stellar labs 3200 User manual

Articulating Crane
Owners’ Manual
Model 3200
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com Rev 1
PN 37808
Subject to Change without Notification.
© 2023 Stellar Industries, Inc.
Installation • Assembly Drawings • Parts

Page ii | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808
P65 Warning / Serial Tag Location
MODELNO.SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PNC5942
®
PATENTINFORMATION
http://www.stellarindustries.com/ip
MODEL NO.SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENT INFORMATION
http://www.stellarindustries.com/ip
Serial Tag
Location
WARNING
Operating, maintaining, and servicing a Stellar
product may expose you to chemicals including, but
not limited to, engine exhaust, carbon monoxide,
phthalates, and lead. These chemicals are known
to the State of California to cause cancer and birth
defects (or other reproductive harm). To keep your
exposure to a minimum, be sure to avoid breathing
exhaust and service your Stellar product in a well-
ventilated area while wearing gloves or washing
your hands frequently. For more information, go to
www.P65Warnings.ca.gov/passenger-vehicle. www.p65warnings.ca.gov
NOTICE
Cold Weather Performance
Although clear data on cold weather performance from every steel manufacturer
is not available for all types and thicknesses of steel, Stellar Industries is
confident that the weldments on our products will operate to 100% of their
intended purpose to temperatures down to -40° F / C.
It is recommended it Stellar manufactured equipment needs to be used in
temperatures below -40° F / C, the operator should pull the unit into a
climate-controlled area and allow the weldments to warm up to and then maintain
a temperature above this level.

Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page iii
Introduction.............................................................................................................................................. iv
Chapter 1 - Specications ............................................................................................................ 1
Specications ...........................................................................................................................................2
Capacity Chart - Decal PN 4161 ..............................................................................................................3
Chapter 2 - Installation.................................................................................................................. 5
General Installation...................................................................................................................................6
Installer Notice.......................................................................................................................................6
Installation Overview .............................................................................................................................6
Torque Data Chart .................................................................................................................................7
Mounting Kit - F550 2017 - PN 87478 ......................................................................................................8
Mounting Kit - F550 2017 - PN 87478 Parts List ......................................................................................9
Mounting Kit - F550 2017 - PN 31040 ...................................................................................................10
Mounting Kit - F550 2017 - PN 31040 Parts List ....................................................................................11
Mounting Kit - Ram - PN 87375..............................................................................................................12
Mounting Kit - Ram - PN 87375 Parts List..............................................................................................13
Mounting Kit - Straight Frame - PN 87377 .............................................................................................14
Mounting Kit - Straight Frame - PN 87377 Parts List .............................................................................15
Hydraulic Installation ..............................................................................................................................16
Face Seal / O-Ring Size Chart ...............................................................................................................17
Hydraulic Kit - PN 13283 ........................................................................................................................18
Hydraulic Kit - PN 13283 Parts List ........................................................................................................19
Control Kit - PN 52257............................................................................................................................20
Control Kit - PN 52257 Parts List............................................................................................................21
Decal Placement - PN 13290 .................................................................................................................22
Chapter 3 - Assembly Drawings................................................................................................. 23
Base Assembly - PN 18156....................................................................................................................24
Base Assembly - PN 18156 Parts List....................................................................................................25
Gear Bearing - PN 69743 .......................................................................................................................26
Stabilizer Valve Bank - PN 61040...........................................................................................................27
Mast Assembly - PN 18157 ....................................................................................................................28
Mast Assembly - PN 18157 Parts List ....................................................................................................29
Valve Bank - PN 50592 ..........................................................................................................................30
Valve Bank - PN 50592 Parts List ..........................................................................................................31
Main Boom Assembly - PN 18158..........................................................................................................32
Main Boom Assembly - PN 18158 Parts List..........................................................................................33
Extension Boom Assembly - PN 18159..................................................................................................34
Extension Boom Assembly - PN 18159 Parts List..................................................................................35
Radio Remote - PN 88454 .....................................................................................................................36
Radio Remote - PN 88454 Parts List .....................................................................................................37
Table of Contents

Page iv | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808
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:
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 Small OTR 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].
WARNING
NOTICE
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 [email protected]
Order Parts [email protected]
Warranty Information [email protected]
DANGER

Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 1
Chapter 1 - Specications
Chapter Contents
Specications ................................................................................................................. 2
Capacity Chart - Decal PN 4161 .................................................................................... 3

Specications
SPECIFICATIONS SHEET- MODEL 4500 CRANE
CRANE RATING: 32,000 FT-LBS (4.42 tm)
STANDARD BOOM LENGTH: 11’ (3.35 m) FROM CL OF CRANE
14’ (4.27 m)FROM CL OF TRUCK
BOOM EXTENSION: HYDRAULIC 32” (81.2 cm)
MAXIMUM HORIZONTAL REACH: 14’ (4.27 m) FROM CL OF CRANE
17’ (5.18 m)FROM CL OF TRUCK
MAXIMUM VERTICAL LIFT: 18’ (5.49 m)FROM TRUCK FRAME
STOWED HEIGHT: 60” (152.4 cm)
MOUNTING SPACE REQUIRED: 24” (61 cm)
APPROXIMATE SHIPPING
WEIGHT: 1900 LB (860 kg)
CONTROLS:
PROPORTIONAL RADIO
CONTROLS STANDARD FOR ALL
FUNCTIONS
CYLINDER SPECIFICATIONS:
INNER LIFT CYLINDER:
4 1/2” (11.4 cm)BORE WITH
INTEGRAL PILOT OPERATED
COUNTERBALANCE VALVES.
OUTER LEFT CYLINDER:
4 1/2” (11.4 cm)BORE WITH
INTEGRAL PILOT OPERATED
COUNTERBALANCE VALVES.
EXTENSION CYLINDER:
2 1⁄2” (6.35 cm)BORE WITH
INTEGRAL PILOT OPERATED
COUNTERBALANCE VALVES.
ROTATION: 290 DEGREE POWER (WORM GEAR)
LIFTING CAPACITIES:
5,000 LBS @ 9’ (2270 kg @ 2.74 m)
4,000 LBS @ 11’ (1815 kg @ 3.35 m)
2,900 LBS @ 14’ (1315 kg @ 4.27 m)
2,200 LBS @ 17’ (1000 kg@ 5.18 m)
POWER SUPPLY REQUIRED: PTO & PUMP
(4.0 gpm @ 2,800 PSI)
(15.14 Lpm @ 193 Bar)
Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 2

Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 3
Capacity Chart - Decal PN 4161

Page 4 | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808

General Installation......................................................................................................... 6
Installer Notice ............................................................................................................. 6
Installation Overview.................................................................................................... 6
Torque Data Chart........................................................................................................ 7
Mounting Kit - F550 2017 - PN 87478............................................................................ 8
Mounting Kit - F550 2017 - PN 87478 Parts List............................................................ 9
Mounting Kit - F550 2017 - PN 31040......................................................................... 10
Mounting Kit - F550 2017 - PN 31040 Parts List...........................................................11
Mounting Kit - Ram - PN 87375.................................................................................... 12
Mounting Kit - Ram - PN 87375 Parts List.................................................................... 13
CHAPTER CONTENTS
Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 5
Chapter 2 - Installation

Page 6 | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808
Installer Notice
According to Federal Law (49 cfr part 571), each nal-stage manufacturer shall complete the vehicle in such
a manner that it conforms to the standards in e󰀨ect on the date of manufacture of the incomplete vehicle,
the date of nal completion, or a date between those two dates. This requirement shall, however, be
superseded by any conicting 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 Tra󰀩c and Motor Vehicle Safety Act.
Please reference the Code of Federal Regulations, title 49 - Transportation, Volume 5 (400-999), for
further information, or visit http://www.gpoaccess.gov/nara/index.html for the full text of Code of Federal
Regulations.
General Installation
This chapter is designed to serve as a general guide for the installation of a Stellar 3200 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 [phone].
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.
WARNING
NOTICE
1. Locate mounting brackets and clamp to chassis. Consider the clearance between the cab/body and
crane.
2. Set crane on chassis and check for interferences.
3. Using mounting bracket as a guide, mark holes to be drilled into truck frame.
4. Remove mounting brackets and drill holes.
5. Mount brackets using specified size Grade 8 bolts, flast washers, and nyloc nuts.
6. Lower crane onto mounting brackets.
7. Mount crane using specified size Grade 8 bolts, flat washers, and nyloc nuts.
8. Connect pressure and return lines per hydraulic kit.
9. Connect (+12V) Power and ground wires inside crane box.
10. Check reservoir for oil and fill if necessary.
11. Operate crane several cycles.
SEE APPROPRIATE MOUNTING KIT DRAWINGS.
Installation Overview

Torque Data Chart
GRADE 5 GRADE 8 GRADE 9
SIZE
(DIA-TPI)
BOLT DIA
(INCHES)
PLAIN
(FT-LB)
PLATED
(FT-LB)
PLATED
(FT-LB)
PLATED
(FT-LB)
PLATED
(FT-LB)
5/16-18 0.3125 17 13 25 18 22
3/8-16 0.3750 31 23 44 33 39
7/16-14 0.4375 49 37 70 52 63
1/2-13 0.5000 75 57 105 80 96
9/16-12 0.5625 110 82 155 115 139
5/8-11 0.6250 150 115 220 160 192
3/4-10 0.7500 265 200 375 280 340
7/8-9 0.8750 395 295 605 455 549
1-8 1.000 590 445 910 680 823
1 1/8-7 1.1250 795 595 1290 965 1167
1 1/4-7 1.2500 1120 840 1815 1360 1646
1 3/8-6 1.3750 1470 1100 2380 1780 2158
1 1/2-6 1.500 1950 1460 3160 2370 2865
NOTE:
When using the torque data in the 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.
• Torque values specified are for bolts with residual oils or no special lubricants applied.
• 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.
• Tighten 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.
Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 7

Page 8 | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808
Mounting Kit - F550 2017 - PN 87478
13
500 FT-LB
10
8
7
8
3
11
8
2
1
8
12
9
5
9
8
56
9
8
4
TYP 12
280 FT-LB
TYP 2
680 FT-LB
TYP 2
SPACER PLATE:
-NOT USED WHEN FACTORY
FRAME REINFORCEMENT PRESENT
-WHEN USED, TACK TO MOUNT
WELDMENT TO HOLD IN PLACE

PN 87478
ITEM PART DESCRIPTION QTY
1 86938 TIE DOWN 4500 F550 SS 1
2 87471 TIE DOWN 4500 F550 CS 1
3 56180 TIE DOWN PLATE 4500 PC BLACK 2
4 C1028 CAP SCR 0.75-10X3.00 HHGR8 12
5 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 24
6 C0538 NUT 0.75-10 HHGR8 NYLOC 12
7 5199 CAP SCR 1.00-8X3.00 HHGR8 2
8 6538 WASHER 1.00 SAE FLAT YELLOW GR8 8
9 6294 NUT 1.00-8 HHGR8 NYLOC 4
10 85505 CAP SCR 1.00-8X12.00 HHGR8 1
11 87569 CAP SCR 1.00-8X11.00 HHGR8 1
12 87570 PLATE SPACER 0.50X2.00X2.00 PC BLACK 1
13 112855 PLATE SPACER TIE DOWN 4500 F550-F600 2
REV. A
NOTE:
CRANE BASE SHOWN FOR REFERENCE.
Mounting Kit - F550 2017 - PN 87478 Parts List
Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 9

Page 10 | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808
Mounting Kit - F550 2017 - PN 31040
7
9
7
280 FT-LB
4
5
1
6
5
82
2
3
9
7
9
TYP 8
680 FT-LB
TYP 4

Mounting Kit - F550 2017 - PN 31040 Parts List
PN 31040
ITEM PART DESCRIPTION QTY
1 56180 TIE DOWN PLATE 4500 PC BLACK 4
2 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 16
3 C0538 NUT 0.75-10 HHGR8 NYLOC 8
4 5199 CAP SCR 1.00-8X3.00 HHGR8 4
5 6538 WASHER 1.00 SAE FLAT YELLOW GR8 8
6 6294 NUT 1.00-8 HHGR8 NYLOC 4
7 31038 TIE DOWN 4500 STRAIGHT FRAME PC BLACK 2
8 58681 CAP SCR 0.75-10X2.50 HHGR8 8
9 58192 SPACER INST KIT 3200/4500 2
NOTE:
CRANE BASE SHOWN FOR REFERENCE.
Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 11

Page 12 | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808
Mounting Kit - Ram - PN 87375
10
7
4
5
1
6
5
82
23
9
7
9
280 FT-LB
10
TYP 8
680 FT-LB
TYP 4
9
10
7
NEED 5TH BOLT ON RAM.
PLACE 1.5" -2.5" FROM EITHER
BOLT OR USE EXISTING HOLE
IN SPACER. THE PLACEMENT
CAN VARY DUE TO CROSS
MEMBERS OR OTHER ITEMS ON
THE FRAME.

Mounting Kit - Ram - PN 87375 Parts List
PN 87375
ITEM PART DESCRIPTION QTY
1 56180 TIE DOWN PLATE 4500 PC BLACK 4
2 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 20
3 C0538 NUT 0.75-10 HHGR8 NYLOC 10
4 5199 CAP SCR 1.00-8X3.00 HHGR8 4
5 6538 WASHER 1.00 SAE FLAT YELLOW GR8 8
6 6294 NUT 1.00-8 HHGR8 NYLOC 4
7 31038 TIE DOWN 4500 STRAIGHT FRAME PC BLACK 2
8 58681 CAP SCR 0.75-10X2.50 HHGR8 10
9 58192 SPACER INST KIT 3200/4500 2
10 48670 SPACER CRANE MNT W/32 DODGE 08 MY PC BLACK 2
REV. A
NOTE:
CRANE BASE SHOWN FOR REFERENCE.
Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 13

Page 14 | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808
Mounting Kit - Straight Frame - PN 87377
280 FT-LB
4
5
1
6
5
82
2
3
7
7
TYP 8
680 FT-LB
TYP 4

Mounting Kit - Straight Frame - PN 87377 Parts List
PN 87377
ITEM PART DESCRIPTION QTY
1 56180 TIE DOWN PLATE 4500 PC BLACK 4
2 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 16
3 C0538 NUT 0.75-10 HHGR8 NYLOC 8
4 5199 CAP SCR 1.00-8X3.00 HHGR8 4
5 6538 WASHER 1.00 SAE FLAT YELLOW GR8 8
6 6294 NUT 1.00-8 HHGR8 NYLOC 4
7 31038 TIE DOWN 4500 STRAIGHT FRAME PC BLACK 2
8 58681 CAP SCR 0.75-10X2.50 HHGR8 8
INITIAL RELEASE
NOTE:
CRANE BASE SHOWN FOR REFERENCE.
Stellar®3200 Articulating Crane Owner’s Manual PN: 37808 | Page 15

Page 16 | Stellar®3200 Articulating Crane Owner’s Manual PN: 37808
Hydraulic Installation
Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without Stellar
Industries’ approval.
Do not touch or grab any hoses that could be under pressure. Release system
pressure before attempting to make adjustments or repairs.
Do not attempt service or repair when PTO is engaged.
Disassemble and assemble hydraulic components on a clean surface.
Clean all metal parts in a nonammable cleaning uid. Then lubricate all components to aid in assembly.
Hydraulic uid expands when heated. This raises the pressure in an unventilated
tank. Release the tank pressure before removing the cap completely. Failure to do so may cause the oil to
shoot out of the tank very rapidly and cause severe burns.
Do not rely on the hydraulic uid to support the boom or crane. If hydraulic uid
escapes, the boom or crane can fall immediately. Make sure the ground or blocking is supporting the boom
before performing any maintenance or repair.
Contaminants in a hydraulic system a󰀨ect operation and will result in serious damage
to the system components. Dirty hydraulic systems are a major cause of component failures.
If evidence of foreign particles is found in the hydraulic system, ush the system.
When installing metal hydraulic tubes, tighten all ttings nger tight. Then , in order, tighten the ttings at
the rigid end, the adjustable end, and the mounting brackets. After tubes are mounted, install the hoses.
Connect both ends of the hose with all ttings nger tight. Position the hose so it does not rub the machine
or another hose and has a minimum of bending and twisting. Tighten ttings in both couplings.
Due to manufacturing methods, there is a natural curvature to a hydraulic hose. The hose should be
installed so any bend is with this curvature.
WARNING
WARNING
WARNING
NOTICE
HYDRAULIC FLUID HAZARDS
•High pressure fluid leak will pierce skin.
• Release pressure before working on system.
STAND CLEAR OF POTENTIAL HIGH
PRESSURE HYDRAULIC FLUID LEAKS
• Wear sturdy gloves and goggles. Detect leaks
with wood or cardboard. NEVER use fingers.
• Fluid injected in skin will injure or kill and
must be surgically removed by trained doctor
immediately or gangrene will result.
BURN HAZARD
• Oil temperatures may exceed 120°F (35°C).
• Do not touch hydraulic system.
• Hot surface can burn.
CHECK HYDRAULIC HOSES, TUBES, AND PIPES DAILY.
WARNING