stellar labs EC2000 User manual

EC2000
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Subject to change without notication.
© 2008 Stellar Industries, Inc. Last Revision: 11/06/08
Safety • Maintenance • Installation • Assembly • Parts
Telescopic Crane
Owner’s Manual

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Stellar Crane Owner’s Manual
Crane Manual Revisions
Date of Revision Section Revised Description of Revision

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Stellar Crane Owner’s Manual
Table of Contents
Contents
Crane Manual Revisions.............................................................. 2
Table of Contents......................................................................... 3
Introduction .................................................................................. 5
Crane Specications ................................................................... 6
Chapter 1 - Safety ....................................................................... 7
Chapter 2 - Operation ................................................................ 9
Chapter 3 - Installation ............................................................. 11
Installation Instructions .......................................................... 11
Wiring Schematic - Power Rotation .................................... 12
Wiring Schematic - Manual Rotation .................................. 12
Control Kit Power Rotation - PN 22930 ............................... 13
Decal Kit - PN 18776 .............................................................. 14
Decals of Note ....................................................................... 14
Gear-Bearing Bolt Maintenance ......................................... 15
Torque Data Chart ................................................................ 15
Chapter 4 - Assembly Drawings .............................................. 17
EC2000 Crane (Standard) - PN 17631 ................................. 17
EC2000 Crane (50’ Wire Rope) - PN 33939 ......................... 18
EC2000 Crane (Short Mast) - PN 19146 ............................... 19
EC2000 Crane (Power Rotation) - PN 22601 ...................... 20
EC2000 Crane (Power Rotation Short) - PN 24906 ............. 21
EC2000 Crane (LH Mount) - PN 56658 ................................. 22
Control Kit Power Rotation - PN 22930 ................................ 23
Chapter 5 - Replacement Parts ............................................... 25
Warranty Information................................................................. 26

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Stellar Crane Owner’s Manual
AN OVERVIEW TO OWNER, OPERATOR AND SERVICE PERSONNEL ABOUT SAFETY
As the owner or employer, it is your responsibility to instruct the operator in the safe opera-
tion of this equipment and to provide the operator with properly maintained equipment.
Failure to read this manual by anyone who will operate, service, or work around this crane
is a misuse of the equipment. Death or serious injury will result from improper use or mainte-
nance of this machine.
Occupational safety is a prime concern of Stellar Industries in the design and production
of this crane. Our goal in writing this manual was the safety of the operator and others who
work around this equipment.
It is your responsibility to know the specic requirements, governmental regulations, pre-
cautions and work hazards that exist in the operation and maintenance of this crane. You
shall make these available and known to all personnel working with and around the equip-
ment, so that all of you will take the necessary and required safety precautions.
FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
It is also your responsibility to operate and maintain your crane with caution, skill, and good
judgment. Following the recognized safety procedures will help you avoid accidents.
Modication to any part of his crane can create a safety hazard and therefore shall not
be made without the manufacturer’s written approval. Use only factory approved acces-
sories, options, and parts on this equipment. The rebuilding or remounting of this equipment
requires the mounting procedures and retesting to be in accordance with factory instruc-
tions. Safety covers and devices must remain installed and maintained in proper working
condition. Safety decals must be maintained, be completely legible, and be properly
located. If safety covers, devices, or decals are missing, they must be replaced with the
proper designated Stellar part.
Be capable, careful, and concerned! Make safety your everyday business!
Attention!
According to Federal Law (49 cfr part 571),
each nal-stage manufacturer shall com-
plete the vehicle in such a manner that it
conforms to the standards in effect on the
date of manufacture of the incomplete ve-
hicle, 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 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 Ve-
hicle Safety Standards and other regulations
issued under the National Traf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
www.gpoaccess.gov/nara/index.html for
the full text of Code of Federal Regulations.

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Stellar Crane Owner’s Manual
Introduction
Stellar Cranes are designed to provide safe
and dependable service. With proper use
and maintenance, these cranes will operate
at peak performance for many years.
To promote this longevity, carefully study the
information contained in this manual before
putting the equipment into service. Though
it is not intended to be a training manual for
beginners, this manual should provide solid
guidelines for the safe and proper usage of
the crane.
Once you feel comfortable with the mate-
rial contained in this manual, strive to exer-
cise your knowledge as you safely operate
and maintain the crane. This process is vital
to the proper use of the unit.
A few notes on this manual:
A copy of this manual is provided with every
crane and shall remain with the crane at
all times. Information contained within this
manual does not cover all maintenance,
operating, or repair instructions pertinent to
all possible situations.
Please be aware that some sections of this
manual contain information pertaining to
Stellar manufactured cranes in general and
may or may not apply to your specic mod-
el.
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 require-
ment or obligation for immediate manda-
tory updating of this manual.
In closing:
If more information is required or technical
assistance is needed, or if you feel that any
part of this manual is unclear or incorrect,
please contact the Stellar Customer Service
Department by phone at 800-321-3741 or
email at [email protected].
ATTENTION
Failure to adhere to the instructions could result in property damage or even
serious bodily injury to the operator or others close to the crane.
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741
Hours: Monday - Friday, 8:00 am - 5:00 pm CST
Or Email at the following addresses:
Technical Questions, and Information [email protected]
Order Parts [email protected]
Warranty Information [email protected]

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Stellar Crane Owner’s Manual
Crane Rating: 6500 ft-lbs (.899 ton-meters)
Standard Boom Length: 4’ (1.219 m) from CL of Crane
Boom Extension: 1st Position: Manual 18” (45.7 cm)
2nd Position: Manual 18” (45.7 cm)
Maximum Horizontal Reach: 7’ (2.13 m) from CL of Crane
Maximum Vertical Lift (from crane base): 10’9” (3.28 m)
Boom Elevation: 0 to +21 to +56 degrees
Winch Specication
Rope Diameter: 3/16” (.476 cm)
Line Pull Speed: 20 ft/min (6.10 m)
Max. Single Part Line: 1800 lbs (816 kg)
Max. Double Part Line: 2000 lbs (905 kg)
Manual Rotation: 340˚ Manual
Power Rotation: 314˚ Power
Lifting Capacities: 1580 lbs @ 4’ (715 kg @ 1.219 m)
1190 lbs @ 5’6” (540 kg @ 1.676 m)
930 lbs @ 7’ (420 kg @ 2.13 m)
Stowed Height: 60” (152.4 cm)
Crane Only: 30” (76.2 cm) - Short Mast
Mounting Space Required: 12” x 12” (30.5 cm x 30.5 cm
Approximate Shipping Weight: 275 lbs (124.7 kg)
230 lbs (104.3 kg) - Short Mast
300 lbs (136.1 kg) - Power Rotation
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
Maximum 1 - part line capacity is
1800lbs (816kg). For greater loads,
use 2 - part line.
Reach in Feet/Meters
Capacity in Pounds/Kilograms
1565lbs
710kg
1985lbs
900kg
2000lbs
905kg
1190lbs
540kg
1580lbs
715kg
930lbs
420kg
1430lbs
650kg
1075lbs
490kg
860lbs
390kg
6’
1.83 M
0’
0’
7’
2.13 M
8’
2.44 M
9’
2.74 M
10’
3.05 M
11’
3.35 M
1’
.305 M
2’
.610 M
3’
.914 M
4’
1.22 M
5’
1.52 M
6’
1.83 M
7’
2.13 M
Crane Specications

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Stellar Crane Owner’s Manual
Chapter 1 - Safety
Please Read the Following Carefully! This
portion of the manual contains information
regarding all Stellar manufactured cranes.
Some items contained within this chapter
may not apply to your specic equipment.
Safety should be the number one thought
on every operator’s mind. Three factors
should exist for safe operation: a qualied
operator, well-maintained equipment, and
the proper use of this equipment. The fol-
lowing information should be read and un-
derstood completely by everyone working
with or near the crane before putting the
unit into operation.
Please take note that Stellar Industries, Inc.
is not liable for accidents incurred by the
crane because of non-fulllment from the
operator’s side of current rules, laws, and
regulations.
GENERAL
It is the responsibility of the owner to instruct
the operator in the safe operation of your
equipment and to provide the operator with
properly maintained equipment.
Trainees or untrained persons shall be under
the direct supervision of qualied persons.
Do not operate equipment under the ad-
verse inuence of alcohol, drugs, or medica-
tion.
PERSONAL SAFETY
Keep clear of all moving parts.
Always wear the prescribed personal safety
devices.
Always wear approved accident-prevention
clothing such as: protective helmets, anti-
slip shoes with steel toes, protective gloves,
anti-noise headphones, protective glasses,
and reective jackets with breathing ap-
paratus. Consult your employer regarding
current safety regulations and accident-pre-
vention equipment.
Do not wear rings, wristwatch, jewelry, loose-
tting or hanging clothing such as ties, torn
garments, scarves, unbuttoned jackets or
unzipped overalls, which could get caught
up in the moving parts of the crane.
Keep a rst-aid box and a re extinguisher
readily available on the truck. Regularly
check to make sure the re extinguisher is
fully charged and the rst-aid kit is stocked.
Do not use controls and hoses as handholds.
These parts move and cannot provide sta-
ble support.
Never allow anyone to ride the crane hook
or load.
MAINTENANCE SAFETY
Never modify or alter any of the equipment,
whether mechanical, electrical, or hydrau-
lic, without explicit approval from Stellar
Industries.
Do not perform any maintenance or repair
work on the crane unless authorized and
trained to do so.
Failure to correctly plumb and wire the
crane can cause a malfunction and dam-
age to the crane and/or operator.
Decals are considered safety equipment.
They must be maintained, as would other
safety devices. Do not remove any Decals.
Replace any Decals that are missing, dam-
aged, or not legible.
The safety instruction plates, notices, load
charts and any other sticker applied to the
crane or service body must be kept legible

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Stellar Crane Owner’s Manual
and in good condition. If necessary, re-
place them.
STABILITY
Know the crane components and their ca-
pabilities and limitations. Overloading the
crane may result in serious injury to self and
others, and damage to the equipment and
immediate surroundings.
Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s
hydraulic, mechanical, and structural design
rather than stability.
The supporting surface under the service
truck must be able to support the weight of
the machine and its load.
Set the parking brake and disengage the
drive axle before attempting a lift.
LOAD SAFETY
Operate the crane in compliance with
the load capacity chart at all times. Know
the weight of the load being lifted. Do not
rely on the overload device to determine
maximum rated loads. If the crane is pick-
ing more than the maximum rated load, the
overlord protection device may be mal-
functioning. Discontinue use immediately
and contact Stellar Customer Service for
support.
Never use a sling bar or anything larger than
the hook throat that could prevent the hook
latch from closing. This would negate the
safety feature.
Do not apply side loads to the booms.
Do not leave a crane load suspended or
unattended.
Do not walk under suspended loads.
Do not position any load over a person nor
should any person be permitted to place
him or herself under a load.
Do not use the boom or the winch to drag a
load.
Do not use the crane boom to push down-
ward onto anything.
ELECTROCUTION
Allow extra space for swaying power lines in
windy conditions.
Keep a minimum of ten feet between any
portion of the crane and an electrical line.
Add an additional 12” for every additional
30,000 Volts or less.
Remember - Death or serious injury can oc-
cur when working near power lines or during
electrical storms.
Use a signal person when operating near
electrical sources.
ENVIRONMENT
Do not operate the crane during electrical
storms.
In dusty work areas, every effort must be tak-
en to keep dust and sand out of the moving
parts of the machinery.
In high humidity work areas, keep parts as
dry as possible and well lubricated.

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Stellar Crane Owner’s Manual
Chapter 2 - Operation
This chapter contains information regarding
the operation of Stellar manufactured tele-
scopic cranes. Please study the following
pages to ensure your familiarity with the op-
eration process. This understanding is vital to
the safe and efcient operation of the crane.
Job-Site Set-Up
Thoroughly plan the lift before positioning the
vehicle. Consider the following:
1. The vehicle should be positioned in an
area free from overhead obstructions to
eliminate the need for repositioning.
2. Position the vehicle so that it is impossible
for any portion of the equipment to come
within the minimum required safe distance of
any power line. Maintain a clearance of at
least 10 feet between any part of the crane,
load line, or load, and any electrical line or
apparatus carrying up to 50,000 volts. One
foot additional clearance is required for ev-
ery additional 30,000 volts or less. Remember
to allow for winds that cause power lines to
sway. It is recommended that a signal per-
son be used when the vehicle is set-up near
power lines.
Crane Controls
1. Be familiar with the sequence and opera-
tion of the crane controls.
2. Each individual crane function should
have control function decals. Replace them
immediately if they are missing or illegible.
3. Keep hands, feet, and control levers free
from mud, grease, and oil.
4. Be familiar with the remote control and
how it operates before attempting to lift a
load.
5. Be prepared before beginning operation
of the crane:
• All protective guards must be in place.
• Be aware of the surroundings: low
branches, power lines, unstable ground.
• Be sure all safety devices provided are in
place and in good operating condition.
• Be prepared for all situations. Keep re
extinguisher and rst aid kit near.
• Be sure all regular maintenance has been
performed.
• Visually inspect all aspects of the crane
for physical damage.
ATTENTION
Stellar Industries, Inc. is not liable
for accidents incurred by the
crane because of the operator’s
non-fulllment of current rules,
laws and regulations.
Power Rotation Remote Manual Rotation Remote
Basic Operation
1. Turn on power to crane. The
power switch will be located on
the crane or in the cab.
2. Operate crane as desired us-
ing the appropriate remote.
3. Stow the crane when nished.
4. Power down crane.

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Stellar Crane Owner’s Manual