Stellar labs 5521 Bedienungsanleitung

Model 5521

Telescopic Crane

Owner’s Manual

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Subject to Change without Notication.

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

3.7 m

3.1 m

2.4 m

1.8 m

1.2 m

4080 kgs

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]

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 (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.

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

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