Stellar Industries Crane Ec3200 Users Manual Telescopic

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Model eC3200
TelesCopiC Crane
owners’ Manual

installation • assembly drawings • parts

EC3200
EC
3200

42818

Stellar Industries, Inc.

Subject to Change without Notification.
© 2012 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

EC3200 Manual Revisions
Date of Revision

Section Revised

Description of Revision

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 . . . . . . . . . . . . . . . . . . . . . . . . . . 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

service@stellarindustries.com
parts@stellarindustries.com
warranty@stellarindustries.com

i

ii

EC3200 Owner’s Manual

This page intentionally left blank.

Specifications

Chapter 1 - Specifications
Model EC3200 Crane
SPECIFICATION SHEET
Crane Rating:

11,500 ft-lb (1.59 TM)

Standard Boom Length:

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:
(worm gear)

410 degree power

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

1

2

EC3200 Owner’s Manual

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

3’

.914 M

6’

1.83 M

7’

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

290 kg

410 kg

11’

2.13 M

640 lbs

905 lbs

710 kg

83.69

0’

6’

1.83 M

3.35 M

15’

0’

4.57 M

Maximum 1 - part line capacity is
1600lbs (725kg). For greater loads,
use 2 - part line.

EC3200

®

PN 42817

Installation

3

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.
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.

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
Important: When installing welder units to the service
5 (400-999), for further information, or visit
bodies, it is highly recommended that a surge
protector is installed on the chassis batteries to protect http://www.gpoaccess.gov/nara/index.html
the crane radio receiver, wiring and other electronic for the full text of Code of Federal
devices from an unexpected electrical spike or surge. Regulations.
Failure to do so could result in extensive damage to
the service body and crane electrical circuit.

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 1-3⁄4” #8 bolts and four (4) #8 7⁄8” flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the Stellar 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.
k
ruc
T
f
to
n
o
Fr

WARNING!
The use of this crane on a
body not capable of handling
the loads imposed on it may
result in serious injury or
death.

Installation

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 ASWS 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

5

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

PART
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

QTY.
4
4

NOTE:
STABILITY DECAL P/N 16881 IS PART OF THIS KIT

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

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:2-11)

ITEM

PART No.

09
08

DESCRIPTION

1
QTY

7

EC3200 Owner’s Manual

BA

EXT
OUT
INNER
UP
ROT
CCW

BA

PRESSURE SWITCH

1

BA

P
G OW
O RO ER
O PT1 UN
PT
D
2

EXT
IN
INNER
DOWN
ROT
CW

Control Kit - PN 42804

BA

BA

A

C
A

B A

B

B

B A
B

A

4
9

5
8

B

A

6
7

B

B A

A

3
10

B

12

1

1
12

2
11

2

11
2

B A

ER

W

10
3

PO

A

REPLACEMENT CONTROLLER
STELLAR P/N 42821

9
4

IT

UN

R1

7
6

2V

GR

4,5,6

Power
Unit

WINCH DOWN

MA
CO IN
NTA
CT

B A

A
B

OU
ND

87
86

A2B
SWITCH

WINCH
UP

WE

8
5

L

PO

NA

SIG

4,5,6
BA

8

7,8

87A
85
30

WINCH
DOWN

3

POWER 12 V

WINCH UP RELAY

GROUND

Winch
9

NOTE: P/N 47409 INCLUDES
HARNESS & WINCH CONTROLLER

PN 42804

12
11

36436

FUSE 250 AMP 46276

1

10

32523

FUSE HOLDER 46039

1

09

47092

WIRE HARNESS 3315 MULTI FUNCTION VB

1

08

47409

COVER SWITCH EC3200

1

07

47410

SWITCH MOM SPST 20A

1

06

9756

CONTACT M TERM SHROUD 14-16 31034

4

05

8384

CABLE SEAL 18-20 PACKARD 39000

4

04

9752

CONNECT 2 PIN SHROUD PACKARD

2

03

17771

SWITCH PUSH BUTTON 9216-03

1

02

42805

WIRE HARNESS 3315 MULTI FUNCTION VB

1

01

42976

RADIO CNTRL ASM 5 FCTN ON/OFF

1

ITEM

PART No.

DESCRIPTION

QTY

Installation

EC3200 Wiring Diagram (Two Battery)

FUSE 250 AMP

MASTER
SWITCH
250 AMP

(STELLAR SUPPLIED)

-

+

(NOT SUPPLIED)

TRUCK BATTERY

UNDERHOOD

CRANE HARNESS

CRANE
START MOTOR
SOLENOID
FUSE 250 AMP

OPT1
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
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

9

10

EC3200 Owner’s Manual

EC3200 Wiring Diagram (One Battery)

FUSE 250 AMP
(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

Note:
With a single battery configuration,
operating the crane when the truck
is not running will drain the truck battery.

GROUND

87

SAFETY BRAKE

87A
86

30

SWITCH
POWER
10 AMP

85

POWER SOURCE FOR
RADIO REMOTE

CAB OR CRANE
COMPARTMENT

Recommended Wire Sizes:
EC3200 - #2
EC4000 - #2
EC5000 - #2
EC6000 - 1/0

Installation

Valve Bank Drawing

ROT
CW

INNER
DOWN

EXT
IN

ROT
CCW

INNER
UP

EXT
OUT

11

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.

Installation

Stability Capacity Chart

STABILITY CAPACITY CHART

13

14

EC3200 Owner’s Manual

Decal Kit Placement - PN 42816

29

7
14,15

03

EC3200
EC
3200

Indicator

Angle

80 70
50

30

20

10

0

01
42818

D1196

60
40

22

25

02
27

9
24

30
26

31

28

PN 42816

*USE THESE DECALS WITH BODY PACKAGE
**THESE DECALS NOT INCLUDED WITH THE DECAL KIT

**31

18472

DECAL MANUAL OPERATION

1

15

13819

DECAL-ANGLE INDICATOR SS

1

30

42820

DECAL VB CONTROL EC3200

1

14

13820

DECAL ANGLE INDICATOR CS

1

29

35234

DECAL STELLAR MADE IN THE USA

1

*13

C1179

DECAL-ELECTROCUTION 4.5x7.5

2

28

42819

DECAL SNATCH BLOCK CAP 3 TON

1

*12

C5918

DECAL-DANGER MOVING O.R.

2

27

28256

DECAL WARNING OVERLOAD DEVICE

1

*11

C4795

DECAL-DANGER O.R.

2

26

25159

DECAL WARNING MANUAL OVERRIDES

1

*10

4190

DECAL-DANGER

1

25

24712

09

9188

DECAL-ROTATE/GREASE

1

24

15171

*08

4189

DECAL-DANGER

1

*23

C4541

DECAL-CRANE STOWING

1

07

4186

DECAL-ELECTROCUTION 2x2.75

1

22

12300

DECAL-TWO BLOCKING

1

*06

C4544

DECAL-DANGER

1

*21

4214

*05

C4540

DECAL-DANGER

1

*20

*04

C4545

DECAL-ELECTROCUTION 5x13

4

*03

42817

DECAL CAPACITY

2

2

02

15172

DECAL ASME/ANSI B30.22/B30.5

01

42818

DECAL IDENTIFICATION

ITEM

PART No.

DESCRIPTION

1

QTY

DECAL CAUTION STOW HOOK
DECAL GREASE WORM DRIVE BEARINGS

1
1

DECAL-SERVICE

1

C0568

DECAL-DIESEL

2

*19

12452

DECAL MANUAL EXT

1

*18

C5911

DECAL-STELLAR 2x4.5

3

*17

C5910

DECAL-STELLAR 4x9.5

1

*16

12451

DECAL HOISTING PERSONNEL

ITEM

PART No.

DESCRIPTION

1

QTY

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
42 795
D0790
D1345
D1810
C22 5 6
56589

DESCRIPTION
BASE EC3200
BEARING SWING DRIVE 170-00058-1
MOTOR 80CC EC3200 YMPH-80-H2(R)-K-S-B
GASKET MOTOR 008-10056-1
C AP SCR 0.50-13 X1.25 SH
CAP SCR 0.50-13X3.50 HHGR8
STOP SLIDIN G E C3200
WASHE R 0.50 FLAT GR8
FTG CPRSN 0.12NPT/0.25 TUBE
TBE AIR SAEJ844 TYPE A .25 (RM)
FTG C OUP L ER PIP E 0.13
ZERK 1/8 NPT STRAIGHT LONG THREAD

QTY.
1
1
1
1 ref
2
13
1
13
2
1
1
1

15

16

EC3200 Owner’s Manual

Base Assembly (Narrow Version) - PN 44613
2
4

11 12
7

10

3

5

8
6

PN 44613
ITEM
1
2
3
4
5
6
7
8
9
10
11
12

PART
44614
41640
62487
21151
D1307
30750
4 2795
D0790
D1345
D1810
C2 25 6
56589

DESCRIPTION
QTY.
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
STO P SLID ING E C3 200
1
WASHER 0. 50 FLAT GR8
13
FTG CPRSN 0.12NPT/0.25 TUBE
2
TBE AIR SAEJ844 TYPE A .25 (RM)
1
F TG COUP LER PIPE 0 .13
1
ZERK 1/8 NPT STRAIGHT LONG THREAD
1

9

1

Assembly Drawings

Mast Assembly - PN 42787
14
16

5
10

9

22

15

1

*
9
22

10
*

20

9

21

6

4

15
11

7

16
13

12

8

3
3
18

P/N 42798 MUST
GO IN THIS MAST
MOUNTING HOLE
2
19
NOTE: WINCH CONTROLLER(P/N 42821)
SHOWN FOR REFERENCE

PN 42787
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
20
21
22

PART
42318
42513
42788
42789
20362
0345
0346
0479
D0917
0478
0340
43579
47411
44475
0343
0420
5870
0492
51896
30659
C6021

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
CAP SCR 0.38-16X1.50 HHGR5
WASHER 0.38 FLAT
CAP SCR 0.25-20X0.75 HHGR5
WASHER 0.25 FLAT SS
CAP SCR 0.25-20X0.50 HHGR5
WASHER 0.25 FLAT
CAP SCR 0.44-14X2.75 MOD EC3200
BRKT OVERRIDE BUTTON EC3200
COVER EC3200 HDPE
WASHER 0.31 USS FLAT ZINC
CAP SCR 0.31-18X0.75 HHGR5
WASHER 0.38 STAR EXTERNAL
CAP SCR 0.38-16X0.75 HHGR5
BRKT COVER EC CRANES
NUT 0.25-20 HH NYLOC SS
CAP SCR 0.25-20X0.75 BTNHD SS

QTY.
1
1
8
7
4
2
2
2
6
3
2
1
1
1
3
3
1
1
1
1
2

17

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
23

25

24

21

6

7

16

12

15

4
3

27

5

26

28
17

28

24

16

11
4

27

1

9 10

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
23
24
25
26
27
28

PART
42303
41641
11 5 44
0340
C5606
43845
c1 5 9 2
42508
D0790
13815PC
C6106
0069
20362
42503
42515ZP
9320
42516ZP
42517ZP
5591
21170
0345
D0 9 1 7
0479
05 2 1
C0 081
C6353
9843

DESCRIPTION
INNER BOOM EC3200
WINCH DC2000 WARN 63899
C O RD RE EL 6 62 0
WASHER 0.25 FLAT
CL AMP 0 .25 BLK VINY L
CAP SCR 0.25-20X0.38 HHGR5
Z E R K 1 / 8 N P T S T R A I GH T
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 IGUS GFI-1618-08
C Y L I N DE R 3 . 0 0 X 1 3 . 0 0
PIN 1.00X6.38 D&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
WA S H E R 0 .2 5 F L A T SS
CAP SCR 0.25-20X0.75 HHGR5
W A S H E R 0 .2 5 L O C K
CL AM P 0.5 0 BLK VINYL
WASHER 0.38 SAE FLAT YELLOW GR8
CAP SCR 0.38-16X0.75 HHGR8

QTY.
1
1
1
3
1
2
1
1
4
2
2
2
1
1
2
6
1
1
1
1
4
2
3
2
1
6
6

Assembly Drawings

19

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
I T EM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

PART
42311
4 2 50 7
D0790
10172
42509
42312
42978PC
4 29 7 7
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
P I N HI T C H 0 . 63 X 4 . 0 0
SHEAVE EC3200 5.00 DIA .22R/1.00THK
PIN 0.75X2.50 COTTER
MACHY WASHER 0.75ID 10GA
C O T T E R P I N . 1 25 X 1 . 0 0
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

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
4 2 52 4 Z P
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
PI N 0 . 7 5 X 2 . 5 0 C O TT E R
COTTER PIN .125X1.00

QTY.
2
1
6
3
2
1
3
1
1
1
2
1
2

Assembly Drawings

Radio Transmitter Assembly

1

2

7
8
3

5

4

NOTE: 1) P/N'S 25999 & 24958 ARE OPTIONAL COVERS
FOR THE SWITCHES AND TRIGGER

6

ITEM
1
2
3
4
5
6
7
8

PART
20088
51830
24385
50932
22600
35441
16975
51831

DESCRIPTION
CONTROL HANDLE HOUSING 4 FCTN HET
CONTROL HANDLE FACE PLT 5 FCTN
GUARD RADIO SWITCH 4 FCTN
CONTROL HANDLE GRIP LESS TRIGGER HET H2
SWITCH TOGGLE HET RADIO 63019300
BATTERY TUBE AA HETRONIC RADIO
SWITCH E STOP ASM HETRONIC RADIO
DECAL CONTROL HANDLE 5 FCTN

QTY.
1
1
1
1
5
1
1
1

21

22

EC3200 Owner’s Manual

This page intentionally left blank.

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 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

23

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



---

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