Manual 13253610

Manual 13253610
Model EC3200
Telescopic Crane
Owners’ Manual
Installation • Assembly Drawings • Parts
Reach in Feet/Meters
Capacity in Pounds/Kilograms
3025 lbs
1450 kg
1372 kg
16’2”
4.92 M
1550 lbs
15’
703 KG
3200 lbs
1450 kg
4.57 M
495 kg
2145 lbs
12’
3.66 M
45º
550 kg
1095 kg
780 lbs
353 kg
1900 lbs
862 kg
1710 lbs
6’
1.83 M
1085 lbs
492 kg
775 kg
3’
.914 M
1565 lbs
640 lbs
905 lbs
290 kg
410 kg
11’
3.35 M
15’
0’
4.57 M
Maximum 1 - part line capacity is
1600lbs (725kg). For greater loads,
use 2 - part line.
EC3200
DANGER
Electrocution Hazard
Death or serious injury will result from
inadequate clearance if crane, load,
or vehicle becomes electrically
charged.
• Maintain safe clearance from high
voltage power sources.
• Never approach vehicle or load if
equipment is near a high voltage
power source.
50
710 kg
7’
2.13 M
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
60
15º
6’
1.83 M
35234
1215 lbs
2415 lbs
30º
3’
.914 M
Proudly Designed
and Manufactured
in the USA by
0
80 7
1450 kg
9’
2.74 M
3200 lbs
60º
404 kg
675 kg
1450 kg
75º
890 lbs
1490 lbs
3200 lbs
83.69
0’
Angle Indicator
1090 lbs
1450 kg
973 kg
1450 kg
80º
40
30
20
C1179
PN 42817
10
0
13820
3200 lbs
3200 lbs
3200 lbs
EC3200
WARNING
Free Falling Boom Hazard
Free falling manual boom
extensions can result in death or
serious injury.
• Properly install retention pins
prior to operation.
• Do not stand in front of
extension when removing
retention pin.
• Do not allow extensions to
free fall.
12452
WARNING
Winch
WARNING
Boom
Exten
Pull
Boom
Down
ding
Fall Hazard
Hoisting personnel on boom,
hook, load, or loadline can result
in death or serious injury.
42818
NOTICE
• Never use crane to hoist
personnel.
WARNING
• Never ride the boom, hook,
load, or any device attached
to crane boom or load line.
Misuse Hazard
Two blocking the crane can result in death
or serious injury.
Never allow the hook block to contact the
boom tip by hoisting up, extending or
lowering the boom.
12300
12451
Misuse Hazard
Do not use stow hook for any lifting applications.
Using the stow hook for anything other than hook
stowage can result in death or serious injury.
This crane has been designed and
manufactured to ASME/ANSI B30.22
and/or B30.5 specifications.
12924
24712
WARNING
Overload Hazard
overload condition
Bypassing the
the overload
by tampering with death or
in
device can result
serious injury.
with overload
Never tamper
28256
device.
NOTICE
Damage may occur if worm gear runs
dry. Keep worm gear lubricated with
Stellar® grease (PN 4460).
9188
GREASE every 3 months.
Apply 3 ‘pumps’ of EP2
(extreme pressure grease)
then rotate crane fully.
15171
LOAD BLOCK RATING
3 Tons
(2,721 KG)
SNATCH BLOCK WEIGHT: 15 LBS (6.80 KG)
42819
Notice: A copy of this manual must remain with the equipment at all times.
For a printable download copy, please visit: www.stellarindustries.com
Stellar Industries, Inc.
Subject to Change without Notification.
© 2016 Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
Last Revision: 02/01/16
EC3200 Manual Revisions
Date of Revision
Chapter 2: Installation
March 25th, 2013
Description of Revision
Sections Revised
Chapter 4: Replacement Parts
Updated Control Kit, Wiring Diagrams, Decal Kits, and
Replacement Parts to reflect engineering changes.
Serial Tag
Location
®
DATE
®
D AT E
PATENT INFORMATION
http://www.stellarindustries.com/ip
PATENT INFORMATION
http://www.stellarindustries.com/ip
MO DE L NO .
M O D EL NO .
S E R I A L N O.
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
SERIAL NO.
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
Table of Contents
Introduction........................................................................................................... ii
Chapter 1 - Specifications...................................................................................... 1
Capacity Chart - Decal PN 42817......................................................................2
Chapter 2 - Installation........................................................................................... 3
General Installation..............................................................................................3
Installer Notice....................................................................................................3
Torque Data Chart.............................................................................................4
Installation Overview............................................................................................5
EC3200 Mounting Detail......................................................................................6
Flatbed Body Reinforcement..............................................................................6
EC3200 Installation Drawing................................................................................7
Hydraulic Kit - PN 42799.......................................................................................8
Valve Bank Drawing.............................................................................................9
Control Kit - PN 42804........................................................................................10
EC3200 Wiring Diagram (Two Battery).............................................................11
EC3200 Wiring Diagram (One Battery)............................................................12
Electrical Circuit Grounding..............................................................................13
Stability Procedure.............................................................................................14
Decal Kit Placement - PN 42816.......................................................................15
Chapter 3 - Assembly Drawings.......................................................................... 17
Base Assembly - PN 42525.................................................................................17
Base Assembly (Narrow Version) - PN 44613....................................................18
Mast Assembly - PN 42787.................................................................................19
Main Boom Assembly - PN 42512......................................................................20
Extension Boom Assembly - PN 42520..............................................................21
Cable & Hook Assembly - PN 42781.................................................................22
Radio Transmitter Assembly - PN 67894............................................................23
Chapter 4 - Replacement Parts........................................................................... 25
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page i
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:
NOTICE
A NOTICE signal word indicates a practice not related to physical injury.
WARNING signal word indicates a hazardous situation which, if not
WARNING A
avoided, could result in death or serious injury.
A DANGER signal word indicates a hazardous situation which, if not
DANGER 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 EC 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]
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 [email protected]
Order [email protected]
Warranty [email protected]
Page ii | Stellar® EC3200 Telescopic Crane Owner’s Manual
Chapter 1 - Specifications
Model EC3200 Crane
SPECIFICATION SHEET
Crane Rating:
Standard Boom Length:
11,500 ft-lb (1.59 TM)
7’ (2.13 m) from CL of Crane
Boom Extension:
1st stage: Hydraulic 48” (121.9 cm)
2nd stage: Manual 48” (121.9 cm)
Maximum Horizontal Reach:
15’ (4.57 m) from CL of Crane
Maximum Vertical Lift:
(from crane base)
16’ 2” (4.93 m)
Boom Elevation:
-5 to +80 degrees
Stowed Height:
(crane only)
24” (61.0 cm)
Mounting Space Required:
18” x 15” (45.7 x 38.1 cm)
Approximate Crane Weight:
730 lbs (331 kg)
Controls:
Radio control standard for all functions.
Winch Specifications
Rope Length:
Rope Diameter:
Line pull speed:
Max. single part line:
Max. double part line:
65 ft (19.8 m)
7/32” (.56 cm)
15 ft/min (4.6 m/min)
1600 lbs (725 kg)
3200 lbs (1450 kg)
Rotation:410 degree power
(worm gear)
Lifting Capacities:
1625 lbs @ 7’ (737 kg @ 2.1 m)
905 lbs @ 11’ (410 kg @ 3.35 m)
640 lbs @ 15’ (290 kg @ 4.6 m)
Power Supply Required:
12 volt power unit
(2.0 gpm @ 2600 psi)
(7.57 lpm @ 179 bar)
*Subject to change without notification
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 1
Capacity Chart - Decal PN 42817
3200 lbs
Reach in Feet/Meters
Capacity in Pounds/Kilograms
3025 lbs
1450 kg
16’2”
1372 kg
4.92 M
1550 lbs
15’
703 KG
3200 lbs
3200 lbs
1450 kg
4.57 M
1090 lbs
1450 kg
495 kg
12’
2145 lbs
3.66 M
973 kg
3200 lbs
1450 kg
80º
890 lbs
1490 lbs
3200 lbs
404 kg
675 kg
1450 kg
9’
2.74 M
3200 lbs
1450 kg
75º
1215 lbs
2415 lbs
60º
45º
550 kg
1095 kg
353 kg
1900 lbs
862 kg
30º
780 lbs
1085 lbs
492 kg
1710 lbs
775 kg
3’
15º
.914 M
1565 lbs
0’
3’
.914 M
6’
1.83 M
7’
2.13 M
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
640 lbs
905 lbs
710 kg
83.69
6’
1.83 M
290 kg
410 kg
11’
3.35 M
15’
0’
4.57 M
Maximum 1 - part line capacity is
1600lbs (725kg). For greater loads,
use 2 - part line.
EC3200
Page 2 | Stellar® EC3200 Telescopic Crane Owner’s Manual
PN 42817
Chapter 2 - Installation
General Installation
This chapter is designed to serve as a general guide for the installation of a EC3200 Crane.
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.
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.
WARNING 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.
NOTICE
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.
Installer 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 (400999), for further information, or visit http://www.gpoaccess.gov/nara/index.html for the full
text of Code of Federal Regulations.
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 3
Torque Data Chart
­ hen using the torque data in the
W
chart, the following rules should be
observed:
• Bolt manufacturer’s particular
specifications 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.
GRADE 5
GRADE 8
Size
Bolt DIA Plain Plated Plain Plated
(DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb)
5/16-18
0.3125
17
13
25
18
3/8-16
0.3750
31
23
44
33
7/16-14
0.4375
49
37
70
52
1/2-13
0.5000
75
57
105
80
9/16-12
0.5625
110
82
155
115
5/8-11
0.6250
150
115
220
160
3/4-10
0.7500
265
200
375
280
7/8-9
0.8750
395
295
605
455
1-8
1.000
590
445
910
680
1 1/8-7
1.1250
795
595
1290
965
1 1/4-7
1.2500
1120
840
1815
1360
1 3/8-6
1.3750
1470
1100
2380
1780
1 1/2-6
1.500
1950
1460
3160
2370
GRADE 9
Plated
(Ft-Lb)
22
39
63
96
139
192
340
549
823
1167
1646
2158
2865
• Torque values specified 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 specific application. Torque values listed are for general use only. Check tightness of
fasteners periodically.
• Shear 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.
• T ighten 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.
Page 4 | Stellar® EC3200 Telescopic Crane 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. U
se 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 2” Grade 9 bolts and four (4) 7⁄8” Grade 9 flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. U
sing 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 bolts may be required –
recommended thread engagement into crane base is 0.75” – use grade 9, zinc plated bolts only.
10. Torque the bolts 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.
ck
ru
fT
to
n
Fro
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 5
EC3200 Mounting Detail
Standard
Narrow
Base
FRONT
FRONT
3.00
14.75
10.00
7.38
5.00
7.38
5.00
10.00
14.75
HOLE MOUNTING DETAIL
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 AWS qualified welder
to proceed as shown in this drawing:
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
Page 6 | Stellar® EC3200 Telescopic Crane Owner’s Manual
EC3200 Installation Drawing
2
3
NOTICE!
Route hoses correctly to ensure
they do not become pinched or
crushed during installation.
Stowed Position
ITEM
2
3
PART
18041
51377
DESCRIPTION
WASHER 0.88 SAE FLAT YELLOW GR9
CAP SCR 0.88-9X2.00 HHGR9
QTY.
4
4
NOTE:
STABILITY DECAL P/N 16881 IS PART OF THIS KIT
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 7
Hydraulic Kit - PN 42799
12 10
ROTATION CCW
11
BOOM DOWN
ROTATION
BOOM UP
ROTATION CW
MAIN
11
12 10
13
14
11
EXTENSION RETRACT
EXTENSION EXTEND
EXT
11
EXT OUT
EXT IN
04
05
12
12
12
12
12
12
02
06
07
03
MAIN UP
ROTATION CCW
ROTATION CW
MAIN DOWN
PN 42799
16
15
14
3861
13
49315
12
C4922
FTG ML FM O'RING 90 DEG
SWITCH PRES OVERLD CD-11C-2900R/WD
1
1
FTG ADAPT 4-6 F5OLO-S
8
11
D1291
FTG ADAPT 4-F5OLO-S
4
10
C1111
FTG ADAPT MSTR/FSTR 10-6 F5OG5
2
07
42984
HOSE-HYD .25X 43
1ref
06
42982
HOSE-HYD .25 X 42
1ref
05
43847
HOSE-HYD .25 X 20
1ref
04
42981
HOSE-HYD .25 X 19
1ref
03
42983
HOSE-HYD .25 X 23
1ref
02
42980
HOSE-HYD .25 X 22
1ref
01
42800
HOSE KIT 3315 CRANE (incl:2-7)
ITEM
PART No.
09
08
DESCRIPTION
Page 8 | Stellar® EC3200 Telescopic Crane Owner’s Manual
1
QTY
Valve Bank Drawing
ROT
CW
INNER
DOWN
EXT
IN
ROT
CCW
INNER
UP
EXT
OUT
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 9
Control Kit - PN 42804
POWER
GROUND
OPT1
OPT2
Power
Unit
Winch
PN 42804
17771
SWITCH PUSH BUTTON 9216-03
NOTE: P/N 47092 INCLUDES HARNESS & WINCH CONTROLLER
Page 10 | Stellar® EC3200 Telescopic Crane Owner’s Manual
EC3200 Wiring Diagram (Two Battery)
FUSE 250 AMP
PN 36436
MASTER
SWITCH
250 AMP
Holder: PN 32523
(STELLAR SUPPLIED)
-
+
(NOT SUPPLIED)
TRUCK BATTERY
UNDERHOOD
CRANE HARNESS
CRANE
START MOTOR
SOLENOID
FUSE 250 AMP
PN 36436
OPT1
Holder: PN 32523
Torque Spec
Large Nuts: 35 in-lbs
Small Nuts: 15 in-lbs
OPT2
(STELLAR SUPPLIED)
GROUND
GROUND
GROUND POST
POWER
-
+
AUX BATTERY
GROUND
LOCATE AUX BATTERY AS
CLOSE TO CRANE AS POSSIBLE
RELAY
87
SAFETY BRAKE
87A
86
30
SWITCH
POWER
10 AMP
85
POWER SOURCE FOR
RADIO REMOTE
CAB OR CRANE
COMPARTMENT
NOTICE
Operating the crane without
the truck engine running could allow the truck
battery to be discharged below levels required
for starter cranking power.
Minimum Wire Sizes:
EC3200 - #2
EC4000 - #2
EC5000 - #2
EC6000 - 1/0
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 11
EC3200 Wiring Diagram (One Battery)
FUSE 250 AMP
PN 36436
Holder: PN 32523
(STELLAR SUPPLIED)
-
+
TRUCK BATTERY
UNDERHOOD
CRANE HARNESS
CRANE
START MOTOR
SOLENOID
OPT1
Torque Spec
Large Nuts: 35 in-lbs
Small Nuts: 15 in-lbs
OPT2
GROUND
GROUND
GROUND POST
POWER
NOTICE
Operating the crane without
the truck engine running could allow the truck
battery to be discharged below levels required
for starter cranking power.
GROUND
87
SAFETY BRAKE
87A
86
30
SWITCH
POWER
10 AMP
85
POWER SOURCE FOR
RADIO REMOTE
CAB OR CRANE
COMPARTMENT
Minimum Wire Sizes:
EC3200 - #2
EC4000 - #2
EC5000 - #2
EC6000 - 1/0
Page 12 | Stellar® EC3200 Telescopic Crane Owner’s Manual
Electrical Circuit Grounding
When installing the crane, always locate a good source for grounding the circuit. A
majority of electrical failures are due to poor grounding. Poor grounding can cause
intermittent operation of the equipment, electrical component failures and cause the
equipment to not operate at all.
Chassis manufacturers usually will have a ground strap which ties into the truck frame
from the battery, but it is always a good idea to check each individual model to verify
where the ground is located. Never use the mechanic body as a ground source. Make
sure the electrical grounds are routed to either the chassis frame rail or the chassis’s main
grounding source.
Stellar provides a stud (PN 40992) for grounding the crane to the chassis frame rail:
Inside Frame Rail
Outside Frame Rail
WARNING Drill the hole to the frame rail in accordance with the chassis body
• builder’s guide.
• Hole size: 21/64”
• The hole location should allow for the shortest length of ground wire while keeping
enough slack for flexibility.
• Be sure to grind the frame rail around the hole to ensure a proper ground connection.
• Frame rail thickness may require additional flat washers (as shown).
• Use an electrical coating on hardware to prevent corrosion.
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 13
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
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:
is
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.
Page 14 | Stellar® EC3200 Telescopic Crane Owner’s Manual
Decal Kit Placement - PN 42816
14
13
Reach in Feet/Meters
Capacity in Pounds/Kilograms
3025 lbs
1450 kg
1372 kg
4.92 M
495 kg
890 lbs
1490 lbs
404 kg
675 kg
60º
45º
9’
2.74 M
550 kg
1095 kg
862 kg
.914 M
640 lbs
905 lbs
290 kg
410 kg
11’
3.35 M
15’
0’
4.57 M
Maximum 1 - part line capacity is
1600lbs (725kg). For greater loads,
use 2 - part line.
EC3200
Electrocution Hazard
Death or serious injury will result from
inadequate clearance if crane, load,
or vehicle becomes electrically
charged.
• Maintain safe clearance from high
voltage power sources.
• Never approach vehicle or load if
equipment is near a high voltage
power source.
18
50
7’
2.13 M
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
60
3’
710 kg
6’
1.83 M
DANGER
492 kg
775 kg
1565 lbs
3’
.914 M
6’
1.83 M
1085 lbs
1710 lbs
83.69
0’
780 lbs
353 kg
1900 lbs
15º
35234
1215 lbs
2415 lbs
30º
Proudly Designed
and Manufactured
in the USA by
80 70
1450 kg
Angle Indicator
12’
3.66 M
973 kg
3200 lbs
EC3200
4.57 M
1090 lbs
2145 lbs
1450 kg
15
15’
703 KG
1450 kg
3200 lbs
75º
06
16’2”
1550 lbs
3200 lbs
1450 kg
1450 kg
80º
40
30
20
10
C1179
PN 42817
0
13820
3200 lbs
3200 lbs
3200 lbs
WARNING
04
02
Free Falling Boom Hazard
Free falling manual boom
extensions can result in death or
serious injury.
• Properly install retention pins
prior to operation.
• Do not stand in front of
extension when removing
retention pin.
• Do not allow extensions to
free fall.
12452
WARNING
Winch
10
42818
03
WARNING
Pull
Boom
Down
ing
WARNING
Boom
Extend
Fall Hazard
Hoisting personnel on boom,
hook, load, or loadline can result
in death or serious injury.
Misuse Hazard
Two blocking the crane can result in death
or serious injury.
• Never use crane to hoist
personnel.
Never allow the hook block to contact the
boom tip by hoisting up, extending or
lowering the boom.
• Never ride the boom, hook,
load, or any device attached
to crane boom or load line.
12300
12451
Misuse Hazard
NOTICE
Do not use stow hook for any lifting applications.
Using the stow hook for anything other than hook
stowage can result in death or serious injury.
This crane has been designed and
manufactured to ASME/ANSI B30.22
and/or B30.5 specifications.
12924
24712
08
12
WARNING
Overload Hazard
overload condition
Bypassing the
the overload
by tampering with death or
in
device can result
serious injury.
with overload
Never tamper
28256
device.
07
GREASE every 3 months.
Apply 3 ‘pumps’ of EP2
(extreme pressure grease)
then rotate crane fully.
Crane Compartment Inner Door
Suggested Placement
15171
21
Kit PN 42816
14
FOR SERVICE ON THIS EQUIPMENT
CONTACT:
STELLAR INDUSTRIES, INC.
190 STATE STREET, GARNER, IA 50438
641-923-3741
800-321-3741
3200 lbs
Reach in Feet/Meters
Capacity in Pounds/Kilograms
3025 lbs
1450 kg
1372 kg
16’2”
4.92 M
1550 lbs
15’
703 KG
3200 lbs
3200 lbs
1450 kg
4214
4.57 M
1090 lbs
1450 kg
495 kg
2145 lbs
12’
3.66 M
973 kg
(Rev E - 08/13/14)
Added Pressure Wash Decal
WARNING
22
3200 lbs
1450 kg
80º
1450 kg
DANGER
Electrocution Hazard
Death or serious injury will
result from touching tethered
remote if crane, load, or vehicle
becomes electrically charged.
Maintain safe clearance from
high voltage power sources.
4186
19
550 kg
1095 kg
862 kg
1710 lbs
6’
6’
492 kg
3’
.914 M
7’
2.13 M
640 lbs
905 lbs
710 kg
1.83 M
1.83 M
1085 lbs
775 kg
1565 lbs
3’
780 lbs
353 kg
1900 lbs
15º
.914 M
16
1215 lbs
2415 lbs
83.69
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
68024
9’
2.74 M
3200 lbs
60º
30º
0’
Failure to follow operating,
maintenance, or safety
instructions can result in
death or serious injury.
404 kg
675 kg
1450 kg
45º
Read and understand all
manuals and safety signs
before operating or servicing
this equipment.
890 lbs
1490 lbs
3200 lbs
75º
Untrained Operator Hazard
290 kg
410 kg
11’
3.35 M
LOAD BLOCK RATING
0’
15’
3 Tons
4.57 M
Maximum 1 - part line capacity is
1600lbs (725kg). For greater loads,
use 2 - part line.
EC3200
(2,721 KG)
SNATCH BLOCK WEIGHT: 15 LBS (6.80 KG)
42819
PN 42817
WARNING
Overload Hazard
Do not exceed equipment load charts and ratings.
Failure to follow equipment load charts and ratings
can result in death or serious injury.
4189
20
26
EC3200
15
17
NOTICE
05
PUSH PULL
EXTENSION
73929
IN
Angle Indicator
OUT
MAIN
70
80
DOWN UP
ROTATION
60
NOTICE
13819
42818
0 10 20
30
CW
11
50
01
Damage may occur if worm gear runs
dry. Keep worm gear lubricated with
Stellar® grease (PN 4460).
9188
40
CCW
42820
WARNING
Movement Hazard
After stowing the crane, always return the valve
bank manual overrides to the neutral position.
Failure to return the manual overrides to the neutral
position can result in death or serious injury.
25159
HOLD BUTTON TO
OPERATE CRANE
MANUALLY.
18472
09
For use with Crane Package
ITEM
PN
01
9188
DESCRIPTION
LOCATION
QTY
DECAL ROTATE/GREASE
Crane Base
02
1
12300 DECAL WARNING TWO BLOCKING
Crane Horse Head
1
03
12451 DECAL WARNING HOISTING PERSONNEL
Main Boom
1
04
12452 DECAL WARNING MANUAL EXT
Main Boom
1
05
13819 DECAL ANGLE INDICATOR SS
Main Boom
1
06
13820 DECAL ANGLE INDICATOR CS
Main Boom
1
07
15171 DECAL GREASE WORM
Crane Base
1
08
15172 DECAL ASME/ANSI B30.22/B30.5
Main Boom
1
09
18472 DECAL MANUAL OPERATION
Power unit cover
1
10
24712 DECAL WARNING STOW HOOK
Crane Boom above stow hook
1
11
25159 DECAL WARNING MANUAL OVERRIDES
Valve Bank
1
12
28256 DECAL WARNING OVERLOAD DEVICE
Main Cylinder
1
13
35234 DECAL STELLAR MADE IN THE USA
Main Boom
1
14
42817 DECAL CAPACITY EC3200
Main Boom and Crane Compartment
2
15
42818 DECAL IDENTIFICATION EC3200
Main Boom (Both Sides)
2
16
42819 DECAL SNATCH BLOCK 3 TON
Snatch Block
1
17
42820 DECAL VB CONTROL ECSERIES
On top of valve bank
1
18
C1179 DECAL DANGER ELECTROCUTION SMALL
Main Boom
1
19
73929 DECAL PRESSURE WASH
Main Boom
1
QTY
For use with Body/Chassis Package
ITEM
PN
DESCRIPTION
LOCATION
20
4186
DECAL DANGER ELECTROCUTION REMOTE
Crane Compartment
1
21
4189
DECAL WARNING OVERLOAD
Crane Compartment
1
22
4214
DECAL SERVICE
Crane Compartment
1
23
68024 DECAL WARNING UNTRAINED OPERATOR
Crane Compartment
1
24*
C4545 DECAL DANGER ELECTROCUTION LARGE
Four corners of the body/chassis
4
25*
C5910 DECAL STELLAR 4x9.5
Suggested: Rear body/tailgate
1
26*
C5911 DECAL STELLAR 2x4.5
Suggested: Side corners of body
3
*Not Shown
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 15
This page intentionally left blank.
Page 16 | Stellar® EC3200 Telescopic Crane Owner’s Manual
Chapter 3 - Assembly Drawings
Base Assembly - PN 42525
4
5
2
3
9
7
10
12
9
11
1
8
6
PN 42525
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
PART
42784
41640
62487
21151
D1307
30750
42795
D0 7 9 0
D1345
D1810
22161
56589
DESCRIPTION
BASE EC3200
BEARING SWING DRIVE 170-00058-1
ROTATION MOTOR EC3200
GASKET MOTOR 008-10056-1
CAP SCR 0.50-13X1.25 SHGR8 W/ RED PATCH
CAP SCR 0.50-13X3.50 HHGR8
STOP SLIDING EC3200
WASHER 0.50 FLAT GR8
FTG CPRSN 0.12NPT/0.25 TUBE
TBE AIR SAEJ844 TYPE A .25 (RM)
FTG 2-2 FP-FP COUPLER STRAIGHT BRASS
ZERK 1/8 NPT STRAIGHT LONG THREAD
QTY.
1
1
1
1 ref
2
13
1
13
2
2.5
1
1
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 17
Base Assembly (Narrow Version) - PN 44613
2
4
11
7
10
3
9
5
1
8
6
PN 44613
ITEM
1
2
3
4
PART
44614
41640
62487
21151
5
D1307
6
7
8
9
10
11
12
30750
42795
D0790
D1345
D1810
22161
56589
DESCRIPTION
BASE EC3200 NARROW
BEARING SWING DRIVE 170-00058-1
ROTATION MOTOR EC3200
GASKET MOTOR 008-10056-1
CAP SCR 0.50-13X1.25 SHGR8 W/ RED
PATCH
CAP SCR 0.50-13X3.50 HHGR8
STOP SLIDING EC3200
WASHER 0.50 FLAT GR8
FTG CPRSN 0.12NPT/0.25 TUBE
TBE AIR SAEJ844 TYPE A .25 (RM)
FTG 2-2 FP-FP COUPLER STRAIGHT BRASS
ZERK 1/8 NPT STRAIGHT LONG THREAD
Page 18 | Stellar® EC3200 Telescopic Crane Owner’s Manual
QTY.
1
1
1
1 ref
2
13
1
13
2
2.5
1
1
12
Mast Assembly - PN 42787
14
16
5
10
9
23
15
1
9
10
9
22
20
9
21
9
6
4
15
8
7
16
11
13
12
3
3
18
P/N 43579 MUST
GO IN THIS MAST
MOUNTING HOLE
2
19
PN 42787
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
20
21
22
23
PART
42318
42513
42788
42789
20362
0345
0346
0 4 79
D0917
0478
0340
43579
47411
44475
0343
0420
5870
0492
518 96
30659
C6021
C6022
DESCRIPTION
MAST EC3200
POWER UNIT 12V EC3200
WASHER 0.44 SAE FLAT YELLOW GR8
CAP SCR 0.44-14X2.25 HHGR8 ZY
BUSHING IGUS GFI-1618-08
C A P SC R 0 . 3 8- 1 6X 1 . 5 0 HH G R5
WASHER 0.38 FLAT
C A P SC R 0 . 2 5- 20 X0 . 7 5 H HGR 5
W A S H ER 0 . 2 5 F L A T S S
C A P S C R 0 . 2 5 - 2 0 X 0 .5 0 H H G R 5
WASHER 0.25 FLAT
CAP SCR 0.44-14X2.75 MOD EC3200
BRKT OVERRIDE BUTTON EC3200
C O V E R E C 3 2 0 0 H DPE
WASHER 0.31 USS FLAT ZINC
C A P S C R 0 . 3 1 - 1 8 X 0 . 7 5 H HG R 5
WASHER 0.38 STAR EXTERNAL
C A P S C R 0 . 3 8 - 1 6 X 0 . 7 5 HH G R 5
BRKT COVE R EC CRANES
NUT 0.25-20 HH NYLOC SS
CAP SCR 0.25-20X0.75 BTNHD SS
CAP SCR 0.25-20X1.00 BTNHD SS
QTY.
1
1
8
7
4
2
2
2
5
2
2
1
1
1
3
3
1
1
1
1
1
1
NOTE: WINCH CONTROLLER(P/N 42821)
SHOWN FOR REFERENCE
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 19
Main Boom Assembly - PN 42512
MOUNTING HARDWARE WILL
BE PART OF THE WINCH PACKAGE.
USE ALL HARDWARE, EXCEPT BOLTS.
2
23
25
24
21
4
6
7
16
12
15
6
27
4
26
28
17
28
24
16
3
11
4
1
9 10
27
5
16
28
13
15
28
27
16
14
8
18
20
19
PN 42512
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
PART
42303
41641
72602
0340
C5606
43845
c1592
42508
D0790
13815PC
C6106
0069
20362
42503
11688CR
9320
42516ZP
42517ZP
5591
21170
0345
34103
D0917
0479
0521
C 0081
C6353
9843
DESCRIPTION
INNER BOOM EC3200
WINCH DC2000 WARN 63899
CORD REEL ASM 15/21 FT CRANE
WASHER 0.25 FLAT
CLAMP 0.25 BLK VINYL
CAP SCR 0.25-20X0.38 HHGR5
ZERK 1/8 NPT STRAIGHT
WEAR PAD 0.50X1.50X2.00
WASHER 0.50 FLAT GR8
PLATE ANGLE INDICATOR
NUT 0.50-13 HHGR5 NYLOC
BUSHING QSI-1618-16
BUSHING BPC16DXR08 1.00X.50
CYLINDER 3.00X13.00 EC3200
PIN 1.00X6.31D&T
PIN CAP 0.44X1.75X0.19 SS
PIN 1.00X5.13 D&T
PIN TEAR DROP 1.00X2.19
WASHER 0.31 SAE FLAT YELLOW GR8
CAP SCR 0.31-18X1.00 HHGR8
CAP SCR 0.38-16X1.50 HHGR5
RECEIVER RADIO CONTROL 6 FCTN H2
WASHER 0.25 FLAT SS
CAP SCR 0.25-20X0.75 HHGR5
WASHER 0.25 LOCK
CLAMP 0.50 BLK VINYL
WASHER 0.38 SAE FLAT YELLOW GR8
CAP SCR 0.38-16X0.75 HHGR8
Page 20 | Stellar® EC3200 Telescopic Crane Owner’s Manual
QTY.
1
1
1
3
1
2
1
1
4
2
2
2
1
1
2
6
1
1
1
1
4
1
2
3
2
1
6
6
Extension Boom Assembly - PN 42520
5
6
12
10
11
1
12
11
9
20
18
2
15
22
8
17
7
5
3
3
14
8
15
16
3
16
19
4
21
3
13
PN 42520
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
PART
42311
42507
D0790
10172
42509
42312
42978PC
42977
42317
42524ZP
0423
37824
0507
27710
C6106
0352
35105
D0178
0505
D0561
42505PC
43846
DESCRIPTION
EXT BOOM 1ST EC3200
CYLINDER 1.50X48.00
WASHER 0.50 FLAT GR8
CAP SCR 0.50-13X1.00 HHGR8 ZY
WEAR PAD 0.38X1.38X1.50
EXT BOOM 2ND EC3200
FLAT BOOM STOP EC3200
PIN HITCH 0.63X4.00
SHEAVE EC3200 5.00 DIA .22R/1.00THK
PIN 0.75X2.50 COTTER
MACHY WASHER 0.75ID 10GA
COTTER PIN .125X1.00
CAP SCR 0.50-13X4.50 HHGR5
SPRING ANTI 2 BLOCK SUMMIT
NUT 0.50-13 HHGR5 NYLOC
WASHER 0.50 USS FLAT ZINC
SWITCH LIMIT E1117-B9111-6C
WASHER #10 SAE FLAT ZINC
CAP SCR 0.50-13X3.50 HHGR5
CAP SCR 0.25-20X0.50 BTNHD SS
PLATE CRADDLE EC3200
SCREW #10-24X0.38 SH SS
QTY.
1
1
9
1
2
1
1
2
2
2
4
4
2
2
3
2
1
2
1
2
1
2
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 21
Cable & Hook Assembly - PN 42781
8
13
3
4
11
12
11
13
2
5
1
3
1
7
6
10
9
PN 42781
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
PART
42523PC
42317
0352
5468
27810
16607PC
47868
42316
9263
C6018
0375
42524ZP
37824
DESCRIPTION
PLATE SNATCH BLOCK EC3200
SHEAVE EC3200 5.00 DIA .22R/1.00THK
WASHER 0.50 USS FLAT ZINC
NUT 0.50-13 HHGR8 NYLOC
SPACER 3315 SNATCH BLOCK UHMW
SPACER 3315 SNATCH BLOCK
CAP SCR 0.50-13X2.75 HHGR8
WIRE ROPE 7/32 7X19 GAC 65FT
PIN .38X3.00 QUICK RELEASE
HOOK CRANE-3 TON
MACHY WASHER 0.75ID 14GA
PIN 0.75X2.50 COTTER
COTTER PIN .125X1.00
Page 22 | Stellar® EC3200 Telescopic Crane Owner’s Manual
QTY.
2
1
6
3
2
1
3
1
1
1
2
1
2
Radio Transmitter Assembly - PN 67894
9
1
10
2
6
7
3
4
SEE NOTE
8
11
NOTE: 1) P/N'S 25999 & 24958 ARE OPTIONAL COVERS
FOR THE SWITCHES AND TRIGGER
5
PN 67894
ITEM
1
2
3
4
5
6
7
8
9
10
11
PART
20088
51830
24385
22600
35441
16975
51831
38475
36156
29460
50932
DESCRIPTION
QTY.
CONTROL HANDLE HOUSING 4 FCTN HET
1
CONTROL HANDLE FACE PLT 5 FCTN
1
GUARD RADIO SWITCH 4 FCTN
1
SWITCH TOGGLE HET RADIO 63019300
5
BATTERY TUBE AA HETRONIC RADIO
1
SWITCH E STOP ASM HETRONIC RADIO
1
DECAL CONTROL HANDLE 5 FCTN
1
SCREW 4MMX12MM PHMS PH
4
SCREW 4MMX14MM PHMS PH
2
SCREW 3MMX35MM PHMS PH
2
CONTROL HANDLE GRIP LESS TRIGGER HET H2
1
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 23
This page intentionally left blank.
Page 24 | Stellar® EC3200 Telescopic Crane Owner’s Manual
Replacement Parts
23
Chapter 4 - Replacement Parts
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
16405
COUNTER BALANCE VALVE (EXTEND SIDE OF CYLINDERS)
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
Stellar® EC3200 Telescopic Crane Owner’s Manual | Page 25
Subject to Change without Notification.
© 2016 Stellar Industries, Inc.
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