1

5

4

5

3

2

YTQNOITPIRCSEDTRAPMETI

125367 RELIEF VALVE 24685/24690 1

25368 SEAL KIT 25367

224960 VALVE FLW CTRL PRP/JP04C3150N 0-8 1

25369 SEAL KIT 24960/25381

325371 VALVE SOLND 3 POS 4 WAY TAND G04571 3

425372 VALVE SOLND 3 POS 4 WAY OPEN G04591 1

25373 SEAL KIT 25371/25372

5 44532 COIL 12VDC DUETSCH CAP012H 9

HYDRAULIC SCHEMATIC

PN 44530

Valve Bank - PN 44530

Installation 

Hydraulic Installation

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

 5521 Owner’s Manual

Hydraulic System

Installation 

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%

tipping.

Set Up:

1. Locate the truck on a test course in position for

loading and engage travel brakes.

2. Set stabilizers so that they make contact with firm,

level footing.

3. Operate the crane under partial load to assure

operator proficiency and proper machine

function.

4. 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.

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.

3. 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.)

4. 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.

5. 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.

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:

6. Record this number in the data box for Zone 1.

This is the revised capacity due to stability for this

zone.

7. Repeat this procedure for each zone until the

worksheet is completed.

8. This is the revised capacity based on stability of

this package.

5521 Stability Data

Max Horizontal Reach: 252” (From the center of

rotation to boom tip)

Boost Stability Test Weight: 1650 lbs.

Non-Boost Stability Test Weight: 1400 lbs.

Stability Procedure

 5521 Owner’s Manual

Decal Kit Placement - PN 57304

PN 57304

*USE THESE DECALS WITH BODY PACKAGE

**THESE DECALS NOT INCLUDED WITH THE DECAL KIT

ITEM

01

*04

02

*03

*05

*06

09

*07

*08

*10

*11

*12

*13

15

14

DECAL HOISTING PERSONNEL

DECAL STELLAR LOGO 6.00 X 16.50

DESCRIPTION

PART No.

52681

PART No.ITEM

QTY

*16

2

12451

DESCRIPTION QTY

1

DECAL ASME/ANSI B30.22/B30.5

DECAL GREASE WORM DRIVE BEARINGS

DECAL-ROTATION ALIGNMENT

C4545 DECAL-ELECTROCUTION 5x13

DECAL CAPACITY 5521

DECAL 5521 IDENTIFICATION57306

57598

DECAL-DANGER

DECAL-DANGERC4540

C4544

DECAL MANUAL EXT12452

4

*19

*17

2

C5910

*18

2

C5911

DECAL-STELLAR 4x9.5

DECAL-STELLAR 2x4.5

C0568

1

*20

*21

1

4214

DECAL-DIESEL

DECAL-SERVICE

9188 DECAL-ROTATE/GREASE

DECAL-DANGER

DECAL-ELECTROCUTION 2x2.754186

4189

DECAL-DANGER

DECAL-DANGER O.R.

4190

C4795

4188

1

24

22

1

12300

*23

1

C4541

DECAL-TWO BLOCKING

DECAL-CRANE STOWING

15171

1

25

26

2

15172

1

1

3

2

1

1

1

1

1

1

DECAL VB CONTROL MECH CRANE

DECAL STELLAR MADE IN THE USA

DECAL SNATCH BLOCK CAP 5 TON

DECAL WARNING OVERLOAD DEVICE

DECAL CAUTION STOW HOOK

41068

31

DECAL-ELECTROCUTION 4.5x7.5

DECAL-DANGER MOVING O.R.C5918

C1179

DECAL-ANGLE INDICATOR SS

DECAL ANGLE INDICATOR CS

D1197

D1196

27

2

24712

28

2

28256

35234

30**

1

29

1

38472

1

1

1

1

1

32 25159 DECAL WARNING MANUAL OVERRIDES 1

33 54588 DECAL CDT 2.00X2.00 2

1

2

®®

5521

3

26

14,15

27

22

29

28

30

25

9

60

50

0

20

30

10

40

Angle Indicator

80

70

33

Assembly Drawings 

.YTQNOITPIRCSEDTRAPMETI

1 47869 BEARING SWING DRIVE CAST 6620 GEARTEK 1

1EDILS 004 0283 POTS245112

3C6069 MOTOR HYD ROSS MK080613AAAB1

11-65001-800 ROTOM TEKSAG151124

5D1345 FTG CPRSN 0.12NPT/0.25 TUBE2

6D1810 TBE AIR SAEJ844 TYPE A .25 (RM)1

131.0 EPIP RELPUOC GTF6522C7

8 56589 ZERK 1/8 NPT STRAIGHT LONG THREAD 1

2HS 00.2X31-05.0 RCS PAC594359

NOTE: ITEMS 1 INCLUDE GUARD & GUARD FASTENERS

8

2

3

GASKET SHOWN AS REFERENCE

4

5

6

5

7

9

1

PN 50364

Base Assembly - PN 50364

Chapter 3 - Assembly Drawings

 5521 Owner’s Manual

PN 57577

.YTQNOITPIRCSEDTRAPMETI

11255 TSAM692751

2 21528 WINCH 2500 5520 CRANE1

3C1026 CAP SCR 0.63-11X2.50 HHGR8 14

4C1006 CAP SCR 0.38-16X2.00 HHGR84

5C5902 WASHER 0.63 SAE FLAT YELLOW GR814

6 0343 WASHER 0.31 USS FLAT ZINC5

7C6353 WASHER 0.38 SAE FLAT YELLOW GR88

827813 COLLAR 0.38X0.75X0.38 UHMW2

9 44530 VB 4 SECT W/PROP STER8GPM DEUTSCH1

10 0342 NUT 0.31-18 HHGR5 NYLOC 2

11 56673 NUT 0.38-16 HHGR8 NYLOC 4

12 57594 BUSHING COMPOSITE MRP 2.00X.504

14 0491 CAP SCR 0.31-18X4.00 HHGR52

15 47425 CAP SCR 6MMX20MM HH 8.8(GR5)4

9

3

5

14

6

6

10

2

4

7

11

15

12

8

Mast Assembly - PN 57577

Assembly Drawings 

33

15

19

423

17

22 21

14

13

20

23

25

26

24

32

12

7

3

6

5

16

16

10

1

11

2

8

9

23 4

3

4

20

20

23

26

27

22

30

29

20

4

23

31

28

18

2BUSHING BPC16DXR24 1.00X1.50006815

2PIN CAP 0.44X1.75X0.19 SS932014

1ZERK 1/8 NPT STRAIGHTc159213

.YTQNOITPIRCSEDTRAPMETI

11255 MOOB RENNI782751

2 54942CYLINDER ASM 6620 INNER CDT1

2T&D 36.9X00.2 NIPPZ312623

691.0X05.2X65.0 PAC NIP24194

1T&D 88.8X00.2 NIPPZ11795

1T&D 83.8X00.1 NIPPZ21796

7D1194PC PLATE ANGLE INDICATOR 2

8 9363 WEAR PAD 1.12X2.00 RND NYLATRON2

9 9545PC PLATE WEAR PAD SUPPORT2

10269 EDIUG EPOR TKRBCP5343101

11 27720 SPACER ROPE GUIDE 6620 UHMW2

10266 LEER DROC4451121

.YTQNOITPIRCSEDTRAPMETI

16 4381BUSHING BPC32DXR32 2.00X2.00 4

17 0340 WASHER 0.25 USS FLAT ZINC2

18 0478 CAP SCR 0.25-20X0.50 HHGR51

19 C6106 NUT 0.50-13 HHGR5 NYLOC 2

20 D0790 WASHER 0.50 SAE FLAT YELLOW GR818

21 9843 CAP SCR 0.38-16X0.75 HHGR82

22 C6353 WASHER 0.38 SAE FLAT YELLOW GR86

23 10172 CAP SCR 0.50-13X1.00 HHGR814

24 12168 CAP SCR 0.38-16X9.00 HHGR52

25 0335 CAP SCR 0.38-16X1.25 HHGR52

26 0347 NUT 0.38-16 HHGR5 NYLOC 4

1GED 06 RETEMONILCNI3943572

28 18765 WASHER #6 SAE FLAT ZINC4

2SS COLYN HH 23-6# TUN6700D92

30 18618 SCREW #6-32X1.00 PHMS PH2

31 0425 MACHY WASHER 1.25ID 10GA2

32 0480 CAP SCR 0.25-20X1.00 HHGR51

1LYNIV KLB 52.0 PMALC6065C33

NOTE: INCLINOMETER MOUNTS

INSIDE THE BOOM. VIEW SHOWS

POSITION OF INCLINOMETER

PN 57581

Main Boom Assembly - PN 57581

 5521 Owner’s Manual

22

28

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15

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25 26 21

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PN 57593

.YTQNOITPIRCSEDTRAPMETI

11255 TS1 MOOB TXE703751

2 50341EXT BOOM 2ND 6621 FLIP SHEAVE 1

3 12929PC PLATE SHEAVE MOUNTING 2

205.4X00.1 HCTIH NIP428214

2HCNYL 65.1X91.0 NIP35755

69363 WEAR PAD 1.12X2.00 RND NYLATRON2

7 9545PC PLATE WEAR PAD SUPPORT2

8 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK2

9 13400 PIN TEAR DROP 1.00X4.38 1

10 13399 PIN TEAR DROP 1.00X3.81 1

11 27719SPACER BOOM TIP 6620 UHMW2

12 10172 CAP SCR 0.50-13X1.00 HHGR88

13 0490 CAP SCR 0.31-18X3.50 HHGR52

14 0420 CAP SCR 0.31-18X0.75 HHGR5 2

15 D0790 WASHER 0.50 SAE FLAT YELLOW GR88

16 C6219 WASHER 0.75 SAE FLAT YELLOW GR81

17 0343 WASHER 0.31 USS FLAT ZINC2

18 0342 NUT 0.31-18 HHGR5 NYLOC 2

19 0425 MACHY WASHER 1.25ID 10GA2

20 49316 CYLINDER EXT ASM 6620 2.0/2.01

21 34354PC ANTI 2 BLOCK COVER LH 1

22 11938 SWITCH LIMIT A2B FURNAS 3SE31701

23 33749 CAP SCR #10-24X1.75 SH4

105.12X501.0 NIAHC4548142

25 D1711 CAP SCR #10-24X0.50 BTNHD SS1

26 C4956 NUT #10-24 HH NYLOC SS1

27 37850 CONNECTOR QUICK LINK 0.131

1KCOLB 2 ITNA THGIEWCP4625382

29 0530 CAP SCR 0.38-16X2.75 HHGR51

30 0347 NUT 0.38-16 HHGR5 NYLOC 1

31 6252 WEAR PAD 0.34X2.50 RND NYLATRON4

32 4974 CAP SCR 0.75-10X2.50 HHGR8 RED PATCH1

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25

26 21

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28

29

45

3

13

11

8

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18

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14

9

14

Extension Boom Assembly (Flip Sheave) - PN 57593

Assembly Drawings 

PN 58290

.YTQNOITPIRCSEDTRAPMETI

11255 TS1 MOOB TXE703751

2 51117 EXT BOOM 6620 2ND CRADLE A2B 1

3C6219WASHER 0.75 SAE FLAT YELLOW GR81

4 4974 CAP SCR 0.75-10X2.50 HHGR8 ZY1

59363 WEAR PAD 1.12X2.00 RND NYLATRON2

6 9545PC PLATE WEAR PAD SUPPORT2

618RG TALF 05.0 REHSAW0970D7

8 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY8

99991 WEAR PAD 0.19X2.50 RND NYLATRON4

10 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK 2

105.4X00.1 HCTIH NIP4282111

1HCNYL 65.1X91.0 NIP357521

13 9706ZP PIN TEAR DROP 1.00X3.252

14 0343WASHER 0.31 USS FLAT ZINC 2

15 0420 CAP SCR 0.31-18X0.75 HHGR51

16 0484 CAP SCR 0.31-18 X 0.50 HHGR5 1

17 27719SPACER BOOM TIP 6620 UHMW2

18 12178 CAP SCR 0.31-18X3.25 HHGR52

2COLYN HH 81-13.0 TUN243091

20 27710 SPRING ANTI 2 BLOCK SUMMIT2

21 C6106 NUT 0.50-13 HHGR5 NYLOC 3

22 0506 CAP SCR 0.50-13X4.00 HHGR51

23 31132 SCREW #10-24X0.50 SH SS2

24 D0178 WASHER #10 SAE FLAT ZINC2

1LYNIV KLB 13.0 PMALC9721352

26 35105 SWITCH LIMIT E1117-B9111-6C1

27 49316 CYLINDER EXT ASM 6620 2.0/2.01

28 0425MACHY WASHER 1.25ID 10GA2

29 51903PC PLATE CRADDLE 6620/66281

30 C1000 CAP SCR 0.50-13X5.00 HHGR52

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7

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25

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22

21

30

Extension Boom Assembly (Cradle A2B) - PN 58290

 5521 Owner’s Manual

.YTQNOITPIRCSEDTRAPMETI

1M1H1 1255 TS1 MOOB TXE529751

2 57930 EXT BOOM 2ND 5521 FLIP SHEAVE 1H1M1

2GNITNUOM EVAEHS ETALPCP929213

205.4X00.1 HCTIH NIP428214

3HCNYL 65.1X91.0 NIP35755

69363WEAR PAD 1.12X2.00 RND NYLATRON2

2TROPPUS DAP RAEW ETALPCP54597

8 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK2

183.4X00.1 PORD RAET NIPPZ004319

118.3X00.1 PORD RAET NIPPZ9933101

11 27719SPACER BOOM TIP 6620 UHMW2

12 10172 CAP SCR 0.50-13X1.00 HHGR88

13 0490 CAP SCR 0.31-18X3.50 HHGR52

14 0420 CAP SCR 0.31-18X0.75 HHGR5 2

15 D0790 WASHER 0.50 SAE FLAT YELLOW GR88

16 0343 WASHER 0.31 USS FLAT ZINC2

17 0342 NUT 0.31-18 HHGR5 NYLOC 2

18 0425 MACHY WASHER 1.25ID 10GA2

1HL REVOC KCOLB 2 ITNA CP4534391

20 11938 SWITCH LIMIT A2B FURNAS 3SE31701

4HS 57.1X42-01# RCS PAC9473312

105.12X501.0 NIAHC4548122

23 D1711 CAP SCR #10-24X0.50 BTNHD SS1

1SS COLYN HH 42-01# TUN6594C42

25 37850 CONNECTOR QUICK LINK 0.131

1KCOLB 2 ITNA THGIEWCP4625362

27 0530 CAP SCR 0.38-16X2.75 HHGR51

28 0347 NUT 0.38-16 HHGR5 NYLOC 1

29 6252 WEAR PAD 0.34X2.50 RND NYLATRON4

30 57936 CYLINDER ASM 5521 MANUAL1

31 C4813 WASHER 0.56 SAE FLAT YELLOW GR84

32 9004 CAP SCR 0.50-13X1.75 HHGR84

100.8X57.0 HCTIH NIP7397533

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PN 57935

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Extension Boom Assembly (Flip Sheave - 1 Hyd/1 Manual) - PN 57935

Assembly Drawings 

.YTQNOITPIRCSEDTRAPMETI

1 57925 EXT BOOM 1ST 5521 1H1M1

2 59147 EXT BOOM 6620 2ND CRADLE A2B 1

39363 WEAR PAD 1.12X2.00 RND NYLATRON2

4 9545PC PLATE WEAR PAD SUPPORT2

028RG TALF 05.0 REHSAW0970D5

6 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY8

79991 WEAR PAD 0.19X2.50 RND NYLATRON4

8 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK 2

105.4X00.1 HCTIH NIP428219

2HCNYL 65.1X91.0 NIP357501

11 9706ZP PIN TEAR DROP 1.00X3.252

12 0343WASHER 0.31 USS FLAT ZINC 2

13 0420 CAP SCR 0.31-18X0.75 HHGR51

14 0484 CAP SCR 0.31-18 X 0.50 HHGR5 1

15 27719SPACER BOOM TIP 6620 UHMW2

16 12178 CAP SCR 0.31-18X3.25 HHGR52

2COLYN HH 81-13.0 TUN243071

18 27710 SPRING ANTI 2 BLOCK SUMMIT2

19C6106 NUT 0.50-13 HHGR5 NYLOC 3

20 0506 CAP SCR 0.50-13X4.00 HHGR51

21 31132 SCREW #10-24X0.50 SH SS2

22 D0178 WASHER #10 SAE FLAT ZINC2

1LYNIV KLB 13.0 PMALC9721332

24 35105 SWITCH LIMIT E1117-B9111-6C1

25 0425 MACHY WASHER 1.25ID 10GA2

26 51903PC PLATE CRADDLE 6620/66281

27 C1000 CAP SCR 0.50-13X5.00 HHGR52

28 57936 CYLINDER ASM 5521 MANUAL1

29 9004 CAP SCR 0.50-13X1.75 HHGR84

100.8X57.0 HCTIH NIP7397503

PN 59146

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Extension Boom Assembly (Cradle A2B - 1 Hyd/1 Manual) - PN 59146

 5521 Owner’s Manual

PN 54942

.YTQNOITPIRCSEDTRAPMETI

1 50918 CYLINDER INNER 4.00X21.38 NEW MAST1

2 41910 MANIFOLD ASM DUAL 10-1CBAL-RLF-CHK1

3 44066 TUBE ASM 0.38X8.25 MAIN 10628/126282

4S-OLO5F-6 TPADA GTF97204

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Cylinder

Serial Tag

Location

Note: Main Cylinder uses

Stellar Seal Kit PN 17724

Manifold Assembly

PN 41910

2

3

5

4

1

4

.YTQNOITPIRCSEDTRAPMETI

1 39425 MANIFOLD CBAL DOUBLE T11A WITH RELIEF1

1NCX-DEXC KCEHC EVLAV809142

1ISP 008 NAL-ADDR EVLAV709143

4 9803 Valve C- SUN CBBD-LJN-35002

5C4961PLUG STR HOLLOW HEX 0.38 6-HP5ON1

Main Cylinder Assembly - PN 54942

Assembly Drawings 

.YTQNOITPIRCSEDTRAPMETI

137548 CYLINDER EXT 2 STAGE 2.0/2.0 PTD 60 1

214115 MANIFOLD ASM 6620 EXT CBBD-LJN-XVN 1

3 11882 CAP SCR 0.38-16X1.75 SH ZC 2

414601 CAP SCR 0.38-16X2.25 SH ZC 1

514442 TUBE ASM 0.38X23.25 EXT CYL 6620 1

614443 TUBE ASM 0.38X102.25 EXT CYL 6620 1

724729 HOSE CLAMP #52 3.00 - 3.75 1

818701 CLAMP PORT TUBE ZR518 1

1 P #36 WRM GEARMALC ESOHD06559

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PN 49316

Cylinder

Serial Tag

Location

Extension Cylinder Uses:

Upper Seal Kit - PN 54778

Lower Seal Kit - PN 20310

Extension Cylinder Assembly - PN 49316

 5521 Owner’s Manual

.YTQNOITPIRCSEDTRAPMETI

1 57932 CYLINDER 2.00X60.00 5521 MANUAL1

2 14115MANIFOLD ASM 6620 EXT CBBD-LJN-XVN 1

3 11882 CAP SCR 0.38-16X1.75 SH ZC2

4 14601 CAP SCR 0.38-16X2.25 SH ZC1

PN 57936

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Extension Cylinder Assembly (1 Hyd/1 Manual) - PN 57936

Assembly Drawings 

PN 57597

.YTQNOITPIRCSEDTRAPMETI

1 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK 1

2 57596PC PLATE SNATCH BLOCK 55212

3 13436 PIN .38X4.00 QUICK RELEASE 1

4 25831 HOOK 5 TON SWIVEL CROSBY 10286231

5 9610 WIRE ROPE 0.31 6X19 IWRC-XIP 90FT1

1RETTOC 60.4X00.1 NIPPZ478936

7 0867 MACHY WASHER 1.00ID 14GA2

200.2X57.0X44.0 RALLOCCP346448

9 0347 NUT 0.38-16 HHGR5 NYLOC 2

2HCNYL 65.1X91.0 NIP357501

1KOOH V GNIHSUB4489311

12 C6219 WASHER 0.75 SAE FLAT YELLOW GR82

13 5841 CAP SCR 0.75-10X4.50 HHGR8 1

14 C0538 NUT 0.75-10 HHGR8 NYLOC 1

15 0531 CAP SCR 0.38-16X3.50 HHGR52

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Cable & Hook Assembly - PN 57597

 5521 Owner’s Manual

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PN 57939

.YTQNOITPIRCSEDTRAPMETI

1 19997PC COVER POWER UNIT 55201

2 16994POWER UNIT 12V 5520 HORZ 1

3 17771 SWITCH PUSH BUTTON 9216-031

4 18472 DECAL MANUAL OPERATION 55201

5 0340 WASHER 0.25 USS FLAT ZINC2

6C6353 WASHER 0.38 SAE FLAT YELLOW GR816

7 0479 CAP SCR 0.25-20X0.75 HHGR52

8 56673 NUT 0.38-16 HHGR8 NYLOC 8

9 59136 BRACKET POWER UNIT 55211

10 16962 CAP SCR 0.38-16X1.50 HHGR88

Power Unit Assembly - PN 57939

Assembly Drawings 

PN 56647

.YTQNOITPIRCSEDTRAPMETI

1 20088 CONTROL HANDLE HOUSING 4 FCTN HET1

2 56657 CONTROL HANDLE FACE PLT W/LABEL 6 FCTN CDT 1

1NTCF 4 HCTIWS OIDAR DRAUG583423

4 35447 CONTROL HANDLE GRIP W/TRIGGER HT H21

524958RUBBER BOOT TRIGGER GUARD HET1

6 22600 SWITCH TOGGLE HET RADIO 630193006

7 35441 BATTERY TUBE AA HETRONIC RADIO1

1LX AVON POTS E HCTIWS658748

3

SEE NOTE

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6

NOTE: 1) P/N'S 25999 & 24958 ARE OPTIONAL COVERS

FOR THE SWITCHES AND TRIGGER

CDT™ Radio Transmitter Assembly - PN 56647

 5521 Owner’s Manual

Replacement Parts 

Chapter 4 - Replacement Parts

PART# DESCRIPTION

C6069 HYDRAULIC SWING MOTOR

25367 RELIEF VALVE

25368 SEAL KIT - RELIEF VALVE

24960 FLOW CONTROL VALVE

25369 SEAL KIT - FLOW CONTROL VALVE

25371 SOLENOID VALVE TAND G04571

25373 SEAL KIT - SOLENOID VALVE

44532 COIL - 12VDC

9803 C-BALANCE VALVE

28485 PRESSURE TRANSDUCER

C2027 O'RING - # 4 FACE SEAL

C2028 O'RING - # 6 FACE SEAL

C2029 O'RING - # 8 FACE SEAL

D1245 O'RING - # 4 SAE

D1246 O'RING - # 6 SAE

D1247 O'RING - # 8 SAE

17724 SEAL KIT - MAIN LIFT CYLINDER

54778 SEAL KIT - EXTENSION CYLINDER (UPPER CYLINDER)

20310 SEAL KIT - EXTENSION CYLINDER (LOWER CYLINDER)

44066 TUBE ASM - MAIN CYLINDER

14442 TUBE ASM - EXTENSION CYLINDER

14443 TUBE ASM - EXTENSION CYLINDER

55827 WORM GEAR - BEARING SWING DRIVE

55829 BEARING & SEAL KIT - BEARING SWING DRIVE

55830 WORM / BEARING & SEAL KIT - BEARING SWING DRIVE

4381 BUSHING 2.00" X 2.00"

0068 BUSHING 1.00" X "1.50

44533 BUSHING 2.00" X 0.75"

9363 WEAR PAD - 2.00" ROUND

6252 WEAR PAD - 2.50" ROUND

9320 PIN CAP .44 X 2.50 X .25

9142 PIN CAP .56 X 2.50" X 0.25" SS

10172 CAP SCR. 0.50-13 X 1.00"

9843 CAP SCR. 0.38-16 X 0.75" GR8

C6353 WASHER 0.38 FLAT GR8

D0790 WASHER 0.50 FLAT GR8

11545 SHEAVE

9610 WIRE ROPE

12824 HITCH PIN 1.00" X 4.50"

57937 HITCH PIN 0.88" X 8.00"

13436 QUICK RELEASE PIN .38 X 4.00"

5753 LYNCH PIN

53493 INCLINOMETER 60 DEGREE

11938 LIMIT SWITCH (CHAIN & WEIGHT) ANTI-2-BLOCK

31670 WEIGHT & CHAIN ASSY - ANTI-2-BLOCK

35105 LIMIT SWITCH (BAR TYPE) ANTI-2-BLOCK

43488PC CRADLE PLATE - ANTI-2-BLOCK (CRADLE/BASKET STYLE)

61048 CRADLE FS/CRADLE A2B (After 8/1/2011)

27710 SPRING - LIMIT SWITCH CRADLE / BASKET

11544 CORD REEL

56647 RADIO TRANSMITTER (HETRONIC RADIO)

35441 BATTERY TUBE (AA) HOLDER (HETRONIC RADIO)

47856 E-STOP SWITCH (HETRONIC RADIO)

22600 TOGGLE SWITCH (HETRONIC RADIO)

35447 HANDLE / TRIGGER ASM (HETRONIC RADIO)

35916 BACK UP CABLE CONTROL - HETRONIC RADIO SYSTEM

18468 12V SOLENOID (12V POWER UNIT ASSEMBLY)

24956 12V SOLENOID (12V POWER UNIT ASSEMBLY)

17771 PUSH BUTTON (12V POWER UNIT ASSEMBLY)

25831 HOOK - 5 TON

19501 SAFETY LATCH FOR 5 TON SWIVEL HOOK

C1592 GREASE ZERK

4460 GEAR BEARING GREASE - MOLUBE (Open Teeth)

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

ofmanufacture,

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 beyond 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 its 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 prepaid; 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.

All 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 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 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.

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.

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 1st, 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