Stellar Industries CRANE EC3200 User's Manual

M odel eC3200

T

elesCopiC

C

rane

o

wners

’ M

anual installation • assembly drawings • parts

EC 3200

Subject to Change without Notification.

© 2012 Stellar Industries, Inc.

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

Date of Revision

EC3200 Manual Revisions

Section Revised Description of Revision

Table of Contents i

Table of Contents

Chapter 1 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Capacity Chart - Decal PN 42817. . . . . . . . . . . . . . . . . . 2

Chapter 2 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Flatbed Body Reinforcement . . . . . . . . . . . . . . . . . . . . . . 5

EC3200 Mounting Detail . . . . . . . . . . . . . . . . . . . . . . . . . . 5

EC3200 Installation Drawing . . . . . . . . . . . . . . . . . . . . . . . 6

Hydraulic Kit - PN 42799. . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Control Kit - PN 42804 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

EC3200 Wiring Diagram (Two Battery) . . . . . . . . . . . . . . 9

EC3200 Wiring Diagram (One Battery) . . . . . . . . . . . . . 10

Valve Bank Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Stability Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Stability Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . . . 13

Decal Kit Placement - PN 42816 . . . . . . . . . . . . . . . . . . 14

Chapter 3 - Assembly Drawings. . . . . . . . . . . . . . . . . . . . . 15

Base Assembly - PN 42525 . . . . . . . . . . . . . . . . . . . . . . . 15

Base Assembly (Narrow Version) - PN 44613. . . . . . . . . 16

Mast Assembly - PN 42787 . . . . . . . . . . . . . . . . . . . . . . . 17

Main Boom Assembly - PN 42512. . . . . . . . . . . . . . . . . . 18

Extension Boom Assembly - PN 42520 . . . . . . . . . . . . . . 19

Cable & Hook Assembly - PN 42781 . . . . . . . . . . . . . . . 20

Radio Transmitter Assembly . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 4 - Replacement Parts . . . . . . . . . . . . . . . . . . . . . 23

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

Order Parts

Warranty Information [email protected]

[email protected]

[email protected]

ii EC3200 Owner’s Manual

This page intentionally left blank.

Chapter 1 - Specifications

Crane Rating:

Standard Boom Length:

Boom Extension:

Maximum Horizontal Reach:

Maximum Vertical Lift:

(from crane base)

Boom Elevation:

Stowed Height:

(crane only)

Mounting Space Required:

Approximate Crane Weight:

Model EC3200 Crane

SPECIFICATION SHEET

11,500 ft-lb (1.59 TM)

7’ (2.13 m) from CL of Crane

1st stage: Hydraulic 48" (121.9 cm)

2nd stage: Manual 48" (121.9 cm)

15’ (4.57 m) from CL of Crane

16’ 2” (4.93 m)

-5 to +80 degrees

24” (61.0 cm)

18” x 15” (45.7 x 38.1 cm)

730 lbs (331 kg)

Radio control standard for all functions.

Controls:

Winch Specifications

Rope Length:

Rope Diameter:

Line pull speed:

Max. single part line:

Max. double part line:

Rotation:

(worm gear)

Lifting Capacities:

65 ft (19.8 m)

7/32" (.56 cm)

15 ft/min (4.6 m/min)

1600 lbs (725 kg)

3200 lbs (1450 kg)

410 degree power

Power Supply Required:

1625 lbs @ 7’ (737 kg @ 2.1 m)

905 lbs @ 11’ (410 kg @ 3.35 m)

640 lbs @ 15’ (290 kg @ 4.6 m)

12 volt power unit

(2.0 gpm @ 2600 psi)

(7.57 lpm @ 179 bar)

*Subject to change without notification

2 EC3200 Owner’s Manual

Capacity Chart - Decal PN 42817

*3200 lbs

1450 kg

*3025 lbs

1372 kg

Reach in Feet/Meters

Capacity in Pounds/Kilograms

*1550 lbs

703 KG

16’2”

4.92

M

15’

4.57

M

3200 lbs

1450 kg

3200 lbs

1450 kg

1090 lbs

495 kg

2145 lbs

973 kg

12’

3.66

M

3200 lbs

1450 kg

80º

3200 lbs

1450 kg

75º

60º

3200 lbs

1450 kg

45º

2415 lbs

1095 kg

30º

1490 lbs

675 kg

1900 lbs

862 kg

15º

1710 lbs

775 kg

1215 lbs

550 kg

890 lbs

404 kg

1085 lbs

492 kg

780 lbs

353 kg

9’

2.74

M

6’

1.83

M

3’

.914

M

1565 lbs

710 kg

905 lbs

410 kg

0’

83.69

3’

.914

M

6’

1.83

M

7’

2.13

M

15’

4.57

M

640 lbs

290 kg

0’

Weight of load handling devices are part of the load lifted and must be deducted from the capacity.

11’

3.35

M

Maximum 1 - part line capacity is

1600lbs (725kg). For greater loads,

® use 2 - part line.

EC3200

PN 42817

Chapter 2 - Installation

Notice: Read this Page Before Installation of the Crane

General Installation Installation Notice

This chapter is designed to serve as a general guide for the installation of a Stellar

EC3200 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.

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.

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.

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.

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.

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.

4 EC3200 Owner’s Manual

Installation Overview

1. Determine that the mounting location for the EC3200 crane is at least 18” x 15” (45.7 x 38.1 cm).

2. Use the detail on the following page to drill .938” 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 EC3200 weighs approximately 800 lbs (360 kg). Note: cranes are shipped with rotation positioned at 180 degrees from

normal stowed travel position. 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 main boom of the Stellar EC3200.

5. Use four (4) 7 ⁄

8

” x 13 ⁄

4

” #8 bolts and four (4) #8 7 ⁄

6. Install a washer on each bolt.

7. Apply Loctite Thread locker #277 to the bolts.

8

” flat washers.

8. Using the lifting device, lower the Stellar EC3200 just above the crane compartment and start the bolts.

Have someone assist in leveling the crane.

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 0.75” – use grade 8, zinc plated cap screws only.

10. Torque the cap screws to 454 ft-lbs.

11. Remove supporting crane.

12. Hook-up hydraulics and electrical using the schematics provided at the end of this chapter.

Note: If questions should arise during any portion of this installation, please contact Stellar Customer Service at (800) 321-3741.

Front of Tru ck

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.

FRONT

EC3200 Mounting Detail

Standard

FRONT

Narrow

Base

3.00

5.00

10.00

7.38

14.75

HOLE MOUNTING DETAIL

5.00

10.00

HOLE MOUNTING DETAIL

Flatbed Body Reinforcement

If it has been determined that the destination body won’t support the crane with a fully rated load, the body must be reinforced.

Use 1/4” fillet welds and an ASWS qualified welder to proceed as shown in this drawing:

7.38

14.75

3/8 PLATE

TUBE 4X2X0.38

Note: Tubing must be at least 4” x 2” x 0.38”

(Except where noted)

TUBE 2X2X0.38(TYP 4)

TRUCK FRAME

TUBE 4X2X0.38

6 EC3200 Owner’s Manual

EC3200 Installation Drawing

3

2

NOTICE!

Route hoses correctly to ensure they do not become pinched or crushed during installation.

Stowed Position

I T E M

2

3

P A R T D E S C R I P T I O N

18041 WASHER 0.88 SAE FLAT YELLOW GR9

51377 CAP SCR 0.88-9X2.00 HHGR9

Q T Y .

4

4

NOTE:

STABILITY DECAL P/N 16881 IS PART OF THIS KIT

ROTATION CCW

ROTATION CW

Hydraulic Kit - PN 42799

12 10

11

ROTATION

BOOM DOWN

BOOM UP

11 12 10

MAIN

14 13

EXTENSION RETRACT

EXTENSION EXTEND

11

11

EXT

12 12

12 12

12 12

02 06 07 03

PN 42799

16

15

14

13

12

11

10

09

08

07

06

05

04

03

02

01

ITEM

3861

49315

C4922

D1291

C1111

42984

42982

43847

42981

42983

42980

42800

PART No.

FTG ML FM O'RING 90 DEG

SWITCH PRES OVERLD CD-11C-2900R/WD

FTG ADAPT 4-6 F5OLO-S

FTG ADAPT 4-F5OLO-S

FTG ADAPT MSTR/FSTR 10-6 F5OG5

HOSE-HYD .25X 43

HOSE-HYD .25 X 42

HOSE-HYD .25 X 20

HOSE-HYD .25 X 19

HOSE-HYD .25 X 23

HOSE-HYD .25 X 22

HOSE KIT 3315 CRANE (incl:2-11)

DESCRIPTION

1ref

1ref

1ref

1ref

1ref

1ref

1

QTY

1

1

8

4

2

8 EC3200 Owner’s Manual

Control Kit - PN 42804

1

4,5,6

A2B

SWITCH

B

A

4,5,6

BA

PRESSURE SWITCH

C

B A

Power

Unit

B

A

B

A

B A

B

A

B

A

B

A

B

A

B A

B A

B

A

B

A

B

A

2

R

GR

OUND

T1

OP

OPT2

GROUND

N

MAI

C

O

N

TA

C

T

PO

WE

R U

PO

WE

R 1

2

V

T S

IG

NA

L

87

86

87A

30

85

GRO

UND

WINCH

UP

WINCH

DOWN

WINCH DOWN

7,8

POWER 12 V

3

WINCH UP RELAY

Winch

9

NOTE: P/N 47409 INCLUDES

HARNESS & WINCH CONTROLLER

03

02

01

ITEM

07

06

05

04

12

11

10

09

08

36436

32523

47092

47409

47410

9756

8384

9752

17771

42805

42976

PART No.

PN 42804

FUSE 250 AMP 46276

FUSE HOLDER 46039

WIRE HARNESS 3315 MULTI FUNCTION VB

COVER SWITCH EC3200

SWITCH MOM SPST 20A

CONTACT M TERM SHROUD 14-16 31034

CABLE SEAL 18-20 PACKARD 39000

CONNECT 2 PIN SHROUD PACKARD

SWITCH PUSH BUTTON 9216-03

WIRE HARNESS 3315 MULTI FUNCTION VB

RADIO CNTRL ASM 5 FCTN ON/OFF

DESCRIPTION

1

1

1

1

1

4

4

2

1

1

1

QTY

REPLACEMENT CONTROLLER

STELLAR P/N 42821

EC3200 Wiring Diagram (Two Battery)

Installation 9

+

TRUCK BATTERY

FUSE 250 AMP

(STELLAR SUPPLIED)

(NOT SUPPLIED)

MASTER

SWITCH

250 AMP

UNDERHOOD

OPT1

OPT2

GROUND

POWER

GROUND

CRANE HARNESS

CRANE

START MOTOR

SOLENOID

Torque Spec

Large Nuts: 35 in-lbs

Small Nuts: 15 in-lbs

GROUND

GROUND POST

SWITCH

POWER

10 AMP

POWER SOURCE FOR

RADIO REMOTE

CAB OR CRANE

COMPARTMENT

FUSE 250 AMP

(STELLAR SUPPLIED)

+

AUX BATTERY

LOCATE AUX BATTERY AS

CLOSE TO CRANE AS POSSIBLE

Recommended Wire Sizes:

EC3200 - #2

EC4000 - #2

EC5000 - #2

EC6000 - 1/0

10 EC3200 Owner’s Manual

EC3200 Wiring Diagram (One Battery)

OPT1

OPT2

GROUND

POWER

GROUND

FUSE 250 AMP

(STELLAR SUPPLIED)

+

TRUCK BATTERY

UNDERHOOD

CRANE HARNESS

CRANE

START MOTOR

SOLENOID

GROUND

Torque Spec

Large Nuts: 35 in-lbs

Small Nuts: 15 in-lbs

GROUND POST

Note:

With a single battery configuration, operating the crane when the truck

is not running will drain the truck battery.

87

86

87A

30

85

SAFETY BRAKE

SWITCH

POWER

10 AMP

POWER SOURCE FOR

RADIO REMOTE

CAB OR CRANE

COMPARTMENT

Recommended Wire Sizes:

EC3200 - #2

EC4000 - #2

EC5000 - #2

EC6000 - 1/0

Valve Bank Drawing

Installation 11

ROT

CW

ROT

CCW

INNER

DOWN

INNER

UP

EXT

IN

EXT

OUT

12 EC3200 Owner’s Manual

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 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 footings.

3. Operate the crane under partial load to assure operator proficiency and proper machine function.

EC3200 Stability Data

Max Horizontal Reach: 180” (From the center of rotation to boom tip)

Stability Test Weight: 755 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.

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.

Stability Capacity Chart

Installation 13

STABILITY CAPACITY CHART

14 EC3200 Owner’s Manual

Decal Kit Placement - PN 42816

9

29

03

24

7070

6060

27

02

14,15

EC 3200 01

25

30

26

31

22

28

7

13819

13820

C1179

C5918

C4795

4190

9188

4189

4186

C4544

C4540

C4545

42817

15172

42818

PART No.

*06

*05

*04

09

*08

07

*03

02

01

ITEM

15

14

*13

*12

*11

*10

DECAL-ANGLE INDICATOR SS

DECAL ANGLE INDICATOR CS

DECAL-ELECTROCUTION 4.5x7.5

DECAL-DANGER MOVING O.R.

DECAL-DANGER O.R.

DECAL-DANGER

DECAL-ROTATE/GREASE

DECAL-DANGER

DECAL-ELECTROCUTION 2x2.75

DECAL-DANGER

DECAL-DANGER

DECAL-ELECTROCUTION 5x13

DECAL CAPACITY

DECAL ASME/ANSI B30.22/B30.5

DECAL IDENTIFICATION

DESCRIPTION

PN 42816

*USE THESE DECALS WITH BODY PACKAGE

**THESE DECALS NOT INCLUDED WITH THE DECAL KIT

2

2

2

1

1

1

1

1

1

1

1

4

2

1

2

QTY

**31

30

29

28

27

26

25

24

*23

22

*21

*20

*19

*18

*17

*16

ITEM

18472

42820

35234

42819

28256

25159

24712

15171

C4541

12300

4214

C0568

12452

C5911

C5910

12451

PART No.

DECAL MANUAL OPERATION

DECAL VB CONTROL EC3200

DECAL STELLAR MADE IN THE USA

DECAL SNATCH BLOCK CAP 3 TON

DECAL WARNING OVERLOAD DEVICE

DECAL WARNING MANUAL OVERRIDES

DECAL CAUTION STOW HOOK

DECAL GREASE WORM DRIVE BEARINGS

DECAL-CRANE STOWING

DECAL-TWO BLOCKING

DECAL-SERVICE

DECAL-DIESEL

DECAL MANUAL EXT

DECAL-STELLAR 2x4.5

DECAL-STELLAR 4x9.5

DECAL HOISTING PERSONNEL

DESCRIPTION

1

1

1

1

1

1

1

1

1

1

2

1

1

3

1

1

QTY

Chapter 3 - Assembly Drawings

Base Assembly - PN 42525

4

5

2

3

12

7

10

9

11

9

6

8

7

8

5

6

9

10

1 1

12

I T E M

1

2

3

4

PN 42525

4

P A

2 7

R T

8 4

D E S C R I P T I O N

B A S E E C 3 2 0 0

41640 BEARING SWING DRIVE 170-00058-1

62487 MOTOR 80CC EC3200 YMPH-80-H2(R)-K-S-B

21151 GASKET MOTOR 008-10056-1

D 1 3 0 7 C A P S C R 0 .

5 0 1 3 X 1 .

2 5 S H

30750 CAP SCR 0.50-13X3.50 HHGR8

4 2 7 9 5

D 0 7 9 0

S T

W

O

A

P

S H

S

E

L I

R

D

0

I

.

N

5

G

0 F

E

L

C

A

3

T

2 0

G

0

R 8

D1345 FTG CPRSN 0.12NPT/0.25 TUBE

D1810 TBE AIR SAEJ844 TYPE A .25 (RM)

C 2 2 5 6 F T G C O U P L E R P I P E 0 .

1 3

56589 ZERK 1/8 NPT STRAIGHT LONG THREAD

1

1 3

1

1

2

1

Q T Y .

1

1

1

1 ref

2

13

1

16 EC3200 Owner’s Manual

Base Assembly (Narrow Version) - PN 44613

2

4

11

12

7

5

3 10

9

6

8

7

8

5

6

9

10

1 1

12

I T E M

1

2

3

4

PN 44613

P A R T

4 4 6 1 4

D E S C

B A S E

R I P T I O

E C 3 2

N

0 0 N A R R O W

41640 BEARING SWING DRIVE 170-00058-1

62487 MOTOR 80CC EC3200 YMPH-80-H2(R)-K-S-B

21151 GASKET MOTOR 008-10056-1

Q T Y .

1

1

1

1 ref

D1307 CAP SCR 0.50-13X1.25 SH

30750 CAP SCR 0.50-13X3.50 HHGR8

4 2 7 9 5

D 0 7 9 0

S T O P

W A

S

S H

L I

E R

D I

0

N G

.

5

E

0 F L

C 3 2 0

A T G

0

R 8

D1345 FTG CPRSN 0.12NPT/0.25 TUBE

D1810 TBE AIR SAEJ844 TYPE A .25 (RM)

C 2 2 5 6 F T G C O U P L E R P I P E 0 .

1 3

56589 ZERK 1/8 NPT STRAIGHT LONG THREAD

2

13

1

1 3

2

1

1

1

1

10

*

10

*

Mast Assembly - PN 42787

14

16 15

9

22

5 1

4

22

9

6

7

20

21

9

11

13

15

16

12

3

3

P/N 42798 MUST

GO IN THIS MAST

MOUNTING HOLE

2

NOTE: WINCH CONTROLLER(P/N 42821)

SHOWN FOR REFERENCE

19

18

8

9

10

5

6

7

I T E M

1

2

3

4

1 1

12

13

1 4

15

16

18

19

20

21

22

PN 42787

P A R T

4 2 3 1 8

D

M

E

A

S C R

S T

I P

E C

T I O N

3 2 0 0

42513 POWER UNIT 12V EC3200

42788 WASHER 0.44 SAE FLAT YELLOW GR8

42789 CAP SCR 0.44-14X2.25 HHGR8 ZY

20362 BUSHING IGUS GFI-1618-08

0345 CAP SCR 0.38-16X1.50 HHGR5

0 3 4 6 W A S H E R 0 .

3 8 F L A T

D

0479

0 9 1 7

0478

CAP SCR 0.25-20X0.75 HHGR5

W A S H E R 0 .

2 5 F L A T S S

CAP SCR 0.25-20X0.50 HHGR5

0 3 4 0 W A S H E R 0 .

2 5 F L A T

43579 CAP SCR 0.44-14X2.75 MOD EC3200

47411 BRKT OVERRIDE BUTTON EC3200

4 4 4 7

0343

5

0420

C O V E R E C 3 2 0 0 H D P E

WASHER 0.31 USS FLAT ZINC

CAP SCR 0.31-18X0.75 HHGR5

5870

0492

WASHER 0.38 STAR EXTERNAL

CAP SCR 0.38-16X0.75 HHGR5

51896 BRKT COVER EC CRANES

30659 NUT 0.25-20 HH NYLOC SS

C6021 CAP SCR 0.25-20X0.75 BTNHD SS

1

1

1

1

2

1

3

3

2

1

1

2

6

3

4

2

2

Q T Y .

1

1

8

7

8

18 EC3200 Owner’s Manual

Main Boom Assembly - PN 42512

MOUNTING HARDWARE WILL

BE PART OF THE WINCH PACKAGE.

USE ALL HARDWARE, EXCEPT BOLTS.

2

21

7

28

27

16

15

12

28

16

17

24

26

4 27

16

11

9

10

28

23

25

24

3

13

28

27

16

15

14

20

19

18

1 4

1 5

16

1 7

18

19

8

9

10

11

1 2

13

I T E M

1

2

3

6

7

4

5

20

21

2 3

24

2 5

2 6

27

28

PN 42512

P

4 2

A

3

R T

0 3

D E S C R I P T I O N

I N N E R B O O M E C 3 2 0 0

41641 WINCH DC2000 WARN 63899

1 1 5 4 4 C O R D R E E L 6 6 2 0

0 3 4 0

C 5 6 0 6

W

C

A

L

S

A

H

M

E R

P 0

0

.

2

.

2 5

5 B

F L A T

L K V I N Y L

43845 CAP SCR 0.25-20X0.38 HHGR5 c 1 5 9 2 Z E R K 1 / 8 N P T S T R A I G H T

42508 WEAR PAD 0.50X1.50X2.00

D 0 7 9 0 W A S H E R 0 .

5 0 F L A T G R 8

13815PC PLATE ANGLE INDICATOR

C6106 NUT 0.50-13 HHGR5 NYLOC

0 0 6 9 B U S H I N G Q S -I 1 6 1 8 1 6

20362 BUSHING IGUS GFI-1618-08

4 2 5 0 3

4 2 5 1 5 Z

9320

P

C Y

P I N

L I

1

N D E R 3 .

.

0 0 X 6 .

3

0 0 X 1 3 .

0 0

8 D & T

PIN CAP 0.44X1.75X0.19 SS

4 2 5 1 6 Z P P I N 1 .

0 0 X 5 .

1 3 D & T

42517ZP PIN TEAR DROP 1.00X2.19

5591 WASHER 0.31 SAE FLAT YELLOW GR8

21170 CAP SCR 0.31-18X1.00 HHGR8

0345

D 0 9 1 7

0479

0 5 2 1

CAP SCR 0.38-16X1.50 HHGR5

W A S H E R 0 .

2 5 F L A T S S

CAP SCR 0.25-20X0.75 HHGR5

W A S H E R 0 .

2 5 L O C K

C 0 0 8 1 C L A M P 0 .

5 0 B L K V I N Y L

C6353 WASHER 0.38 SAE FLAT YELLOW GR8

9843 CAP SCR 0.38-16X0.75 HHGR8

6

4

1

1

4

2

1

1

1

1

2

6

2

2

1

6

3

2

6

Q T Y .

1

3

1

1

1

1

4

2

2

1

5

1

8

Extension Boom Assembly - PN 42520

2

5

1

6

8

3

4

20

5

7

12

11

8

12

10

9

11

18

17

22

3

19

16

13

PN 42520

1 0

11

1 2

13

8

9

6

7

14

15

16

17

18

19

20

21

22

I T E M

1

4

5

2

3

P A R T D E S C R I P T I O N

42311 EXT BOOM 1ST EC3200

4 2 5 0 7 C Y L I N D E R 1 .

5 0 X 4 8 .

0 0

D0790 WASHER 0.50 FLAT GR8

10172 CAP SCR 0.50-13X1.00 HHGR8 ZY

42509 WEAR PAD 0.38X1.38X1.50

42312 EXT BOOM 2ND EC3200

42978PC FLAT BOOM STOP EC3200

4 2 9 7 7 P I N H I T C H 0 .

6 3 X 4 .

0 0

42317 SHEAVE EC3200 5.00 DIA .22R/1.00THK

4 2 5 2 4 Z P

0423

3 7 8 2 4

0507

P I N 0 .

7 5 X 2 .

5 0 C O T T E R

MACHY WASHER 0.75ID 10GA

C O T T E R P I N . 1 2 5 X 1 .

0 0

CAP SCR 0.50-13X4.50 HHGR5

27710 SPRING ANTI 2 BLOCK SUMMIT

C6106 NUT 0.50-13 HHGR5 NYLOC

0352 WASHER 0.50 USS FLAT ZINC

35105 SWITCH LIMIT E1117-B9111-6C

D0178 WASHER #10 SAE FLAT ZINC

0505 CAP SCR 0.50-13X3.50 HHGR5

D0561 CAP SCR 0.25-20X0.50 BTNHD SS

42505PC PLATE CRADDLE EC3200

43846 SCREW #10-24X0.38 SH SS

4

2

2

4

2

2

1

1

Q T Y .

1

1

2

1

9

1

2

2

1

2

2

1

2

3

15

3

14

15

3

21

16

20 EC3200 Owner’s Manual

Cable & Hook Assembly - PN 42781

8

13

11

12

11

13

4

3

2

5

1

1

6

10 9

9

1 0

11

1 2

1 3

6

7

8

I T E M

1

2

3

4

5

PN 42781

P A R T D E S C R I P T I O N

42523PC PLATE SNATCH BLOCK EC3200

42317 SHEAVE EC3200 5.00 DIA .22R/1.00THK

0352

5468

WASHER 0.50 USS FLAT ZINC

NUT 0.50-13 HHGR8 NYLOC

27810 SPACER 3315 SNATCH BLOCK UHMW

16607PC SPACER 3315 SNATCH BLOCK

47868 CAP SCR 0.50-13X2.75 HHGR8

42316 WIRE ROPE 7/32 7X19 GAC 65FT

9263

C 6 0 1 8

0375

4 2 5 2 4 Z P

3 7 8 2 4

PIN .38X3.00 QUICK RELEASE

H O O K

C

C R A N E 3 T O N

MACHY WASHER 0.75ID 14GA

P I N 0 .

7 5 X 2 .

5 0 C O T T E R

O T T E R P I N . 1 2 5 X 1 .

0 0

1

1

2

1

2

1

3

1

Q T Y .

2

1

6

3

2

3

7

3

8

Radio Transmitter Assembly

Assembly Drawings 21

1

2

7

5

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

FOR THE SWITCHES AND TRIGGER

4

6

5

6

7

8

I T E M

1

2

3

4

P A R T D E S C R I P T I O N

20088 CONTROL HANDLE HOUSING 4 FCTN HET

51830 CONTROL HANDLE FACE PLT 5 FCTN

24385 GUARD RADIO SWITCH 4 FCTN

50932 CONTROL HANDLE GRIP LESS TRIGGER HET H2

22600 SWITCH TOGGLE HET RADIO 63019300

35441 BATTERY TUBE AA HETRONIC RADIO

16975 SWITCH E STOP ASM HETRONIC RADIO

51831 DECAL CONTROL HANDLE 5 FCTN

5

1

1

1

Q T Y .

1

1

1

1

22 EC3200 Owner’s Manual

This page intentionally left blank.

Chapter 4 - Replacement Parts

HYDRAULIC COMPONENTS

PART# DESCRIPTION

42840 HYDRAULIC SWING MOTOR

21151 GASKET - HYDRAULIC SWING MOTOR

42513 POWER UNIT 12V EC3200

44028 VALVE CARTRIDGE - POWER UNIT 12V #19012-D

44027 VALVE COIL - POWER UNIT 12V #11494-D

44029 MOTOR 12V - POWER UNIT #08111-1

44030 12V SOLENOID (12volt hydraulic system) #17757

44026 HYDRAULIC RESERVOIR - POWER UNIT 12V #14071

44025 FILL CAP - HYDRAULIC RESERVOIR

9803 C-BALANCE VALVE

43892 SEAL KIT - MAIN LIFT CYLINDER

43893 SEAL KIT - EXTENSION CYLINDER

49315 PRESSURE SWITCH

42821 CONTROLLER SOLENOID

C2027 O'RING - # 4 FACE SEAL

C2028 O'RING - # 6 FACE SEAL

D1245 O'RING - # 4 SAE

D1246 O'RING - # 6 SAE

ASSEMBLY COMPONENTS

44375 WORM GEAR - ROTATION BEARING

44383 BEARING & SEAL KIT - ROTATION BEARING

44376 BEARING RETAINER - ROTATION BEARING

44377 ADAPTER HOUSING - HYDRAULIC MOTOR

20362 BUSHING 1.00" X 0.50"

0069 BUSHING 1.00" X 1.00"

42508 WEAR PAD 0.38" X 1.50" X 2.00"

42509 WEAR PAD 0.38" X 1.38" X 1.50"

42978 BOOM STOP FLAT

9320 PIN CAP 0.44" X 1.75" X 0.25" SS

C6353 WASHER 0.38 FLAT GR8

13573 CAP SCR. 0.38-16 X 1.00" GR8

0375 MACHINE WASHER -0.75" ID 14GA.

0423 MACHINE WASHER -0.75" ID 10GA.

42317 SHEAVE

42316 WIRE ROPE

42977 HITCH PIN 0.63" X 4.00"

9263 QUICK RELEASE PIN .38 X 3.00"

42505PC CRADLE PLATE

27710 SPRING ANTI-2-BLOCK

C6018 HOOK 3-TON

10709 SAFETY LATCH FOR 3 TON HOOK

C1592 GREASE ZERK

ELECTRICAL COMPONENTS

35105 LIMIT SWITCH

11544 CORD REEL

17771 PUSH BUTTON (12volt hydraulic system)

47410 MOMENTARY SWITCH

41641 WINCH

28978 BOSCH RELAY

36436 FUSE 250 AMP

RADIO REMOTE COMPONENTS

42976 RADIO REMOTE SYSTEM

50932 HANDLE ASM

16975 E-STOP SWITCH

22600 TOGGLE SWITCH

20088 LOWER TRANSMITTER HOUSING

35441 BATTERY TUBE HOLDER

35916 BACK UP CORD

24 EC3200 Owner’s Manual

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 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 warrantyapplicable 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