Specifications

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NOTICE

9188

Damage may occur if worm gear runs

dry. Keep worm gear lubricated with

Stellar

grease (PN 4460).

WARNING

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

oom Exte

Boom

Down

3’

.914 M

0’

6’

1.83 M

7’

2.13 M

11’

3.35 M

15’

4.57 M

0’

3’

.914 M

6’

1.83 M

9’

2.74 M

12’

3.66 M

15’

4.57 M

16’2”

4.92 M

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 42817

Maximum 1 - part line capacity is

1600lbs (725kg). For greater loads,

use 2 - part line.

15º

30º

45º

60º

75º

80º

410 kg

905 lbs

1490 lbs

3200 lbs

1710 lbs

775 kg

3200 lbs

1450 kg

2415 lbs

862 kg

1095 kg

1900 lbs

3200 lbs

1450 kg

675 kg

1372 kg

1450 kg

3200 lbs

1450 kg

3200 lbs

973 kg

2145 lbs

703 KG

1550 lbs

3200 lbs

1450 kg

3025 lbs

890 lbs

290 kg

640 lbs

550 kg

353 kg

780 lbs

492 kg

1085 lbs

404 kg

1215 lbs

1090 lbs

495 kg

83.69

710 kg

1565 lbs

ECEC32003200

13820

Angle Indicator

GREASE every 3 months.

Apply 3 ‘pumps’ of EP2

(extreme pressure grease)

then rotate crane fully.

15171

NOTICE

12924

This crane has been designed and

manufactured to ASME/ANSI B30.22

and/or B30.5 specifications.

WARNING

24712

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.

Misuse Hazard

WARNING

2825

Overload Hazard

Bypassing the overload condition

by tampering

with the overload

device can result i

n death or

serious inj

ury.

Never tamper wi

th overload

device.

35234

Proudly Designed

and Manufactured

in the USA by

ECEC32003200

4281842818

3 Tons

(2,721 KG)

LOAD BLOCK RATING

SNATCH BLOCK WEIGHT: 15 LBS (6.80 KG)

42819

12452

WARNING

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.

Free Falling Boom Hazard

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.

C1179

12451

WARNING

Hoisting personnel on boom,

hook, load, or loadline can result

in death or serious injury.

• Never use crane to hoist

personnel.

• Never ride the boom, hook,

load, or any device attached

to crane boom or load line.

Fall Hazard

Installation • Assembly Drawings • Parts

TELESCOPIC CRANE

OWNERS’ MANUAL

MODEL EC3200

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Last Revision: 07/30/14

Subject to Change without Notification.

Summary of content (28 pages)

PAGE 1
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).
PAGE 2
EC3200 Manual Revisions Date of Revision March 25th, 2013 Sections Revised Chapter 2: Installation Chapter 4: Replacement Parts Description of Revision Updated Control Kit, Wiring Diagrams, Decal Kits, and Replacement Parts to reflect engineering changes.
PAGE 3
Table of Contents 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 . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 4
ii EC3200 Owner’s Manual About this manual 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.
PAGE 5
Chapter 1 - Specifications Crane Rating: Specifications Model EC3200 Crane SPECIFICATION SHEET Standard Boom Length: Boom Extension: Maximum Horizontal Reach: Maximum Vertical Lift: (from crane base) 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) Boom Elevation: -5 to +80 degrees Mounting Space Required: 18” x 15” (45.7 x 38.
PAGE 6
2 EC3200 Owner’s Manual Capacity Chart - Decal PN 42817 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 4.57 M 1090 lbs 1450 kg 495 kg 2145 lbs 12’ 3.66 M 973 kg 3200 lbs 1450 kg 80º 3200 lbs 1450 kg 45º 9’ 2.74 M 3200 lbs 60º 404 kg 675 kg 1450 kg 75º 890 lbs 1490 lbs 1215 lbs 2415 lbs 550 kg 1095 kg 353 kg 1900 lbs 862 kg 30º 1710 lbs 15º 0’ 3’ .
PAGE 7
Chapter 2 - Installation Installation 3 General Installation 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.
PAGE 8
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).
PAGE 9
Installation 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.
PAGE 10
6 EC3200 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 P ART 18041 51377 D E SC R I P T I O N WASHER 0.88 SAE FLAT YELLOW GR9 CAP SCR 0.88-9X2.00 HHGR9 Q T Y.
PAGE 11
Installation Hydraulic Kit - PN 42799 12 10 11 ROTATION CCW 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
PAGE 12
EC3200 Owner’s Manual Control Kit - PN 42804 Power Unit POWER GROUND OPT1 OPT2 8 Winch PN 42804 17771 SWITCH PUSH BUTTON 9216-03 NOTE: P/N 47092 INCLUDES HARNESS & WINCH CONTROLLER
PAGE 13
EC3200 Wiring Diagram (Two Battery) FUSE 250 AMP PN 36436 Installation 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 87 SAFETY BRAKE 87A 86 30 SWITCH POWER 10 A
PAGE 14
10 EC3200 Owner’s Manual 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.
PAGE 15
Installation Valve Bank Drawing ROT CW INNER DOWN EXT IN ROT CCW INNER UP EXT OUT 11
PAGE 16
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.
PAGE 17
Stability Capacity Chart STABILITY CAPACITY CHART Installation 13
PAGE 18
EC3200 Owner’s Manual Decal Kit Placement - PN 42816 14 3200 lbs 13 Reach in Feet Feet/Meters t/Meters Capacity Pounds/Kilograms Capacit ty in Pounds/ Kilograms 3025 lbs 1450 1450 kg g 4 4.92 .92 M 1550 lbs 495 495 kg g 3.66 M 3.66 973 973 kg 890 lbs 1490 lbs 404 404 kg 675 kg g 675 9’ 1450 1450 kg g 45º 550 5 50 kg 1 095 kg g 1095 780 lbs 353 353 kg 1900 lbs 862 8 62 kg 30º 775 775 kg g 290 290 kg 0’ 15’’ 15 4 4.57 .
PAGE 19
Assembly Drawings 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 42 7 95 D0 7 9 0 D1345 D1810 C22 5 6 56589 DESC RIPT ION BA SE E C 3 2 0 0 BEARING SWING DRIVE 170-00058-1 MOTOR 80CC EC3200 YMPH-80-H2(R)-K-S-B GASKET MOTOR 008-10056-1 C A P S C R 0 .5 0-13 X 1 .2 5 S H CAP SCR 0.50-13X3.50 HHGR8 S TOP S L I DIN G E C 3 200 WASHER 0.50 FLAT GR8 FTG CPRSN 0.12NPT/0.
PAGE 20
16 EC3200 Owner’s Manual Base Assembly (Narrow Version) - PN 44613 2 4 11 12 7 10 3 5 8 6 PN 44613 I TE M 1 2 3 4 5 6 7 8 9 10 11 12 PART 44614 41640 62487 21151 D1307 30750 4 2 795 D0 7 9 0 D1345 D1810 C225 6 56589 D E SCRI P T I ON Q T Y. BASE EC3200 NARROW 1 BEARING SWING DRIVE 170-00058-1 1 MOTOR 80CC EC3200 YMPH-80-H2(R)-K-S-B 1 GASKET MOTOR 008-10056-1 1 ref CAP SCR 0.50-13X1.25 SH 2 CAP SCR 0.50-13X3.50 HHGR8 13 S T OP S L ID I N G E C 3 2 00 1 WASHER 0.50 FLAT GR8 13 FTG CPRSN 0.12NPT/0.
PAGE 21
Assembly Drawings 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 PA RT 42318 42513 42788 42789 2 0 3 62 0345 0346 047 9 D0 9 1 7 0478 0340 43579 47411 44475 0343 0420 58 70 0492 51896 30659 C6021 C6022 D E SCR IPTION MAST EC3200 POWER UNIT 12V EC3200 WASHER 0.44 SAE FLAT YELLOW GR8 CAP SCR 0.44-14X2.
PAGE 22
18 EC3200 Owner’s Manual Main Boom Assembly - PN 42512 MOUNTING HARDWARE WILL BE PART OF THE WINCH PACKAGE. USE ALL HARDWARE, EXCEPT BOLTS.
PAGE 23
Assembly Drawings Extension Boom Assembly - PN 42520 19 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 PA R T 42311 42 507 D0790 10172 42509 42312 42978PC 42977 42317 42524ZP 0423 37824 0507 27710 C6106 0352 35105 D0178 0505 D0561 42505PC 43846 D E S C RI P T I O N EXT BOOM 1ST EC3200 CY LINDER 1 . 50X48. 00 WASHER 0.50 FLAT GR8 CAP SCR 0.50-13X1.00 HHGR8 ZY WEAR PAD 0.38X1.38X1.
PAGE 24
20 EC3200 Owner’s Manual 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 DE SC RI PTION 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.
PAGE 25
Assembly Drawings 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 I TEM 1 2 3 4 5 6 7 8 9 10 11 PART 20088 51830 24385 22600 35441 16975 51831 38475 36156 29460 50932 21 DESCRIPTI ON Q TY.
PAGE 26
22 EC3200 Owner’s Manual This page intentionally left blank.
PAGE 27
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 43892 SEAL KIT - MAIN LIFT CYLINDER 43893
PAGE 28
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.