Download Crane EE-6353 Specifications
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MODEL EC6000 TELESCOPIC CRANE OWNERS’ MANUAL Installation • Assembly Drawings • Parts 2720 kg Reach in Feet/Meters Capacity in Pounds/Kilograms 6000 lbs 2720 kg 22'10" 6.96m Angle Indicator 3600 lbs 1630 kg 2720 kg 6000 lbs 18' 5.49m 2545 lbs 2720 kg 1150 kg 4715 lbs 2135 kg 2080 lbs 1510 kg 6000 lbs 940 kg 2720 kg 12' 3.66m 6000 lbs 75º 2720 kg 60º 2730 lbs 4845 lbs 1235 kg 2195 kg 45º DANGER 845 kg 2450 lbs 6' 1.83m 1110 kg 3560 lbs 1610 kg Electrocution Hazard 3' .914 m 3450 lbs 1560 kg 3' .914 m 6' 1.83m 9' 2.74m 11' 3.35m 2375 lbs 1075 kg 16' 4.87m 1810 lbs 820 kg Death or serious injury will result from inadequate clearance if crane, load, or vehicle becomes electrically charged. 0' 21' 6.40m Maximum 1 - part line capacity is 3000 lbs (1360 kg). For greater loads, use 2 - part line. EC6000 EC 6000 • Maintain safe clearance from high voltage power sources. 50 15º 0' Weight of load handling devices are part of the load lifted and must be deducted from the capacity. 60 1795 kg 35234 9' 2.74m 1870 lbs 3965 lbs 30º Proudly Designed and Manufactured in the USA by 80 70 15' 4.57m 3340 lbs 2720 kg 40 30 20 • Never approach vehicle or load if equipment is near a high voltage power source. 10 0 13820 6000 lbs 6000 lbs 6000 lbs 80º C1179 PN 53525 EC6000 EC 6000 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 WARNING Fall Hazard • Never use crane to hoist personnel. • Never ride the boom, hook, load, or any device attached to crane boom or load line. 12451 WARNING Winch Boom Down Pull g Boom Hoisting personnel on boom, hook, load, or loadline can result in death or serious injury. 53524 Extendin 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 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 G WARNIN Hazard Overload condition the overload Bypassing with the overload or by tampering result in death device can serious injury. with overload Never tamper device. NOTICE Damage may occur if worm gear runs dry. Keep worm gear lubricated with Stellar® grease (PN 4460). 9188 28256 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 Stellar Industries, Inc. Subject to Change without Notification. © 2013 Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 www.stellarindustries.com Last Revision: 07/24/13 EC6000 Manual Revisions Date of Revision March 25th, 2013 Sections Revised Chapter 2: Installation Description of Revision Updated Decal Kit Table of Contents Table of Contents Chapter 1 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1 Capacity Chart - Decal PN 53525 . . . . . . . . . . . . . . . . .2 Chapter 2 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Flatbed Body Reinforcement . . . . . . . . . . . . . . . . . . . . .5 EC6000 Mounting Detail . . . . . . . . . . . . . . . . . . . . . . . . .5 EC6000 Installation Drawing . . . . . . . . . . . . . . . . . . . . . .6 Hydraulic Kit - PN 54857 . . . . . . . . . . . . . . . . . . . . . . . . . .7 Control Kit - PN 54859 . . . . . . . . . . . . . . . . . . . . . . . . . . .8 EC6000 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .9 Valve Bank Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Stability Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Stability Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . .12 Decal Kit Placement - PN 53523 . . . . . . . . . . . . . . . . . .13 Chapter 3 - Assembly Drawings . . . . . . . . . . . . . . . . . . . .15 Base Assembly - PN 50364 . . . . . . . . . . . . . . . . . . . . . . .15 Mast Assembly - PN 53379 . . . . . . . . . . . . . . . . . . . . . . .16 Main Boom Assembly - PN 53223 . . . . . . . . . . . . . . . . .17 Extension Boom Assembly - PN 53264 . . . . . . . . . . . . .18 Cable & Hook Assembly - PN 50492 . . . . . . . . . . . . . . .19 Radio Transmitter Assembly . . . . . . . . . . . . . . . . . . . . . .20 Chapter 4 - Replacement Parts . . . . . . . . . . . . . . . . . . . . .21 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] i ii EC6000 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. A WARNING signal word indicates a hazardous situation which, if not avoided, could result in death or serious injury. A DANGER signal word indicates a hazardous situation which, if not avoided, will result in death or serious injury. Information contained within this manual does not cover operation, maintenance, or troubleshooting. Please refer to the General EC Series 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. 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]. Chapter 1 - Specifications Crane Rating: Specifications Model EC6000 Crane SPECIFICATION SHEET Standard Boom Length: Boom Extension: Maximum Horizontal Reach: Maximum Vertical Lift: (from crane base) 38,000 ft-lb (5.25 TM) 11’ (3.35 m) from CL of Crane 1st stage: Hydraulic 60" (152.4 cm) 2nd stage: Manual 60" (152.4 cm) 21’ (6.40 m) from CL of Crane 22’ 10” (6.96 m) Boom Elevation: -5 to +80 degrees Mounting Space Required: 20” x 21” (50.8 x 53.3 cm) Controls: Radio control standard for all functions. Stowed Height: (crane only) Approximate Crane Weight: Winch Specifications Rope Length: Rope Diameter: Line pull speed: Max. single part line: Max. double part line: Rotation: (worm gear) Lifting Capacities: Power Supply Required: *Subject to change without notification 34.41” (87.40 cm) 1600 lbs (725 kg) 90 ft (27.4m) 5/16" (.79 cm) 16 ft/min (4.88 m/min) 3000 lbs (1360 kg) 6000 lbs (2720 kg) 400 degree power 6000 lbs @ 6’4” (2720 kg @ 1.9 m) 2375 lbs @ 16’ (1075 kg @ 4.87 m) 1810 lbs @ 21’ (820 kg @ 6.4 m) 12 volt power unit (2.0 gpm @ 2900 psi) (7.57 lpm @ 200 bar) 1 2 EC6000 Owner’s Manual Capacity Chart - Decal PN 53525 6000 lbs 2720 kg Reach in Feet/Meters Capacity in Pounds/Kilograms 6000 lbs 2720 kg 22'10" 6.96m 3600 lbs 1630 kg 18' 5.49m 6000 lbs 2720 kg 6000 lbs 2545 lbs 2720 kg 1150 kg 4715 lbs 2135 kg 15' 4.57m 3340 lbs 6000 lbs 2720 kg 80º 2080 lbs 1510 kg 6000 lbs 12' 3.66m 940 kg 2720 kg 6000 lbs 75º 2720 kg 60º 2730 lbs 4845 lbs 1235 kg 2195 kg 45º 1870 lbs 3965 lbs 1795 kg 9' 2.74m 845 kg 2450 lbs 30º 6' 1.83m 1110 kg 3560 lbs 15º 1610 kg 3' .914 m 3450 lbs 1560 kg 0' 3' .914 m 6' 1.83m 9' 2.74m Weight of load handling devices are part of the load lifted and must be deducted from the capacity. 11' 3.35m 2375 lbs 1075 kg 16' 4.87m 1810 lbs 820 kg 0' 21' 6.40m Maximum 1 - part line capacity is 3000 lbs (1360 kg). For greater loads, use 2 - part line. EC6000 EC 6000 PN 53525 Chapter 2 - Installation Installation 3 General Installation This chapter is designed to serve as a general guide for the installation of a Stellar EC6000 Crane on a Stellar Service Body. Each installation is considered unique so certain portions of this chapter may or may not apply to your direct application. If a question should arise during the installation process, please contact Stellar Customer Service at (800) 321 3741. This crane is designed for use with a Stellar Service Body installed on a vehicle that meets the minimum chassis requirements of the crane. It is the installer’s responsibility to assure that the crane is mounted on a platform that will support the maximum crane rating of this crane. Do not install this crane on a body not capable of handling the loads imposed on it. Failure to do so may result in serious injury or death. When installing welder units to the service bodies, it is highly recommended that a surge protector is installed on the chassis batteries to protect the crane radio receiver, wiring and other electronic devices from an unexpected electrical spike or surge. Failure to do so could result in extensive damage to the service body and crane electrical circuit. Installation 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. 4 EC6000 Owner’s Manual Installation Overview 1. Determine that the mounting location for the EC6000 crane is at least 18” x 20” (45.7 x 50.8 cm). 2. Use the detail below to drill 1.06” 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 EC6000 weighs approximately 1600 lbs (725 kg). Note: cranes are shipped with rotation positioned at 200 degrees of 400 degree system. 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 lifting rings on the Stellar EC6000. 5. Use four (4) 1” x 3” Grade 8 bolts and four (4) 1” Grade 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 EC6000 just above the crane compartment and start the bolts. Have someone assist in leveling the crane. Note: the rotation motor should be to the door side of crane compartment and the boom should be extended back over the rear bumper. 9. Secure the crane using the mounting hardware provided. Note: longer or shorter bolts may be required – recommended thread engagement into crane base is 1.75” – use grade 8, zinc plated bolts only. 10. Torque the bolts to 680 ft-lbs. 11. Remove supporting crane. 12. Hook-up hydraulics and electrical using the schematics provided in this chapter. Note: If questions should arise during any portion of this installation, please contact Stellar Customer Service at (800) 321-3741. Installation EC6000 Mounting Detail FRONT Motor Ø1.063 4 Places 14.75 Ø6.00 7.38 7.38 14.75 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 5 6 EC6000 Owner’s Manual EC6000 Installation Drawing 4 3 2 ITEM 2 3 4 PART 5199 6538 53376 NOTICE! Route hoses correctly to ensure they do not become pinched or crushed during installation. DESCRIPTION CAP SCR 1.00X8X3.00 HHGR8 ZY WASHER 1.00 SAE FLAT YELLOW GR8 CRANE EC6000 QTY. 4 4 1 Hydraulic Kit - PN 54857 PN 54857 Installation 7 EC6000 Owner’s Manual Control Kit - PN 54859 Replacement Controller Stellar PN 54862 POWER GROUND OPT1 OPT2 8 PN 54859 NOTE: P/N 54860 INCLUDES HARNESS & WINCH CONTROLLER Installation EC6000 Wiring Diagram FUSE 300 AMP PN 54918 MASTER SWITCH 250 AMP Holder: PN 32523 (STELLAR SUPPLIED) - + (NOT SUPPLIED) TRUCK BATTERY UNDERHOOD CRANE HARNESS CRANE START MOTOR SOLENOID FUSE 300 AMP PN 54918 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 AMP 85 Note: operating the crane without the truck engine running could allow the truck battery to be discharged below levels required for starter cranking power. POWER SOURCE FOR RADIO REMOTE CAB OR CRANE COMPARTMENT Minimum Wire Sizes: EC3200 - #2 EC4000 - #2 EC5000 - #2 EC6000 - 1/0 9 10 EC6000 Owner’s Manual Valve Bank Drawing ROT CW INNER DOWN EXT IN ROT CCW INNER UP EXT OUT Stability Procedure Installation 11 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. EC6000 Stability Data Max Horizontal Reach: 252” (From the center of rotation to boom tip) Stability Test Weight: 2135 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. 12 EC6000 Owner’s Manual Stability Capacity Chart STABILITY CAPACITY CHART For a decal version of this capacity chart, please contact Stellar Customer Service at (800) 321-3741 Decal Placement Kit - PN 53523 13 2720 kg 2720 22'10" 6.96m 6.96m 3600 lb llbs Angle Ind Indicator icator 1630 kg 18' 5.49m 5.49m 6000 lb llbs 2545 5 llbs lbs 2720 27 720 20 kg 1150 11 150 50 kg 4715 lb llbss 2135 2135 kg 15' 4.57m 4.57m 3340 lb llbss 6000 llbs b 2720 kg 2720 2080 0 lb llbss 1510 1510 kg 6000 lb llbs 80º 12' 3.66m 3.66m 940 9 40 kg 2720 27 20 kg 6000 0 lb llbss 75º Proudly Pr oudlyy Designed Designed and Manufactured Manufactured in the USA by by 2720 kg 60º 2730 lb llbss lb 4845 lbs 1235 12 35 kg 2195 21 95 kg 45º 845 845 kg 2450 llbs b 6' 1.83m 1.83m 1110 1110 kg 3560 lb llbss 3' 914 m ..914 3450 0 lb llbss 1560 15 56 60 kg 0' 3' 914 m ..914 6' 1.83m 1.83m 35 35234 234 DANGER 1610 1 10 kg 9' 2.74m 2.74m e Weight We igh ght off lo load ad ha handling ndlin ing g de devices vice ces ar are p art o e lo ad lifted an d mu st b e part off th the load and must be d educted fr om m the th t e capacity. capacity. deducted from 11' 3.35m 3.35m 2375 5 lb llbss 10 075 75 kg 1075 16' 4.87m 4.87m 1810 llbs bs 20 kg 820 0' 21' 6.40m 6.40m Ma Maximum ximu 1 - p part art lin line e cap capacity pac acity is 3000 kg). For greater 3 000 lbs bs ((1360 1360 60 k g). F or g reater loads, lloa oads, u se 2 - p art lin li e. use part line. EEC6000 C6000 00 0 Electrocution Electrocution Hazard ous injur y will rresult esult ffrom rom De Death ath orr seri serious injury in adequate clearance if crane, loa d, inadequate load, or vehicle becomes electr ically electrically char ged. charged. • Main tain ssafe afe clearance clearance ffrom rom hi igh gh Maintain high voltage power sou rces. sources. • Never ap proach veh icle or load if approach vehicle equ ipment nt is near a high volt tage age equipment voltage pow er source. power PN 5 53525 3525 C1179 C11 1179 18 50 15º 15 600 1795 1795 kg 9' 2.74m 2.74m 1870 lb llbss 3965 lbs lbs 30º 80 80 70 17 40 30 20 10 04 16 06 Reach in FFeet/Meters eet/Met e t/Met eters ers Capacity Pounds/Kilograms Capacit y in Pou nds/K s/Kilogram ilograms 6000 lb llbs 2720 kg 2720 kg 2720 0 13820 13820 6000 llbs b 6000 lb llbs 13 Installation EEC6000 C6000 00 0 02 WARNING WARNING Free Fr F ee Falling Falling Bo Boom oom Ha Hazard aza ard a Free boom Fr ee ffalling alling manual bo om extensions ex tensions can can result result in death death or erious injury. sserious injury. • Properly Properly install in n tall retention ret ntiion pins prior prior to to operation. operattion. ion. • Do Do nott stand stand in front front of extension when ex tension w hen rremoving emoving rretention et ntion ion pin. • Do Do nott allow extensions extensions to to free free fall. fall. 1 12452 2452 WARNING W ARNING nch Win Winch W WARNING ARNING Boom B oom Down Down Pu Pull g dinn xten E Extending om Boom B Fall F all H a Hazard aza a ard rd Hoist Hoisting stin in ng p personnel on boom, ersonnel o nb oom, hook, orr loadl loadline hook, load, o line ine ccan an rresult esult death injury. in deat th h or sserious errious ious injur y. Misu Misuse se H Hazard azard • Never use hoist se crane crane tto o ho ist personnel. personnel. 53524 10 NOTICE This crane has been desi designed igned gned and manufactured to ASME/ANSI B30.22 and/or B30.5 . specificati ions. ons. specifications. 129 12924 24 T Two wo blo blocking cking g tthe he cr crane ane can result esult iin nd death eat ath or sserious erio ous in njur jury. injury. boom,, hoo hook, he boom k, • Never ride ide tthe load, device attached load, or any devic ea att ached tto o ccrane rane boom or load line. he Ne ver a llow tthe he h ook blo ock tto o con tact tthe Never allow hook block contact bo om o m ttip ip by ho isting u p, ext endin ng g or boom hoisting up, extending lo wering wer ing the the boo om o m. lowering boom. 12451 12300 1 300 W WARNING ARNING Mi Misuse suse H Hazard azard Do Do not not use usse stow stow hook hook for fo f r any any lifting lliftiting g applications. appllication ns. hook U siing the the stow sttow hook hook for for anything an nyth hing other other than than hook Using stowag ge ccan an re esu sult iin nd ea ath th o eri rious in nj ry. stowage result death orr se serious injury. 2 24712 4712 03 08 G ARNING W WARNIN load Hazard Over Overload ion condition conditio overload he overload ng tthe rload ypassin overl B Bypassing he overload the h tth wit with ampering lt in b byy ttampering death or r sul in death can result vice can de device injury. serious injury. serious oad overrlo th overload with tamp r with Neverr tamper Never 256 28256 28 device. Crane Compartment Inner Door Suggested Placement 15171 15171 07 21 17 FOR F OR R SERVICE SERVIC CE ON ON THIS THIS EQUIPMENT EQUIPMENT CO NTACT: CONTACT: ST ELLAR INDUSTRIES, INDUSTR RIE IES, INC. INC. STELLAR 190 S ST ATE S ST REET, GARN ER, IIA A 50438 50438 190 STATE STREET, GARNER, 641-923-3 3741 641-923-3741 800-321-3 3741 800-321-3741 lbss 6000 lb 20 kg k 2720 2720 kg 22'10" 22'10" 6.96m 6.96m 3600 lb lbs 1630 kg 2720 kg 6000 lb lbs 18' 5.49m 5.49m 2545 lbs lb 2720 kg kg 1150 kg kg 4715 lbs lbs 2135 kg kg 15' 4.57m 4.57m 3340 lb lbss 6000 lb lbs 2720 0 kg 2080 lb lbss 1510 10 kg k 6000 lbs lb 80º 22 14 Rea Reach ch in Feet/Meters Feet/ eet/Meterrs Capacity Pounds/Kilograms Cap C acit city y in P ounds/Kilograms 6000 lb lbs lbss 6000 lb 421 4 4214 WARNING WARNING 6000 lbs lbs 2730 lb 4845 lbs lb 1235 kg kg 2195 kg 45º 1795 95 kg k 3T Tons ons 9' 2.74m 2.74m (2,721 1 KG) 1870 lb lbss 3965 lb 3 lbss 845 kg 2450 lb lbs 30º 6' 1.83m 1.83m 1110 110 kg k SNATCH SNATCH BLOCK BLOCK WEIGHT: WEIGHT: 15 15 LBS LBS (6.80 (6.80 KG) KG) 42819 4 2819 28 19 3560 lb lbs 15º 1610 kg kg 3' 914 m ..914 3450 lbs lb kg 1560 kg 0' 3' 914 m ..914 6' 1.83m 1.83m 9' 2.74m 2.74m vices a Weight W eig ight of loa load ad dh handling andling de devices are re pa he lo ad llifted ifted a ust be part rt of tthe load and nd m must de ducted ffrom rom om th the c ap pacity. deducted capacity. 6 68024 8024 LOAD BLOCK RATING RA ATI TING 2720 20 kg kg 60º R Read ead a and nd u un understand nde stand all all a m anuals and and safety safetty signs signs manuals b efo fore operating operratiting go serrviici c ng before orr servicing tthis his e quip pmen nt. equipment. F ail re to a to follow follow operating, opera ratiting g, Failure m ainten a nance, or or safety safetty maintenance, iinstructions nstru n ructions can ca an result resultt in in d ea ath ho serio s iinjury. nj ry. death orr serious 12' 3.66m 3.66m 940 0 kg kg 2720 kg kg 75º Un Untrained train ne ed O Operator pe erator H Hazard aza a za ard 11' 3.35m 3.35m 2375 lb lbss kg 1075 kg 16' 4.87m 4.87m 1810 lb lbs kg 820 kg 0' 21' 6.40m 6.40m Maximum axi um um 1 - part part line line ne capacity capacity is 3000 (1360 kg). For greater loads, 30 00 lbs (136 0k g). F orr gr reater loa oads, use se 2 - p art lin ine. part line. EEC6000 C6000 00 0 P PN N 53525 535 5 3525 DANGER E Electrocution lectrocution H Hazard azard a will D Death ea ath h or or serious serrious injury injurry will result ffrom rom touching touchin ng te eth thered result tethered rremote em mote iiff ccrane, rane, lload, oad, o eh hicle orr vvehicle becomes s el ectrrica allly ccharged. harged. becomes electrically Maintain n safe safe fe clearance clea ara ran nce from from Maintain h gh hi h vo lta age p owe err so rces. high voltage power sources. 4 4186 186 WARNING WARNING Overload O e load H er Hazard azard Do not D not exceed n exceed e equipment qui men nt llo load ad ch charts arts a and nd rra ratings. atiings. F aillurre to to follow follow e quipmen nt lload oad ch arts and and rratings atting a gs Failure equipment charts c an re sultt iin nd ea ath or or se rious iinjury. ri njurryy. can result death serious 4 4189 189 20 19 16 05 15 80 An Angle gle Indicator Indica di tor 53524 5 138 13819 19 EC6000 EC 6000 00 00 00 0 70 P2 Apply App ply 3 ‘pumps’ of E EP2 (ext reme pressure grease) (extreme then rot ate crane ful ly. rotate fully. 60 GREASE every 3 months. PUSH P ULL PUSH PULL 50 NOTICE occur if worm gear runs Damage may occur dry. Keep Ke eep worm gear lubri cated with dry. lubricated Stel ellar ar® grease (PN 4460).. Stellar 9188 918 188 01 12 0 10 20 3300 EXTENSION EXTENSION IN 40 OUT MAIN DOWN UP ROTATION R OTATION N CW CCW CCW 42820 11 WARNING WARNING Movement Movement Hazard Hazard he valv e Af After ter sstowing towing tthe he ccrane, rane, a always lways rreturn etturn tthe valve osition. ba nk m anual ove rrides tto o tthe he n eut uttral p bank manual overrides neutral position. he m anual over rides tto o th en eutral F ailure tto o rreturn etur urn tthe Failure manual overrides the neutral po sitition ion ccan an rresult esult iin nd eath o eriou ious inju ry. position death orr se serious injury. 25 25159 159 HO HOLD LD B BUTTON UTT N T TO O OPERATE CRANE RANE OPERA ATE EC MANUALLY. M ANUA ALL LLY Y. 18472 09 Kit PN 53523 (Rev C - 11/22/13) For use with Crane Package ITEM 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 PN 9188 12300 12451 12452 13819 13820 15171 15172 18472 24712 25159 28256 35234 42819 42820 53524 53525 C1179 DESCRIPTION ROTATE/GREASE DECAL RO TA ATE/GREASE WARNING DECAL W ARNING TWO BLOCKING WARNING DECAL W ARNING HOISTING PERSONNEL WARNING DECAL W ARNING MANUAL EXT INDICATOR DECAL ANGLE INDIC ATO TOR SS INDICATOR DECAL ANGLE INDIC ATO TOR CS DECAL GREASE WORM DECAL ASME/ANSI B30.22/B30.5 OPERATION DECAL MANUAL OPER ATTTION WARNING ARNING STOW HOOK DECAL W WARNING ARNING MANUAL OVERRIDES DECAL W WARNING DECAL W ARNING OVERLOAD DEVICE DECAL STELLAR MADE IN THE USA SNATCH DECAL SN ATCH BLOCK 3 TON DECAL VB CONTROL ECSERIES IDENTIFICATION DECAL IDENTIFIC ATION EC6000 E CAPACITY DECAL CA PACITY EC6000 DECAL DANGER ELECTROCUTION SMALL LOCATION Crane Base Crane Horse Head Main Boom Main Boom Main Boom Main Boom Crane Base Main Boom On top of valve bank Crane Boom above stow hook Valve Valve Bank Main Cylinder Main Boom Snatch Block On top of valve bank Main Boom (Both Sides) Main Boom and Crane Compartment Main Boom QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 LOCATION Crane Compartment Crane Compartment Crane Compartment Crane Compartment Four corners corners of the body/chassis Suggested: Rear body/tailgate Suggested: Side corners of body QTY 1 1 1 1 4 1 3 For use with Body/Chassis Package ITEM 19 20 21 22 23* 24* 25* PN 4186 4189 4214 68024 C4545 C5910 C5911 *Not Shown DESCRIPTION DECAL DANGER ELECTROCUTION REMOTE WARNING ARNING OVERLOAD DECAL W SERVICE DECAL SE RVICE WARNING OPERATOR ARNING UNTRAINED OPER ATOR DECAL W DECAL DANGER ELECTROCUTION LARGE DECAL STELLAR 4x9.5 DECAL STELLAR 2x4.5 14 EC6000 Owner’s Manual Assembly Drawings Chapter 3 - Assembly Drawings 15 Base Assembly - PN 50364 2 5 4 3 1 5 9 8 6 GASKET SHOWN AS REFERENCE 7 PN 50364 ITEM 1 2 3 4 5 6 7 8 9 PART 47869 11542 C6069 211 51 D1345 D1810 C2256 56589 53495 DESCRIPTION BEARING SWING DRIVE CAST 6620 GEARTEK STOP 3820 400 SLIDE MOTOR HYD ROSS MK080613AAAB GASKET M OTOR 008-10056-1 FTG CPRSN 0.12NPT/0.25 TUBE TBE AIR SAEJ844 TYPE A .25 (RM) FTG COUPLER PI PE 0. 1 3 ZERK 1/8 NPT STRAIGHT LONG THREAD CAP SC R 0.5 0 -13 X 2 .0 0 S H QTY. 1 1 1 1 2 1 1 1 2 NOTE: ITEMS 1 INCLUDE GUARD & GUARD FASTENERS 16 EC6000 Owner’s Manual Mast Assembly - PN 53379 7 18 1 10 12 13 14 6 21 14 13 14 15 5 3 10 6 12 9 18 7 11 8 10 4 16 17 20 19 2 PN 53379 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART 53200 53378 54858 47411 51896 0343 0420 0346 0345 0340 0479 0478 C6021 D0917 30659 C1026 C5902 21810 0492 5870 54862 DES CRIPT ION MAST EC6000 POWER UNIT 12V EC6000 CO VER EC6 000 HDP E BRKT OVERRIDE BUTTON EC3200 BRKT COVER EC CRANES WASHER 0.31 USS FLAT ZINC CAP SCR 0.31-18X0.75 HHGR5 WASHER 0.38 USS FLAT ZINC CAP SCR 0.38-16X1.50 HHGR5 WASHER 0.25 USS FLAT ZINC CAP SCR 0.25-20X0.75 HHGR5 CAP SCR 0.25-20X0.50 HHGR5 CAP SCR 0.25-20X0.75 BTNHD SS WASHER 0.25 FLAT SS NUT 0.25-20 HH NYLOC SS CAP SCR 0.63-11X2.50 HHGR8 WASHER 0.63 SAE FLAT YELLOW GR8 BUSHING BPC24DXR12 1.50X.75 CAP SCR 0.38-16X0.75 HHGR5 WASHER 0.38 STAR EXTERNAL CONTROLLER WARN 34278 DO EC6000 CONTROLLER SHOWN AS REFERENCE Q T Y. 1 1 1 1 1 3 3 2 2 5 2 3 2 3 1 16 16 4 1 1 1 Assembly Drawings Main Boom Assembly - PN 53223 NUT USED AS WEDGE FOR WIRE ROPE 27 35 24 26 25 23 14 5 3 6 11 5 3 16 17 18 17 38 2 29 19 28 16 3 37 36 8 8 9 1 10 16 14 17 4 12 13 15 20 22 32 21 33 31 PN 53223 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 29 30 31 32 33 34 35 36 37 38 PART 53224 72602 0340 C5606 43845 c1592 42508 D0 7 9 0 13815PC C6106 16 067 21810 53232 53231ZP 7403 C6353 D E S C R IP T I O N INNER BOOM EC6000 CORD REEL ASM 21 FT CRANE WASHER 0.25 FLAT C LAMP 0.25 BLK VINYL CAP SCR 0.25-20X0.38 HHGR5 ZERK 1/8 NPT STRAIGHT WEAR PAD 0.50X1.50X2.00 W ASHER 0. 50 FL AT GR8 PLATE ANGLE INDICATOR NUT 0.50-13 HHGR5 NYLOC B US HI NG QS I- 24 26-16 BUSHING GSI-2426-12 1.50X0.75 C YLI NDER 4.00X21 .00 PIN 1.50 X6.88 D&T PIN CAP 0.44X 2.50X0.19 WASHER 0.38 FLAT GR8 CAP SCR 0.38-16X0.75 HHGR8 (TRQ 33 9843 FT/LBS) 4 2516ZP PIN 1. 00 X5.13 D&T 9320 PIN CAP 0.44X1.75X0.19 SS 53518ZP PIN TEAR DROP 1.50X2.19 5591 WASHER 0.31 SAE FLAT YELLOW GR8 53521 CAP SCR 0.31-18X0.75 HHGR8 34103 RECEIVER RADIO CONTROL 6 FCTN H2 D 0917 WASHER 0.25 FLAT SS 0479 CAP SCR 0.25-20X0.75 HHGR5 0521 W A S HE R 0 . 2 5 L O C K 53230 WINCH 3000DC WARN 50111 CAP SCR 12MMX45MM HHGR8 42788 WASHER 0.44 SAE FLAT YELLOW GR8 51168PC COVER WEAR PAD EC5000 0492 CAP SCR 0.38-16X0.75 HHGR5 0346 WASHER 0.38 USS FLAT ZINC 0523 WAS HER 0 .38 LOCK 51169 WEAR PAD 0.50X1.00 RND 05 36 N U T 0 . 4 4 - 1 4 HH G R 5 C5946 HOSE CLAMP #8 RUBBER COATED 0480 CAP SCR 0.25-20X1.00 HHGR5 0333 NUT 0.25-20 HHGR5 NYLOC 34 QTY. 1 1 4 1 2 1 1 4 2 2 2 1 1 2 4 6 6 1 2 1 1 1 1 2 2 2 1 4 4 2 8 8 8 4 1 1 1 1 RADIO RECEIVER SHOWN AS REFERENCE ONLY 30 7 17 18 EC6000 Owner’s Manual Extension Boom Assembly - PN 53264 5 6 1 9 12 2 12 10 11 11 22 19 7 8 3 5 PART 50 6 12 53265 D0 7 9 0 10172 42509 5 0 6 17 42978PC 42977 50387 42 524ZP 0423 37824 5 03 86 PC 0507 27710 C6106 0352 35105 D0178 43846 0505 D0561 3 16 3 15 3 16 17 17 4 21 DES CRIPT ION EX T B O O M 1 S T E C 5 0 0 0 CYLINDER 2.00X60.00 EC6000 WASHER 0.50 FLAT GR8 CAP SCR 0.50-13X1.00 HHGR8 ZY WEAR PAD 0.38X1.38X1.50 E XT B O OM 2 ND E C 5 0 0 0 FLAT BOOM STOP EC3200 PIN HITCH 0.63X4.00 SHEAVE EC4000 6.75 DIA .31R/1.00THK P IN 0. 75X2.50 COTTE R MACHY WASHER 0.75ID 10GA COTTER PIN .125X1.00 P L A TE C RA D D L E EC40 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 SCREW #10-24X0.38 SH SS CAP SCR 0.50-13X3.50 HHGR5 CAP SCR 0.25-20X0.50 BTNHD SS 13 3 14 PN 53264 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 18 8 20 Q T Y. 1 1 9 1 2 1 1 2 2 2 4 4 1 2 2 3 2 1 2 2 1 2 Assembly Drawings Cable & Hook Assembly - PN 50492 8 13 3 4 11 12 11 5 13 2 1 3 7 1 6 10 9 PN 50492 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 PART 50493PC 50387 0352 5468 27810 16607PC 47868 9610 9263 C 60 18 0375 42524Z P 37824 DES CRIPT ION PLATE SNATCH BLOCK EC4000 SHEAVE EC4000 6.75 DIA .31R/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 0.31 6X19 IWRC-XIP 90FT PIN .38X3.00 QUICK RELEASE HOOK CRAN E-3 TON MACHY WASHER 0.75ID 14GA P IN 0.75X2.50 COTTER COTTER PIN .125X1.00 Q T Y. 2 1 6 3 2 1 3 1 1 1 2 1 2 19 20 EC6000 Owner’s Manual 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 PAR T 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 Q T Y. 1 1 1 1 5 1 1 1 Replacement Parts Chapter 4 - Replacement Parts HYDRAULIC COMPONENTS PART# DESCRIPTION C6069 HYDRAULIC SWING MOTOR 21151 GASKET - HYDRAULIC SWING MOTOR 53378 POWER UNIT 12V EC6000 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 44025 FILL CAP - HYDRAULIC RESERVOIR 9803 C-BALANCE VALVE 51840 SEAL KIT - MAIN LIFT CYLINDER 55205 SEAL KIT - EXTENSION CYLINDER 44534 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 WORM GEAR - ROTATION BEARING 55827 BEARING & SEAL KIT - ROTATION BEARING 55829 SEAL & SHIM KIT 55978 44533 BUSHING 2.00" X 0.75" 4381 BUSHING 2.00" X 2.00" 42508 WEAR PAD 0.38" X 1.50" X 2.00" 42509 WEAR PAD 0.38" X 1.38" X 1.50" 51169 WEAR PAD 0.50" X 1.00" RND 11542 BOOM STOP FLAT 7403 PIN CAP 0.44" X 2.50" X 0.19" SS 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. 50387 SHEAVE 9610 WIRE ROPE 42977 HITCH PIN 0.63" X 4.00" 9263 QUICK RELEASE PIN .38 X 3.00" 50386PC 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 47410 MOMENTARY SWITCH 17771 PUSH BUTTON (12volt hydraulic system) 53230 WINCH 54918 FUSE 300 AMP 28978 BOSCH RELAY RADIO REMOTE COMPONENTS 42976 RADIO REMOTE SYSTEM 50932 HANDLE ASM 16975 E-STOP SWITCH 22600 TOGGLE SWITCH 20088 LOWER TRANSMITTER HOUSING 51830 UPPER FACE PLATE HOUSING 51831 FACE PLATE DECAL 24385 SWITCH PROTECTION GUARD 35441 BATTERY TUBE HOLDER 35916 BACK UP CORD 21 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