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stellar labs Flex Series Owner's Manual

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Owner's Manual
Safety, Installation, Maintenance, and Operation
Subject to Change without Notification.
© 2006 Stellar Industries, Inc.
Stellar Flex™ Series Hooklift
FLEX36
108-12-36
120-14-36
Stellar Industries, Inc.
www.stellarindustries.com
60-8-36
84-10-36
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
Manual Part No. 35551
Last Revision: 4/25/06

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  • Page 1 Owner’s Manual Safety, Installation, Maintenance, and Operation Stellar Flex™ Series Hooklift FLEX36 60-8-36 84-10-36 108-12-36 120-14-36 Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 www.stellarindustries.com Manual Part No. 35551 Subject to Change without Notification. ©...
  • Page 2 Stellar Flex Manual Revisions Date of Revision Section Revised Description of Revision April 25th, 2006 Chapter 7: Assembly Updated the Main Cylinder Drawing for the 84-10, Drawings 108-12, 120-14 to reflect the new tubing additions.
  • Page 3 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 operation 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 HOOKLIFT IS A MISUSE OF THE EQUIPMENT.
  • Page 4 Introduction repair instructions pertinent to all possible situ- Stellar Hooklifts are designed to provide safe ations. This manual is not binding. Stellar and dependable service for a variety of opera- Industries, Inc. reserves the right to change, at tions. With proper use and maintenance, any time, any or all of the items, components, Stellar Hooklifts will operate at peak perform- and parts deemed necessary for product...

  • Page 5: Table Of Contents

    Table of Contents Chapter 1 - Safety Chapter 2 - Operation Chapter 3 - Maintenance Chapter 4 - Specifications Chapter 5 - Decals Chapter 6 - Installation Chapter 7 - Assembly Drawings Chapter 8 - Hydraulics/Electrical Chapter 9 - Replacement Parts Chapter 10 - Troubleshooting 10-1...

  • Page 6: Chapter 1 - Safety

    Chapter 1 - Safety PERSONAL SAFETY Please Read the Following Carefully! This portion of the manual contains infor- Keep clear of all moving parts. mation regarding all Stellar manufactured hooklifts. Some items contained within this Always wear the prescribed personal safety chapter may not apply to your specific devices.
  • Page 7 Release system pressure before attempting to operating the controls. make adjustments or repairs. Do not attempt to lift fixed loads. Do not attempt service or repair when PTO is Know the weight of your load to avoid overload- engaged. ing the equipment. Decals are considered safety equipment.
  • Page 8 HOOKLIFT CONTROLS 1. Be familiar with the sequence and operation of the hooklift controls. 2. Each individual hooklift 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.

  • Page 9: Chapter 2 - Operation

    Chapter 2 - Operation Operation Overview Job-Site Set-Up Thoroughly plan the lift before positioning the vehicle. Consider the following: Unloading Operation 1. The vehicle should be positioned in an area free from overhead obstructions to eliminate the 1. Stop the truck at the location you wish to unload. need for repositioning.
  • Page 10 Unloading Operation 1. Stop the truck at the location you wish to 2. Put the truck in neutral and engage the unload. PTO. 3. Locate the black control lever labeled tilt. 4. Pull tilt lever until full stroke is reached, thus releasing tabs.
  • Page 11 Loading Operation 2. Engage the hook to the body by maneuver- 1. Perform the steps for unloading a container. ing the loader with the red(lift) lever and the black (tilt) lever.. 4. Push the black(tilt) lever until the tilt is fully 3.
  • Page 12 Dumping Operation 1. Stop the truck at the location you wish to 2. Put the truck in neutral and engage the dump the load. PTO. 3. Locate the red lever labeled lift. 4. Pull the lift lever to dump the body. 5.
  • Page 13 Operator Information Operator Requirements Operator Conduct Operation is limited to the following people: 1. Operators will not engage in any operation that A. Qualified individual. would cause them to divert attention away from the B. Trainees under direct supervision operation of the hooklift. of the qualified individual.

  • Page 14: Chapter 3 - Maintenance

    Chapter 3 - Maintenance Daily Inspection WARNING - Read the Following Daily Inspection should occur each day before before performing any mainte- the hooklift is put into use. Each day, inspect nance on the hooklift. the hooklift for all of the following: 1.
  • Page 15 Monthly Inspection Monthly Inspection should occur at the begin- Service ning of every work month. Each month, The following general suggestions should inspect the hooklift for all of the following: be helpful in analyzing and servicing your 1. Frame bolt tightness - turn barrel nuts and hooklift.
  • Page 16 Choice Lubricants for DX Bearings Greases Recommended Type of Grease Description Premium Quality Stabilized, Anti-Oxidant Lithium Base Multi-Purpose Lithium Base with 3% Molybdenum Disulfide High Drop Point Multi-Purpose Calcium Based, for General Automotive and Industrial Use Calcium Grease, Water Stabilized, High Drop Point Anti-Friction Bearing Calcium Based with EP Additives Lithium Based...

  • Page 17: Chapter 4 - Specifications

    Chapter 4 - Specifications • Standard in-cab manual controls which allow for precise metering of the manual hydraulic valve. Solenoid-activated hydraulic control valve with electric remote control pendant is optional. • Ten (10) gallon capacity frame-mounted oil reservoir. • Hydraulic flow shall not exceed 16-gallons per minute. •...
  • Page 18 Stellar Flex Model 60-8 Hydraulic Hooklift Specifications Lifting Capacity: Check table 1.1 for variable lifting capabilities. Container Length: 8-foot through 9-foot. Longer bodies up to 10-feet may be accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
  • Page 19 Stellar Flex Model 84-10 Hydraulic Hooklift Specifications Lifting Capacity: Check table 1.1 for variable lifting capabilities. Container Length: 10-foot through 12-foot. Longer bodies up to 13-feet may be accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
  • Page 20 Stellar Flex Model 108-12 Hydraulic Hooklift Specifications Lifting Capacity: Check table 1.1 for variable lifting capabilities. Container Length: 12-foot through 14-foot. Longer bodies up to 16-feet may be accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
  • Page 21 Stellar Flex Model 120-14 Hydraulic Hooklift Specifications Lifting Capacity: Check table 1.1 for variable lifting capabilities. Container Length: 13-foot through 15-foot. Longer bodies up to 16-feet may be accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).

  • Page 22: Chapter 5 - Decals

    Chapter 5 - Decals Decals of Note Moving Tilt Hazard Decal Location: On each side of the tilt. Function: To inform the operator of the hazard associated with tilt operation, the possible conse- quences should the hazard occur, and how to avoid the hazard PN: C0865 Misuse Hazard Decal...
  • Page 23 Decal Placement PN 35559 Chapter 5 - Decals...

  • Page 24: Chapter 6 - Installation

    Chapter 6 - Installation INSTALLATION INSTRUCTIONS OVERVIEW READ ALL INSTRUCTIONS BEFORE PROCEEDING Mount PTO and pump. Mount reservoir valve combo to truck frame. Connect suction and pressure to tank, valve bank, and pump. Fill oil reservoir to sight gauge (Petro-Canada Hydrex 32 is recommended). Install controllers and cables in cab.
  • Page 25 Setting System Relief Pressure Pressure vs. Capacity Table 1.1* 15500 60 CA 14500 84 CA 108 CA 13500 120 CA 12500 11500 10500 9500 8500 Never Exceed the Maximum Pressure of 4400 psi. 7500 Never adjust System Relief Pressure to allow Loader Capacity to exceed chassis GVW and always per- 6500 form a weight distribution before installation and...
  • Page 26 Setting System Relief Pressure Continued 2. Push the red (lift) lever until the boom bottoms out. 1. Engage the PTO. Run the PTO at 1200 RPM. Keep pushing the lever forward until steps 3-5 are complete. 4. Adjust the system relief pressure using 4 mm allen 3.
  • Page 27 Installation Instructions for the Power Beyond VDM8 Valve These instructions ar intended for correct installation of power beyond on a Salami VDM8 valve bank. If any hydraulic component is integrated after this valve the power beyond must be installed correctly, or serious damage may incur to the hydraulic system. 2.
  • Page 28 Mounting Kit (60-8) Mounting Kit P/N 33320 ITEM PART DESCRIPTION QTY. D0143 TIE DOWN CHANNEL C1025 CAP SCR 0.63-11X2.00 HHGR8 ZY C1038 WASHER 0.63 FLAT 24868 NUT 0.63-11 HH NYLOC D0045 BACKUP ALARM .97 DECIBAL Chapter 6 - Installation...
  • Page 29 Mounting Kit (84-10, 108-12, 120-14) P/N 23700 Chapter 6 - Installation...
  • Page 30 Rotary Valve (60-8, 84-10, 108-12, 120-14) 37741 22450 WLDMT ROTARY VALVE ECCENTRIC D1638 O'RING 1.12X1.38X0.12 568-216 3748 WASHER ROTARY VALVE 0480 CAP SCR 0.25-20X1.00 HHGR5 0353 CAP SCR 0.38-16X2.00 HHGR5 0347 NUT 0.38-16 HH NYLOC 0977 O'RING 1.00X1.25X0.12 568-214 22449 PLATE ROTARY VALVE ARM 0482 CAP SCR 0.25-20 X 3.00 HHGR5 0333 NUT 0.25-20 HHGR5 NYLOC 7350 FTG ST RUN TEE 8R5OLO...
  • Page 31 10 Gallon Hydraulic (60-8, 84-10, 108-12, 120-14) P/N 35883 26455 RSRVR ASM 10GAL K MODEL C4227 FTG MF/MSTR 90 8-12 C5OLO-S 1115 FTG NIPPLE HEX MALE 0101-20-20 26731 HOSE 0.50(381-JC-J9-8-8-8-18-0) c2242 ST EL 0.75 90 DEG BLK 0352 WASHER 0.50 USS FLAT ZINC 3320 NIPPLE 0.75X12.00 PIPE C6106 NUT 0.50-13 HHGR5 NYLOC 0506...
  • Page 32 Dump Light Kit Installation • Bolt L-bracket to front of base, drilling and tapping holes in appropriate area. • Attach dump light switch to L-bracket. • Drill and tap ¼-20 hole in bottom of secondary tube. Hole should be located directly above dump light switch when secondary is in lowered position.
  • Page 33 Subframe (60-8) Chapter 6 - Installation 6-10...
  • Page 34 Subframe (84-10) Chapter 6 - Installation 6-11...
  • Page 35 Subframe (108-12) Chapter 6 - Installation 6-12...
  • Page 36 Subframe (120-14) Chapter 6 - Installation 6-13...

  • Page 37: Chapter 7 - Assembly Drawings

    Chapter 7 - Assembly Drawings Base Assembly (60-8) P/N 31823 ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 31815 BASE WLDMT 60- 8 FLEX36 C0953 CAP SCR 0.38-16X4.00 HHGR5 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0347 NUT 0.38-16 HH NYLOC 19291 ROLLER 4" OD c1592 ZERK 1/8 NPT STRAIGHT 1546 THRUST WASHER 2.01DIA UHMW .12THK...
  • Page 38 Base Assembly (84-10) P/N 33337 ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 33338 BASE WLDMT 84-10 FLEX36 c1592 ZERK 1/8 NPT STRAIGHT 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK C0078 HOSE CLAMP #8 RUBBER COATED 19291 ROLLER 4" OD 0479 CAP SCR 0.25-20X0.75 HHGR5 1546 THRUST WASHER 2.01DIA UHMW .12THK 0333...
  • Page 39 Base Assembly (108-12) P/N 34245 ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 34246 BASE WLDMT 108-12 FLEX36 0532 CAP SCR 0.38-16X3.75 HHGR5 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0347 NUT 0.38-16 HH NYLOC 19291 ROLLER 4" OD c1592 ZERK 1/8 NPT STRAIGHT 1546 THRUST WASHER 2.01DIA UHMW .12THK C0078 HOSE CLAMP #8 RUBBER COATED...
  • Page 40 Base Assembly (120-14) P/N 33419 ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 33418 BASE WLDMT 120-14 FLEX36 0532 CAP SCR 0.38-16X3.75 HHGR5 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0347 NUT 0.38-16 HH NYLOC 19291 ROLLER 4" OD c1592 ZERK 1/8 NPT STRAIGHT 1546 THRUST WASHER 2.01DIA UHMW .12THK C0078 HOSE CLAMP #8 RUBBER COATED...
  • Page 41 Dump Assembly (60-8) P/N 31824 ITEM PART DESCRIPTION QTY. 31822 DUMP WLDMT 60-8 FLEX36 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 22227 PIN 2.00X25.25 2257 SNAP RING INSIDE 2.00 33062 TAB LOADER WLDMT BREAK AWAY 0332 CAP SCR 0.31-18X1.75 HHGR5 23301 TAB LOADER BREAK AWAY 0506 CAP SCR 0.50-13X4.00 HHGR5 0333...
  • Page 42 Dump Assembly (84-10) P/N 33339 ITEM PART DESCRIPTION QTY. 33340 DUMP WLDMT 84-10 FLEX36 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 22227 PIN 2.00X25.25 2257 SNAP RING INSIDE 2.00 33062 TAB LOADER WLDMT BREAK AWAY 0332 CAP SCR 0.31-18X1.75 HHGR5 23301 TAB LOADER BREAK AWAY 0506 CAP SCR 0.50-13X4.00 HHGR5 0333...
  • Page 43 Dump Assembly (108-12) P/N 34247 ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 34248 DUMP WLDMT 108-12 FLEX36 0506 CAP SCR 0.50-13X4.00 HHGR5 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0332 CAP SCR 0.31-18X1.75 HHGR5 22227 PIN 2.00X25.25 0333 NUT 0.25-20 HHGR5 NYLOC 2257 SNAP RING INSIDE 2.00 C6106 NUT 0.50-13 HHGR5 NYLOC...
  • Page 44 Dump Assembly (120-14) P/N 33417 ITEM PART DESCRIPTION QTY. 33416 DUMP WLDMT 120-14 FLEX36 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 22227 PIN 2.00X25.25 2257 SNAP RING INSIDE 2.00 33062 TAB LOADER WLDMT BREAK AWAY 23301 TAB LOADER BREAK AWAY 0506 CAP SCR 0.50-13X4.00 HHGR5 0332 CAP SCR 0.31-18X1.75 HHGR5 0333...
  • Page 45 Secondary Assembly (60-8) P/N 33047 ITEM PART DESCRIPTION QTY. 33048 SECONDARY WLDMT 60-8 FLEX36 27116 CYLINDER ASM 27020 4.00X29.63 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 22286 PIN 2.00X16.00 2257 SNAP RING INSIDE 2.00 0068 BUSHING QSI-1618-24 0069 BUSHING QSI-1618-16 22285 PIN 1.00X15.00 3875 SNAP RING 1.00 INTERNAL c1592 ZERK 1/8 NPT STRAIGHT...
  • Page 46 Secondary Assembly (84-10) P/N 33341 ITEM PART DESCRIPTION QTY. 33342 SECONDARY WLDMT 84-10 FLEX36 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0069 BUSHING QSI-1618-16 3875 SNAP RING 1.00 INTERNAL 22285 PIN 1.00X15.00 22286 PIN 2.00X16.00 2257 SNAP RING INSIDE 2.00 0068 BUSHING QSI-1618-24 33404 CYLINDER ASM 5.50X40.00 c1592 ZERK 1/8 NPT STRAIGHT Chapter 7 - Assembly Drawings...
  • Page 47 Secondary Assembly (108-12) P/N 34249 ITEM PART DESCRIPTION QTY. 34250 SECONDARY WLDMT 108-12 FLEX36 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0068 BUSHING QSI-1618-24 0069 BUSHING QSI-1618-16 3875 SNAP RING 1.00 INTERNAL 22285 PIN 1.00X15.00 22286 PIN 2.00X16.00 2257 SNAP RING INSIDE 2.00 33462 CYLINDER ASM 5.50X52.38 c1592 ZERK 1/8 NPT STRAIGHT Chapter 7 - Assembly Drawings...
  • Page 48 Secondary Assembly (120-14) P/N 33415 ITEM PART DESCRIPTION QTY. 33414 SECONDARY WLDMT 120-14 FLEX36 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0068 BUSHING QSI-1618-24 0069 BUSHING QSI-1618-16 3875 SNAP RING 1.00 INTERNAL 22285 PIN 1.00X15.00 22286 PIN 2.00X16.00 2257 SNAP RING INSIDE 2.00 33462 CYLINDER ASM 5.50X52.38 c1592 ZERK 1/8 NPT STRAIGHT Chapter 7 - Assembly Drawings...
  • Page 49 Tilt Assembly (60-8, 84-10, 108-12, 120-14) P/N 33049 ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 33050 TILT WLDMT FLEX36 33103 PIN WLDMT 1.00X10.50 23460 CYLINDER ASM 3.00X17.00 D0419 THRUST WASHER 0069 BUSHING QSI-1618-16 33104 COLLAR 1.03X2.00X1.00 0064 PIN 1.00X3.38 0339 CAP SCR 0.25-20X2.50 HHGR5 0110...
  • Page 50 Tilt Assembly (Optional Tall Tilt) P/N 35032 Chapter 7 - Assembly Drawings 7-14...
  • Page 51 Tilt Cylinder (60-8, 84-10, 108-12, 120-14) P/N 23460 Note: This Tilt Cylinder uses Stellar Seal Kit P/N C6301. ITEM PART DESCRIPTION QTY. 3767 CYLINDER 3.00X17.00 0279 FTG ADAPT 6-F5OLO-S 0068 BUSHING QSI-1618-24 Chapter 7 - Assembly Drawings 7-15...
  • Page 52 Main Cylinder (60-8) P/N 27116 Note: This Main Cylinder uses Stellar Seal Kit P/N 32565. ITEM PART DESCRIPTION QTY. 27020 CYLINDER 4.00X29.63 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 15822 MANIFOLD DOUBLE T11A 5000 PSI 27117 TUBE ASM 0.50X11.94 19369 HOSE CLAMP 4.13-7.00 5416K38 18701 CLAMP PORT TUBE ZR518 D1290 FTG ADAPT 8-6 F5OLO-S Chapter 7 - Assembly Drawings...
  • Page 53 Main Cylinder (84-10) P/N 33404 BUSHINGS SHOWN AS REFERENCE Note: This Main Cylinder uses Stellar Seal Kit P/N 35646. D1290 FTG ADAPT 8-6 F5OLO-S 15822 MANIFOLD DOUBLE T11A 5000 PSI 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 19369 HOSE CLAMP 4.13-7.00 5416K38 18701 CLAMP PORT TUBE ZR518 16256 TUBE ASM 0.50X6.75 MAIN CYL 60-10-8 Chapter 7 - Assembly Drawings...
  • Page 54 Main Cylinder (108-12, 120-14) P/N 33462 BUSHINGS SHOWN AS REFERENCE Note: This Main Cylinder uses Stellar Seal Kit P/N 35646. D1290 FTG ADAPT 8-6 F5OLO-S 15822 MANIFOLD DOUBLE T11A 5000 PSI 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 19369 HOSE CLAMP 4.13-7.00 5416K38 18701 CLAMP PORT TUBE ZR518 16256...

  • Page 55: Chapter 8 - Hydraulics/Electrical

    Chapter 8 - Hydraulics - Electrical Hose Kit (60-8) P/N 34616 PRESSURE FROM PUMP RETURN TO TANK Chapter 8 - Hydraulics-Electrical...
  • Page 56 Hose Kit (84-10) P/N 34617 PRESSURE FROM PUMP RETURN TO TANK Chapter 8 - Hydraulics-Electrical...
  • Page 57 Hose Kit (108-12) P/N 34618 PRESSURE FROM PUMP RETURN TO TANK Chapter 8 - Hydraulics-Electrical...
  • Page 58 Hose Kit (120-14) HOSE KIT P/N 34619 PRESSURE FROM PUMP RETURN TO TANK Chapter 8 - Hydraulics-Electrical...
  • Page 59 Part 1: Controller Assembly (60-8, 84-10, 108-12, 120-14) P/N 26414 In Cab Installation At Valve Installation Chapter 8 - Hydraulics-Electrical...
  • Page 60 Part 2: Controller Assembly (60-8, 84-10, 108-12, 120-14) Danger MISUSE HAZARD Operation of loader when dump tabs are not properly fastened, can result in unexpected personal and equipment damage. Inspect tabs daily. 26134 Installation Instructions: Connect the 12 Volt ignition wire to a key-on battery source. Hookup the wire harness in the cab to the wire harness from the loader Alarm will now sound when dump tabs have been damaged.

  • Page 61: Chapter 9 - Replacement Parts

    Chapter 9 - Replacement Parts Part# Description Where Used C6222 Hydraulic Filter 60-8 thru 120-14 C5552 Hydraulic Filter Strainer 60-8 thru 120-14 15462 Fill Cap Asm 60-8 thru 120-14 15463 Thermo Sight Gauge 60-8 thru 120-14 C2028 O Ring #6 Face Seal 60-8 thru 120-14 C2029 O Ring #8 Face Seal...

  • Page 62: Chapter 10 - Troubleshooting

    Chapter 10 - Troubleshooting Problem: Hydraulic system gets extremely hot. This chapter will list a number of Solutions: potential problems that may occur • Make sure the hydraulic filter has been changed per the maintenance page of the Hooklift Owner’s Manual. while operating the Hooklift.
  • Page 63 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. The warranty period shall cover the following: Twelve (12) month warranty on parts, Twelve (12) month repair labor, and...

This manual is also suitable for:

Flex3660-8-3684-10-36108-12-36120-14-36

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