Installation • Assembly Drawings • PartsMay 21, 2014 · Specifications 1 Chapter 1 -...
Transcript of Installation • Assembly Drawings • PartsMay 21, 2014 · Specifications 1 Chapter 1 -...
NOTICE
9188
Damage may occur if worm gear runs dry. Keep worm gear lubricated with Stellar® grease (PN 4460).
WARNING
Misuse HazardTwo blocking the crane can result in deathor serious injury.
Never allow the hook block to contact theboom tip by hoisting up, extending orlowering the boom.
12300
Winch Pull
Boom Extending
BoomDown
1382
0
20010
3040
6070
80
50
Angle Indicator
GREASE every 3 months.Apply 3 ‘pumps’ of EP2
(extreme pressure grease)then rotate crane fully.
15171
NOTICE
12924
This crane has been designed and manufactured to ASME/ANSI B30.22 and/or B30.5 specifications.
WARNING
24712
Do not use stow hook for any lifting applications.Using the stow hook for anything other than hookstowage can result in death or serious injury.
Misuse Hazard
WARNING
28256
Overload Hazard
Bypassing the overload condition
by tampering with the overload
device can result in death or
serious injury.
Never tamper with overload
device.
35234
Proudly Designedand Manufacturedin the USA by
3 Tons(2,721 KG)
LOAD BLOCK RATING
SNATCH BLOCK WEIGHT: 15 LBS (6.80 KG)42819
12452
WARNINGFree falling manual boom extensions can result in death or serious injury.• Properly install retention pins prior to operation.• Do not stand in front of extension when removing retention pin.• Do not allow extensions to free fall.
Free Falling Boom Hazard
DANGERElectrocution Hazard
Death or serious injury will result from inadequate clearance if crane, load, or vehicle becomes electrically charged.• Maintain safe clearance from high voltage power sources.• Never approach vehicle or load if equipment is near a high voltage power source.
C1179
12451
WARNINGHoisting personnel on boom, hook, load, or loadline can result in death or serious injury.• Never use crane to hoist personnel.• Never ride the boom, hook, load, or any device attached to crane boom or load line.
Fall HazardECEC600060005352453524
Reach in Feet/MetersCapacity in Pounds/Kilograms
Weight of load handling devices are part of the load lifted and must be deducted from the capacity.
PN 53525
Maximum 1 - part line capacity is 3000 lbs (1360 kg). For greater loads, use 2 - part line.
3'0'
75º
60º
6000 lbs
6000 lbs
6000 lbs
80º
16' 21'
0'
9'6' 11'
1810 lbs3450 lbs
15º
30º
2375 lbs
45º
3'
6'
9'
12'
15'
18'
22'10"
.914 m 1.83m 2.74m 3.35m 4.87m 6.40m
.914 m
1.83m
2.74m
4.57m
5.49m
3.66m
6.96m
1560 kg 1075 kg 820 kg
2720 kg
2720 kg
2720 kg 6000 lbs2720 kg
6000 lbs2720 kg
6000 lbs2720 kg
6000 lbs2720 kg
3560 lbs1610 kg
1795 kg3965 lbs
4845 lbs2195 kg
1110 kg2450 lbs
2730 lbs1235 kg
1510 kg3340 lbs
4715 lbs2135 kg
1870 lbs845 kg
2080 lbs940 kg
2545 lbs1150 kg
1630 kg3600 lbs
ECEC60006000
Installation • Assembly Drawings • Parts
TELESCOPIC CRANEOWNERS’ MANUAL
MODEL EC6000
Stellar Industries, Inc.190 State StreetPO Box 169
Garner, IA 50438800-321-3741
Fax: 641-923-2811www.stellarindustries.com Last Revision: 05/21/14
Subject to Change without Notification.© 2014 Stellar Industries, Inc.
EC6000 Manual RevisionsDate of Revision
March 25th, 2013
Description of Revision
Updated Decal Kit
Sections Revised
Chapter 2: Installation
Table of Contents i
Find a Dealer Near You:http://www.stellarindustries.com/pages/dist/distsearch.htm
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST
Or email at the following addresses:
Technical Questions, and Information [email protected] Parts [email protected] Information [email protected]
Table of ContentsChapter 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 - PN 67894 . . . . . . . . . . . .20
Chapter 4 - Replacement Parts . . . . . . . . . . . . . . . . . . . . .21
ii EC6000 Owner’s Manual
A copy of this manual is provided with every crane and can be found in the hard plasticmanual case that is installed on the chassis. A copy of this manual shall remain with thecrane at all times.
Throughout the manual, three signal words will be used to bring attention to importantitems:
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, ortroubleshooting. Please refer to the General EC Series Crane Manual for details on theseitems.
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 productimprovement or commercial/production purposes. This right is kept with no requirement orobligation for immediate mandatory updating of this manual.
If more information is required or technical assistance is needed, or if you feel that anypart of this manual is unclear or incorrect, please contact the Stellar Customer ServiceDepartment by phone at 800-321-3741 or email at [email protected].
About this manual
1Specifications 1
Chapter 1 - SpecificationsModel EC6000 CraneSPECIFICATION SHEET
Crane Rating: 38,000 ft-lb (5.25 TM)
Standard Boom Length: 11’ (3.35 m) from CL of Crane
Boom Extension: 1st stage: Hydraulic 60" (152.4 cm)2nd stage: Manual 60" (152.4 cm)
Maximum Horizontal Reach: 21’ (6.40 m) from CL of Crane
Maximum Vertical Lift: 22’ 10” (6.96 m)(from crane base)
Boom Elevation: -5 to +80 degrees
Stowed Height: 34.41” (87.40 cm)(crane only)
Mounting Space Required: 20” x 21” (50.8 x 53.3 cm)
Approximate Crane Weight: 1600 lbs (725 kg)
Controls: Radio control standard for all functions.
Winch SpecificationsRope Length: 90 ft (27.4m)Rope Diameter: 5/16" (.79 cm)Line pull speed: 16 ft/min (4.88 m/min)Max. single part line: 3000 lbs (1360 kg)Max. double part line: 6000 lbs (2720 kg)
Rotation: 400 degree power (worm gear)
Lifting Capacities: 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)
Power Supply Required: 12 volt power unit(2.0 gpm @ 2900 psi)(7.57 lpm @ 200 bar)
*Subject to change without notification
2 EC6000 Owner’s Manual
Reach in Feet/MetersCapacity in Pounds/Kilograms
Weight of load handling devices are part of the load lifted and must be deducted from the capacity.
PN 53525
Maximum 1 - part line capacity is 3000 lbs (1360 kg). For greater loads, use 2 - part line.
3'0'
75º
60º
6000 lbs
6000 lbs
6000 lbs
80º
16' 21'
0'
9'6' 11'
1810 lbs3450 lbs
15º
30º
2375 lbs
45º
3'
6'
9'
12'
15'
18'
22'10"
.914 m 1.83m 2.74m 3.35m 4.87m 6.40m
.914 m
1.83m
2.74m
4.57m
5.49m
3.66m
6.96m
1560 kg 1075 kg 820 kg
2720 kg
2720 kg
2720 kg 6000 lbs2720 kg
6000 lbs2720 kg
6000 lbs2720 kg
6000 lbs2720 kg
3560 lbs1610 kg
1795 kg3965 lbs
4845 lbs2195 kg
1110 kg2450 lbs
2730 lbs1235 kg
1510 kg3340 lbs
4715 lbs2135 kg
1870 lbs845 kg
2080 lbs940 kg
2545 lbs1150 kg
1630 kg3600 lbs
ECEC60006000
Capacity Chart - Decal PN 53525
3Installation 3
Chapter 2 - Installation
According to Federal Law (49 cfr part 571), each final-stage manufacturer shall completethe vehicle in such a manner that it conforms to the standards in effect on the date ofmanufacture of the incomplete vehicle, the date of final completion, or a date betweenthose two dates. This requirement shall, however, be superseded by any conflictingprovisions of a standard that applies by its terms to vehicles manufactured in two or morestages.
Therefore, the installer of Stellar cranes and bodies is considered one of the manufacturersof the vehicle. As such a manufacturer, the installer is responsible for compliance with allapplicable federal and state regulations. They are required to certify that the vehicle is incompliance with the Federal Motor Vehicle Safety Standards and other regulations issuedunder the National Traffic 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 fulltext of Code of Federal Regulations.
Installation Notice
This chapter is designed to serve as a general guide for the installation of a Stellar EC6000Crane on a Stellar Service Body. Each installation is considered unique so certain portionsof this chapter may or may not apply to your direct application. If a question should ariseduring 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 meetsthe minimum chassis requirements of the crane. It is the installer’s responsibility to assurethat the crane is mounted on a platform that will support the maximum crane rating of thiscrane.
Do not install this crane on a body not capable of handling the loadsimposed on it. Failure to do so may result in serious injury or death.
When installing welder units to the service bodies, it is highlyrecommended that a surge protector is installed on the chassis batteries to protect thecrane radio receiver, wiring and other electronic devices from an unexpected electricalspike or surge. Failure to do so could result in extensive damage to the service body andcrane electrical circuit.
General Installation
4 EC6000 Owner’s Manual
Installation Overview1. 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 thebase 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 weighsapproximately 1600 lbs (725 kg). Note: cranes are shipped with rotation positioned at 200 degrees of 400degree system. This will allow for easy installation of the crane and permanent connection of all hydraulicand 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 cranecompartment 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.
5Installation 5
FRONTMotor
Hole Mounting Detail
Ø1.063
7.38
14.75
7.38
14.75
Ø6.00
4 Places
EC6000 Mounting Detail
TUBE 4X2X0.38
TRUCK FRAME
TUBE 4X2X0.38
3/8 PLATE
TUBE 2X2X0.38(TYP 4)
Flatbed Body ReinforcementIf it has been determined that the destinationbody won’t support the crane with a fullyrated load, the body must be reinforced.Use 1/4” fillet welds and an AWS qualifiedwelder to proceed as shown in this drawing:
Note: Tubing must beat least 4” x 2” x 0.38”(Except where noted)
6 EC6000 Owner’s Manual
2
3
4
.YTQNOITPIRCSEDTRAPMETI2 5199 CAP SCR 1.00X8X3.00 HHGR8 ZY 43 6538 WASHER 1.00 SAE FLAT YELLOW GR8 4
10006CE ENARC673354
EC6000 Installation Drawing
NOTICE!Route hoses correctly to ensurethey do not become pinched orcrushed during installation.
7Installation 7
PN 54857
Hydraulic Kit - PN 54857
8 EC6000 Owner’s Manual
NOTE: P/N 54860 INCLUDES HARNESS & WINCH CONTROLLER
POW
ERG
RO
UN
DO
PT1
OPT
2
PN 54859
Replacement ControllerStellar PN 54862
Control Kit - PN 54859
Installation 9
+-
FUSE 300 AMPPN 54918
(STELLAR SUPPLIED)
UNDERHOOD
TRUCK BATTERY
MASTER
250 AMPHolder: PN 32523
AUX BATTERY
- +
CRANE
COMPARTMENTCAB OR CRANE
10 AMPPOWERSWITCH
START MOTOR SOLENOID
GROUND POST
CRANE HARNESS
GROUND
GROUND
LOCATE AUX BATTERY ASCLOSE TO CRANE AS POSSIBLE
GROUND
POWER
OPT1
OPT2
SWITCH
(NOT SUPPLIED)
POWER SOURCE FOR RADIO REMOTE
Torque SpecLarge Nuts: 35 in-lbsSmall Nuts: 15 in-lbs
Minimum Wire Sizes:EC3200 - #2EC4000 - #2EC5000 - #2EC6000 - 1/0
Note: operating the crane without the truck engine running could allow the truck battery to be discharged below levels required for starter cranking power.
FUSE 300 AMPPN 54918
(STELLAR SUPPLIED)Holder: PN 32523
SAFETY BRAKE87A
3086 85
87
RELAY
EC6000 Wiring Diagram
10 EC6000 Owner’s Manual
ROTCCW
ROTCW
INNERUP
INNERDOWN
EXT OUT
EXTIN
Valve Bank Drawing
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, withouttipping over the truck. Every Stellar crane installed must be tested for stability todetermine the actual load capacity of the final truck package. The actual test datamust be recorded and supplied with the truck at the time of in-service and should be keptwith the truck at all times. The following procedure will test the truck package for stabilityand will provide a stability capacity chart. The load limit information shown on thestability 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 propermachine function.
Test Procedure1. Rotate the crane into Zone 1 position.2. With the crane fully retracted and the boom horizontal, winch the test weight off theground. 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 truckbecomes unstable (Again, use the winch to keep the weight within six inches of theground.)
4. If the boom goes full extension without becoming unstable, the crane is termed stablefor 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 thetruck becomes stable and measure the horizontal reach in this position (center ofrotation to boom tip). This is the stable horizontal reach for this zone. Stable horizontalreach divided by Maximum horizontal reach multiplied by 100 equals the percentageof rated capacity for this zone. Use the following formula to determine the percentageof rated capacity:
6. Record this number in the data box for Zone 1. This is the revised capacity due tostability 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.
EC6000 Stability DataMax Horizontal Reach: 252” (From the center of rotation to boom tip)Stability Test Weight: 2135 lbs.
Stability Procedure
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
Installation 13
WARNING
25159
After stowing the crane, always return the valve bank manual overrides to the neutral position.Failure to return the manual overrides to the neutral position can result in death or serious injury.
Movement Hazard
NOTICE
9188
Damage may occur if worm gear runs dry. Keep worm gear lubricated with Stellar® grease (PN 4460).
WARNING
Misuse HazardTwo blocking the crane can result in deathor serious injury.
Never allow the hook block to contact theboom tip by hoisting up, extending orlowering the boom.
12300
Winch Pull
Boom Extending
BoomDown
01
05
06
10
12
1817
17
16
1615
14
20
22
23
21
03
04
07
08
09
02
13819
200 1030
8070
50
40
60
Angle Indicator
1382
0
20010
3040
6070
80
50
Angle Indicator
GREASE every 3 months.Apply 3 ‘pumps’ of EP2
(extreme pressure grease)then rotate crane fully.
15171
NOTICE
12924
This crane has been designed and manufactured to ASME/ANSI B30.22 and/or B30.5 specifications.
HOLD BUTTON TOOPERATE CRANE
MANUALLY. 18472
WARNING
24712
Do not use stow hook for any lifting applications.
Using the stow hook for anything other than hookstowage can result in death or serious injury.
Misuse Hazard
WARNING
28256
Overload Hazard
Bypassing the overload condition
by tampering with the overload
device can result in death or
serious injury.
Never tamper with overload
device.
35234
Proudly Designedand Manufacturedin the USA by
11
3 Tons(2,721 KG)
LOAD BLOCK RATING
SNATCH BLOCK WEIGHT: 15 LBS (6.80 KG)42819
12452
WARNINGFree falling manual boom extensions can result in death or serious injury.• Properly install retention pins prior to operation.• Do not stand in front of extension when removing retention pin.• Do not allow extensions to free fall.
Free Falling Boom Hazard
42820
PULLPUSH
OUTINEXTENSION
UPDOWNMAIN
CCWCWROTATION
WARNING
Read and understand allmanuals and safety signs before operating or servicing this equipment.
Failure to follow operating, maintenance, or safety instructions can result in death or serious injury.
Untrained Operator Hazard
68024
DANGER
Death or serious injury will result from touching tethered remote if crane, load, or vehicle becomes electrically charged.Maintain safe clearance fromhigh voltage power sources.
Electrocution Hazard
4186
DANGERElectrocution Hazard
Death or serious injury will result from inadequate clearance if crane, load, or vehicle becomes electrically charged.
• Maintain safe clearance from high voltage power sources.
• Never approach vehicle or load if equipment is near a high voltage power source.
C1179
12451
WARNING
Hoisting personnel on boom, hook, load, or loadline can result in death or serious injury.
• Never use crane to hoist personnel.
• Never ride the boom, hook, load, or any device attached to crane boom or load line.
Fall Hazard
WARNING
4189
Do not exceed equipment load charts and ratings.
Failure to follow equipment load charts and ratings can result in death or serious injury.
Overload Hazard
13
FOR SERVICE ON THIS EQUIPMENTCONTACT:
STELLAR INDUSTRIES, INC.190 STATE STREET, GARNER, IA 50438
641-923-3741800-321-3741
4214
Crane Compartment Inner DoorSuggested Placement
EC600053524
EC600053524
Reach in Feet/MetersCapacity in Pounds/Kilograms
Weight of load handling devices are part of the load lifted and must be deducted from the capacity.
PN 53525
Maximum 1 - part line capacity is 3000 lbs (1360 kg). For greater loads, use 2 - part line.
3'0'
75º
60º
6000 lbs
6000 lbs
6000 lbs
80º
16' 21'
0'
9'6' 11'
1810 lbs3450 lbs
15º
30º
2375 lbs
45º
3'
6'
9'
12'
15'
18'
22'10"
.914 m 1.83m 2.74m 3.35m 4.87m 6.40m
.914 m
1.83m
2.74m
4.57m
5.49m
3.66m
6.96m
1560 kg 1075 kg 820 kg
2720 kg
2720 kg
2720 kg 6000 lbs2720 kg
6000 lbs2720 kg
6000 lbs2720 kg
6000 lbs2720 kg
3560 lbs1610 kg
1795 kg3965 lbs
4845 lbs2195 kg
1110 kg2450 lbs
2730 lbs1235 kg
1510 kg3340 lbs
4715 lbs2135 kg
1870 lbs845 kg
2080 lbs940 kg
2545 lbs1150 kg
1630 kg3600 lbs
EC6000
Reach in Feet/MetersCapacity in Pounds/Kilograms
Weight of load handling devices are part of the load lifted and must be deducted from the capacity.
PN 53525
Maximum 1 - part line capacity is 3000 lbs (1360 kg). For greater loads, use 2 - part line.
3'0'
75º
60º
6000 lbs
6000 lbs
6000 lbs
80º
16' 21'
0'
9'6' 11'
1810 lbs3450 lbs
15º
30º
2375 lbs
45º
3'
6'
9'
12'
15'
18'
22'10"
.914 m 1.83m 2.74m 3.35m 4.87m 6.40m
.914 m
1.83m
2.74m
4.57m
5.49m
3.66m
6.96m
1560 kg 1075 kg 820 kg
2720 kg
2720 kg
2720 kg 6000 lbs2720 kg
6000 lbs2720 kg
6000 lbs2720 kg
6000 lbs2720 kg
3560 lbs1610 kg
1795 kg3965 lbs
4845 lbs2195 kg
1110 kg2450 lbs
2730 lbs1235 kg
1510 kg3340 lbs
4715 lbs2135 kg
1870 lbs845 kg
2080 lbs940 kg
2545 lbs1150 kg
1630 kg3600 lbs
EC6000
19NOTICE
73929
For use with Crane Package
ITEM PN DESCRIPTION LOCATION QTY
01 9188 DECAL ROTATE/GREASE Crane Base 1
02 12300 DECAL WARNING TWO BLOCKING Crane Horse Head 1
03 12451 DECAL WARNING HOISTING PERSONNEL Main Boom 1
04 12452 DECAL WARNING MANUAL EXT Main Boom 1
05 13819 DECAL ANGLE INDICATOR SS Main Boom 1
06 13820 DECAL ANGLE INDICATOR CS Main Boom 1
07 15171 DECAL GREASE WORM Crane Base 1
08 15172 DECAL ASME/ANSI B30.22/B30.5 Main Boom 1
09 18472 DECAL MANUAL OPERATION 1
10 24712 DECAL WARNING STOW HOOK Crane Boom above stow hook 1
11 25159 DECAL WARNING MANUAL OVERRIDES Valve Bank 1
12 28256 DECAL WARNING OVERLOAD DEVICE Main Cylinder 1
13 35234 DECAL STELLAR MADE IN THE USA Main Boom 1
14 42819 DECAL SNATCH BLOCK 3 TON Snatch Block 1
15 42820 DECAL VB CONTROL ECSERIES 1
16 53524 DECAL IDENTIFICATION EC6000 Main Boom (Both Sides) 2
17 53525 DECAL CAPACITY EC6000 Main Boom and Crane Compartment 2
18 C1179 DECAL DANGER ELECTROCUTION SMALL Main Boom 1
19 73929 DECAL PRESSURE WASH Main Boom 1
For use with Body/Chassis Package
ITEM PN DESCRIPTION LOCATION QTY
20 4186DECAL DANGER ELECTROCUTION REMOTE Crane Compartment 1
21 4189 DECAL WARNING OVERLOAD Crane Compartment 1
22 4214 DECAL SERVICE Crane Compartment 1
23 68024 DECAL WARNING UNTRAINED OPERATOR Crane Compartment 1
24* C4545 DECAL DANGER ELECTROCUTION LARGE Four corners of the body/chassis 4
25* C4795 DECAL WARNING STABILIZERS Stabilizers 2
26* C5910 DECAL STELLAR 4x9.5 1
27* C5911 DECAL STELLAR 2x4.5 3
*Not Shown
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ightWe
kg
kg
kg
NOTICE
9188 grease (PN 4460).. Keep worm gear lubricated with . Keep worm gear lubricated with
grease (PN 4460).Stellardry. Keep worm gear lubricated with S ellarSte
Damage may occur if worm gear runs
01
17
0771
fullythen rotate crane)ssure grease(extreme pre
of EP2Apply 3 ‘pumps
every 3 months.GREASE every 3 months.
115
m frctedueddadloe f thart op
had oa l ofghtt of
0' 3'
6000 lbs
6000 lbs
75º
80º
914 m
2720 6000 lbs
2720 6000 lbs
2720
2720
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NOTICE
41292and/or B30.5 specifications.ASME/ANSI B30.22
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22'10"
18'
15'
12'
9'
6'
3'
45º
2720
lbs
2720 00 lbs
2720 6000 lbs
gk1610 3560 lbs
lbs
g2195
3965 lbsgk1795
2450 lbs
g1235
g1110
g3340 lbs
k1510
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gk940 bs2080 lbs
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gk1630
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IA 50438 T, INC.I
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Suggested PlacementCrane Compartment Inner Door
00000000000000C660006
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PN 53523(Rev D - 08/13/14)
Added Pressure Wash Decal
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k2720
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25159
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.YANUALLMCRANETE OPERA
OTON BUTTHOLD
11
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(2,721 KG)ons3 T
TIONAATROTCW CCW
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19NOTICE
73929
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For use with Crane Package
ITEM PN DESCRIPTION
01 9188 TE/GREASEAATE/GREASEDECAL ROT
02 12300 ARNING TWO BLOCKINGDECAL W
03 12451 ARNING HOISTING PERSONNELDECAL W
04 12452 ARNING MANUAL EXTDECAL W
05 13819 TOR DECAL ANGLE INDICA T
06 13820 TOR DECAL ANGLE INDICA T
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LOCATION
Crane Base
ARNING TWO BLOCKING Crane Horse Head
ARNING HOISTING PERSONNEL Main Boom
ARNING MANUAL EXT Main Boom
TOR SS Main Boom
TOR CS Main Boom
.
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QTY
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09
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07 15171 DECAL GREASE WORM
08 15172 DECAL ASME/ANSI B30.22/B30.5
09 18472 TIODECAL MANUAL OPERA T
10 24712 ARNING STOW HOOKDECAL W
11 25159 ARNING MANUAL OVERRIDESDECAL W
12 28256 ARNING OVERLOAD DEVICEDECAL W
13 35234 DECAL STELLAR MADE IN THE USA
14 42819 TCH BLOCK 3 TDECAL SNA ATCH BLOCK 3 TON
15 42820 DECAL VB CONTROL ECSERIES
16 53524 TION ECDECAL IDENTIFICA ATION EC6000
.
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S
Crane Base
DECAL ASME/ANSI B30.22/B30.5 Main Boom
TION Power unit cover
ARNING STOW HOOK Crane Boom above stow hook
ARNING MANUAL OVERRIDES alve BankVValve Bank
ARNING OVERLOAD DEVICE Main Cylinder
DECAL STELLAR MADE IN THE USA Main Boom
TCH BLOCK 3 TON Snatch Block
DECAL VB CONTROL ECSERIES On top of valve bank
TION EC6000 Main Boom (Both Sides)
.
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.
18472
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1
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Crane Boom above stow hook 1
1
1
1
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1
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17 53525 ACITY EC6000DECAL CAP
18 C1179 DECAL DANGER ELECTROCUTION SMALL
19 73929 ASHDECAL PRESSURE W
For use with Body/Chassis Package
ITEM PN DESCRIPTION
20 4186DECAL DANGER ELECTROCUTION REMOTE
21 4189 ARNING OVERLOADDECAL W
22 4214 VICEDECAL SER
23 68024 ARNING UNTRAINED OPERADECAL W
24* C4545 DECAL DANGER ELECTROCUTION LARGE
.
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ACITY EC6000 Main Boom and Crane Compartment
DECAL DANGER ELECTROCUTION SMALL Main Boom
Main Boom
LOCATION
DECAL DANGER ELECTROCUTION Crane Compartment
ARNING OVERLOAD Crane Compartment
Crane Compartment
TOR NED OPERA ATOR Crane Compartment
DECAL DANGER ELECTROCUTION LARGE ners of the body/chassisFour cor
.
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Main Boom and Crane Compartment 2
1
1
QTY
1
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1
ners of the body/chassis 4
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24* C4545 DECAL DANGER ELECTROCUTION LARGE
25* C4795 ABILIZARNING ST ADECAL W
26* C5910 DECAL STELLAR 4x9.5
27* C5911 DECAL STELLAR 2x4.5
*Not Shown
.
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.
18472
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S
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DECAL DANGER ELECTROCUTION LARGE ners of the body/chassisFour cor
ABILIZERS Stabilizers
Suggested: Rear body/tailgate
ners of bodySuggested: Side cor
.
.
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.
18472
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ners of the body/chassis 4
2
Suggested: Rear body/tailgate 1
ners of body 3
Decal Placement Kit - PN 53523
14 EC6000 Owner’s Manual
15
.YTQNOITPIRCSEDTRAPMETI1 47869 BEARING SWING DRIVE CAST 6620 GEARTEK 1
1EDILS 004 0283 POTS2451123 C6069 MOTOR HYD ROSS MK080613AAAB 1
11-65001-800 ROTOM TEKSAG1511245 D1345 FTG CPRSN 0.12NPT/0.25 TUBE 26 D1810 TBE AIR SAEJ844 TYPE A .25 (RM) 1
131.0 EPIP RELPUOC GTF6522C78 56589 ZERK 1/8 NPT STRAIGHT LONG THREAD 1
2HS 00.2X31-05.0 RCS PAC594359
NOTE: ITEMS 1 INCLUDE GUARD & GUARD FASTENERS
8
2
3
GASKET SHOWN AS REFERENCE
45
6
5
7
9
1
PN 50364
Base Assembly - PN 50364
Assembly Drawings 15
Chapter 3 - Assembly Drawings
16 EC6000 Owner’s Manual
10
20
192
89
4
10
11
76
3
131476
13 14 515
14
118
10
12
21
12
17
16
18
CONTROLLER SHOWN AS REFERENCE
.YTQNOITPIRCSEDTRAPMETI10006CE TSAM002351
2 53378 POWER UNIT 12V EC6000 11EC3200 HDPE REVOC444753
4 47411 BRKT OVERRIDE BUTTON EC3200 15 51896 BRKT COVER EC CRANES 16 0343 WASHER 0.31 USS FLAT ZINC 37 0420 CAP SCR 0.31-18X0.75 HHGR5 38 0346 WASHER 0.38 USS FLAT ZINC 29 0345 CAP SCR 0.38-16X1.50 HHGR5 210 0340 WASHER 0.25 USS FLAT ZINC 511 0479 CAP SCR 0.25-20X0.75 HHGR5 212 0478 CAP SCR 0.25-20X0.50 HHGR5 313 C6021 CAP SCR 0.25-20X0.75 BTNHD SS 2
3SS TALF 52.0 REHSAW7190D4115 30659 NUT 0.25-20 HH NYLOC SS 116 C1026 CAP SCR 0.63-11X2.50 HHGR8 1617 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 1618 21810 BUSHING BPC24DXR12 1.50X.75 419 0492 CAP SCR 0.38-16X0.75 HHGR5 120 5870 WASHER 0.38 STAR EXTERNAL 121 54862 CONTROLLER WARN 34278 DO EC6000 1
PN 53379
Mast Assembly - PN 53379
17Assembly Drawings 17
PN 53223
3
7
1
34
5
252624
23
27
6
2829
18
1916
1717
16
1411
10
8 9
1213
202122
14
34
30
3233
31
35
FOR WIRE ROPE
15
16
17
8
NUT USED AS WEDGE
363738
2
3
5
RADIO RECEIVER SHOWN AS REFERENCE ONLY
.YTQNOITPIRCSEDTRAPMETI10006CE MOOB RENNI422351
2 72602 CORD REEL ASM 21 FT CRANE 14TALF 52.0 REHSAW043031LYNIV KLB 52.0 PMALC6065C4
5 43845 CAP SCR 0.25-20X0.38 HHGR5 21THGIARTS TPN 8/1 KREZ2951c6
7 42508 WEAR PAD 0.50X1.50X2.00 148RG TALF 05.0 REHSAW0970D8
9 13815PC PLATE ANGLE INDICATOR 210 C6106 NUT 0.50-13 HHGR5 NYLOC 2
261-6242-ISQ GNIHSUB760611112 21810 BUSHING GSI-2426-12 1.50X0.75 1
100.12X00.4 REDNILYC23235312T&D 88.6X05.1 NIPPZ1323541491.0X05.2X44.0 PAC NIP30475168RG TALF 83.0 REHSAW3536C61
17 9843 CAP SCR 0.38-16X0.75 HHGR8 (TRQ 33 FT/LBS) 6
1T&D 31.5X00.1 NIPPZ615248119 9320 PIN CAP 0.44X1.75X0.19 SS 220 53518ZP PIN TEAR DROP 1.50X2.19 121 5591 WASHER 0.31 SAE FLAT YELLOW GR8 122 53521 CAP SCR 0.31-18X0.75 HHGR8 123 34103 RECEIVER RADIO CONTROL 6 FCTN H2 1
2SS TALF 52.0 REHSAW7190D4225 0479 CAP SCR 0.25-20X0.75 HHGR5 2
2KCOL 52.0 REHSAW1250621NRAW CD0003 HCNIW0323572
28 50111 CAP SCR 12MMX45MM HHGR8 429 42788 WASHER 0.44 SAE FLAT YELLOW GR8 430 51168PC COVER WEAR PAD EC5000 231 0492 CAP SCR 0.38-16X0.75 HHGR5 832 0346 WASHER 0.38 USS FLAT ZINC 8
8KCOL 83.0 REHSAW32503334 51169 WEAR PAD 0.50X1.00 RND 4
15RGHH 41-44.0 TUN635053
36 C5946 HOSE CLAMP #8 RUBBER COATED 1
37 0480 CAP SCR 0.25-20X1.00 HHGR5 1
38 0333 NUT 0.25-20 HHGR5 NYLOC 1
Main Boom Assembly - PN 53223
18 EC6000 Owner’s Manual
7
16
1713
3
14
21
17
3
153
3
16
18
19 20
8
12
11
109
1112
2
1
5
6
34
85
22
.YTQNOITPIRCSEDTRAPMETI10005CE TS1 MOOB TXE216051
2 53265 CYLINDER 2.00X60.00 EC6000 198RG TALF 05.0 REHSAW0970D3
4 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 15 42509 WEAR PAD 0.38X1.38X1.50 2
10005CE DN2 MOOB TXE7160567 42978PC FLAT BOOM STOP EC3200 1
200.4X36.0 HCTIH NIP7792489 50387 SHEAVE EC4000 6.75 DIA .31R/1.00THK 2
2RETTOC 05.2X57.0 NIPPZ425240111 0423 MACHY WASHER 0.75ID 10GA 4
400.1X521. NIP RETTOC428732110004CE ELDDARC ETALPCP6830531
14 0507 CAP SCR 0.50-13X4.50 HHGR5 215 27710 SPRING ANTI 2 BLOCK SUMMIT 216 C6106 NUT 0.50-13 HHGR5 NYLOC 317 0352 WASHER 0.50 USS FLAT ZINC 218 35105 SWITCH LIMIT E1117-B9111-6C 119 D0178 WASHER #10 SAE FLAT ZINC 220 43846 SCREW #10-24X0.38 SH SS 221 0505 CAP SCR 0.50-13X3.50 HHGR5 122 D0561 CAP SCR 0.25-20X0.50 BTNHD SS 2
PN 53264
Extension Boom Assembly - PN 53264
19Assembly Drawings 19
.YTQNOITPIRCSEDTRAPMETI1 50493PC PLATE SNATCH BLOCK EC4000 22 50387 SHEAVE EC4000 6.75 DIA .31R/1.00THK 13 0352 WASHER 0.50 USS FLAT ZINC 64 5468 NUT 0.50-13 HHGR8 NYLOC 35 27810 SPACER 3315 SNATCH BLOCK UHMW 26 16607PC SPACER 3315 SNATCH BLOCK 17 47868 CAP SCR 0.50-13X2.75 HHGR8 38 9610 WIRE ROPE 0.31 6X19 IWRC-XIP 90FT 19 9263 PIN .38X3.00 QUICK RELEASE 1
1NOT 3-ENARC KOOH8106C0111 0375 MACHY WASHER 0.75ID 14GA 2
1RETTOC 05.2X57.0 NIPPZ4252421200.1X521. NIP RETTOC4287331
8
13
11
12
1113
43
1
2
10 9
1
5
3
7
6
PN 50492
Cable & Hook Assembly - PN 50492
20 EC6000 Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI1 20088 CONTROL HANDLE HOUSING 4 FCTN HET 12 51830 CONTROL HANDLE FACE PLT 5 FCTN 13 24385 GUARD RADIO SWITCH 4 FCTN 14 22600 SWITCH TOGGLE HET RADIO 63019300 55 35441 BATTERY TUBE AA HETRONIC RADIO 16 16975 SWITCH E STOP ASM HETRONIC RADIO 17 51831 DECAL CONTROL HANDLE 5 FCTN 18 38475 SCREW 4MMX12MM PHMS PH 49 36156 SCREW 4MMX14MM PHMS PH 210 29460 SCREW 3MMX35MM PHMS PH 211 50932 CONTROL HANDLE GRIP LESS TRIGGER HET H2 1
SEE NOTE
3
5
11
1
2
6
4
10
NOTE: 1) P/N'S 25999 & 24958 ARE OPTIONAL COVERS FOR THE SWITCHES AND TRIGGER
7
8
9
PN 67894
Radio Transmitter Assembly - PN 67894
21
HYDRAULIC COMPONENTSPART# DESCRIPTIONC6069 HYDRAULIC SWING MOTOR21151 GASKET - HYDRAULIC SWING MOTOR53378 POWER UNIT 12V EC600044028 VALVE CARTRIDGE - POWER UNIT 12V #19012-D44027 VALVE COIL - POWER UNIT 12V #11494-D44029 MOTOR 12V - POWER UNIT #08111-144030 12V SOLENOID (12volt hydraulic system) #1775744025 FILL CAP - HYDRAULIC RESERVOIR9803 C-BALANCE VALVE
51840 SEAL KIT - MAIN LIFT CYLINDER55205 SEAL KIT - EXTENSION CYLINDER44534 PRESSURE SWITCH54862 CONTROLLER SOLENOIDC2027 O'RING - # 4 FACE SEALC2028 O'RING - # 6 FACE SEALD1245 O'RING - # 4 SAED1246 O'RING - # 6 SAE
ASSEMBLY COMPONENTSWORM GEAR - ROTATION BEARINGBEARING & SEAL KIT - ROTATION BEARINGSEAL & SHIM KIT
44533
558275582955978
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" RND11542 BOOM STOP FLAT7403 PIN CAP 0.44" X 2.50" X 0.19" SS9320 PIN CAP 0.44" X 1.75" X 0.25" SS
C6353 WASHER 0.38 FLAT GR813573 CAP SCR. 0.38-16 X 1.00" GR80375 MACHINE WASHER -0.75" ID 14GA.0423 MACHINE WASHER -0.75" ID 10GA.
50387 SHEAVE9610 WIRE ROPE
42977 HITCH PIN 0.63" X 4.00"9263 QUICK RELEASE PIN .38 X 3.00"
50386PC CRADLE PLATE27710 SPRING ANTI-2-BLOCKC6018 HOOK 3-TON10709 SAFETY LATCH FOR 3 TON HOOKC1592 GREASE ZERK
ELECTRICAL COMPONENTS35105 LIMIT SWITCH11544 CORD REEL47410 MOMENTARY SWITCH17771 PUSH BUTTON (12volt hydraulic system)53230 WINCH54918 FUSE 300 AMP28978 BOSCH RELAY
RADIO REMOTE COMPONENTS42976 RADIO REMOTE SYSTEM50932 HANDLE ASM16975 E-STOP SWITCH22600 TOGGLE SWITCH20088 LOWER TRANSMITTER HOUSING51830 UPPER FACE PLATE HOUSING51831 FACE PLATE DECAL24385 SWITCH PROTECTION GUARD35441 BATTERY TUBE HOLDER35916 BACK UP CORD
Replacement Parts 21
Chapter 4 - Replacement Parts