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stellar labs ECCR Owner's Manual

Container carrier
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C
C
ONTAINER
ARRIER
O
' M
WNERS
ANUAL
Safety • Operation • Parts
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
Subject to Change without Notification.
www.stellarindustries.com
© 2009 Stellar Industries, Inc.
Last Revision: 05/12/09

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  • Page 1 ONTAINER ARRIER ’ M WNERS ANUAL Safety • Operation • Parts Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 Subject to Change without Notification. www.stellarindustries.com © 2009 Stellar Industries, Inc. Last Revision: 05/12/09...
  • Page 2 ECCR Owner’s Manual Stellar ECCR Manual Revisions Date of Revision Section Revised Description of Revision...
  • Page 3 Table of Contents Table of Contents...
  • Page 4 ECCR 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.
  • Page 5 Introduction Stellar Container carriers are designed to general and may or may not apply to your provide safe and dependable service. With specific model. proper use and maintenance, these container carriers will operate at peak This manual is not binding. Stellar Industries, performance for many years.
  • Page 6 ECCR Owner’s Manual ECCR Nomenclature Lift Frame Fork Frame Inner Lift Frame Base Frame ECCR Specifications Center of gravity of container is located approximately 43” behind rear axle. For “moment” calculations, subtract 740 lbs. from the weight of container. Specifications...
  • Page 7 Safety Chapter 1 - Safety Please Read the Following Carefully! shoes with steel toes, protective gloves, anti- This portion of the manual contains noise headphones, protective glasses, information regarding all Stellar breathing apparatus, and reflective jackets. manufactured container carriers. Some Consult your employer regarding current items contained within this chapter may not safety regulations and accident-prevention...
  • Page 8 ECCR Owner’s Manual safety devices. Do not remove any decals. Replace any decals that are missing, Do not push on fixed objects or bodies with damaged, or not the forks of the container carrier. legible. Do not permit loose objects on the container The safety instruction plates, notices, load carrier.

  • Page 9: Decal Placement

    Safety Decal Placement 7 BOTH SIDES 8 BOTH SIDES BOTH SIDES BOTH SIDES ITEM PART DESCRIPTION QTY. 45976 DECAL DNGR WATCH ELEC LINES 45726 DECAL WARNING HYDRAULIC SAFETY 45974 DECAL CAUTION-OPERATING INST. 45906 DECAL HOIST UP (IN TRUCK CAB) 45975 DECAL CAUTION-FORK CARRIAGE (QTY 1 IN TRUCK CAB) C5910 DECAL STELLAR LOGO 4.00X9.50...
  • Page 10 ECCR Owner’s Manual...

  • Page 11: Chapter 2 - Operation

    Operation Chapter 2 - Operation Job-Site Set-Up 1. Qualified individual. Thoroughly plan the lift before positioning the 2. Trainees under direct supervision of the quali- vehicle. Consider the following: fied individual. 1. The vehicle should be positioned in an area 3.
  • Page 12 ECCR Owner’s Manual Lifting a Front Load Container Lower Forks Raise Lift Frame 2. Engage the pump and raise the lift frame up 1. If the forks are in the stored position, a minimum of 2” to disengage the automatic manually rotate them to the extended safety latch.
  • Page 13 Operation Lifting a Front Load Container Continued... Tilt Back Forks to Container Raise Lift Frame 6. Raise the lift frame and tilt the forks up until 5. Back the truck up to the container to be lifted the container clears the ground. and align the forks with the container pockets.
  • Page 14 ECCR Owner’s Manual Placing a Front Load Container Tilt Forks Raise Lift Frame Extend Inner Back Lift Frame 1. Back the truck up close to where the container 2. Fully extend the inner lift frame and tilt the will be placed. From the transport position, the forks down.
  • Page 15 Operation Lifting a Rear Load Container Raise Lift Frame 1. If the forks are in the extended position, 2. Engage the pump and raise the lift frame up a manually rotate them to the stored position minimum of 2” to disengage the automatic and lock in place with the fork stop pin.
  • Page 16 ECCR Owner’s Manual Placing a Rear Load Container Raise Tilt Lift Forks Frame Extend Inner Back Lift Frame 1. Back the truck up close to where the container 2. Back the truck up until the container is will be placed. Set both trunnion bar stops to centered over the area where you want ‘unlocked’...
  • Page 17 Operation Trunnion Bar Stops Trunnion Trunnion Stop Stop Unlocked Locked Position Position Operation of Rotator Important Notes: Do not lift a container heavier than 8,000 lbs. max Do not rotate fork carriage with forks in stored posi- tion. Possible damage to fork carriage may result. Do not use rotator with rear load container.
  • Page 18 ECCR Owner’s Manual Warning! Cylinder Collision Point CYLINDER COLLISION POINT Do not fully extend the tilt cylinder when the inner lift frame is fully retracted. Equipment damage WILL result.

  • Page 19: Chapter 4 - Installation

    Chapter 4 - Installation Installation Container Carrier Mounting and Assembly or higher grade. If higher grade fasteners Study names and locations of the parts and are used, these should only be tightened to familiarize yourself with the container carrier the strength of the original. before starting the assembly .
  • Page 20 ECCR Owner’s Manual Truck Chassis The Stellar Container Carrier will mount on any dual rear wheel chassis, one ton or larger, that meets minimum dimensional requirements. (See Figure 1 below.) Figure 1 84” Minimum Center of grav- Cab-to-Axle 32” ity of container...
  • Page 21 Installation Pintle Hitch Detail - PN 46125 FRAME RAIL WELD BACK VIEW FRAME RAIL 1/4" WELD PN 46125 ITEM PART DESCRIPTION QTY. 4401 TIE DOWN RING 4.25X4.25X0.63 44913 FLAT HITCH PLATE STIFFENER KPCC 5406 PINTLE HOOK 30000# PH-T-60-AOL-8 5468 NUT 0.50-13 HHGR8 NYLOC 8833 CAP SCR 0.50-13X2.00 HHGR8 44918PC...
  • Page 22 ECCR Owner’s Manual Container Carrier Mounting Instructions 1. Carefully remove the banding holding the fenders and box of parts. 2. Set the container carrier on the truck frame with the rear of the container carrier even with the truck frame. See Figure 1. Center the container carrier on the truck frame at the front and rear.
  • Page 23 Installation Oil Tank, Valve and Hose Installation Refer to Figure 7 on the next page for the JIC fittings (part#25--300) and two (2) 90º steps listed below: 3/4 JIC female to 3/4 JIC male fittings 1. Mount the hydraulic tank to the support (part#25--310) in the cap end ports of frame of the container carrier with four the fork tilt cylinders.
  • Page 24 ECCR Owner’s Manual Oil Tank, Valve and Hose Installation Continued... Figure 7 New Pump Pic Here... Please read the following closely: Clean all hydraulic components and keep all hoses, tubes, valves, and fittings capped until they are to be installed.
  • Page 25 Installation Oil Tank, Valve and Hose Installation Continued... Item PN Description Qty. 46154 PUMP HYD MUNCIE 11 GPM KPCC 48939 FTG 1.00(M)NPT TO 1.25 BARB C4819 HOSE CLAMP HC-200 17767 HOSE SUCT 1.25 10FT 47772 FTG TEE 8 WJTX-S 46721 HOSE 0.5(471TC-JC-J9-8-8-8-84) C6229 FILTER LONG ZAE-10L C5552 FILTER STRAINER TFS-1220-0...
  • Page 26 ECCR Owner’s Manual Hose Installation - Rotator It e m PartNum ber PartDesc ri pt i on Qty. 24--389R Hose Assembly 1/2” x 210” JIC 25--362 1/2NPT (M) to 3/4 JIC (M) 90_ Fitting 25--312 O--Ring 37_ Flare x 45_ Ell...

  • Page 27: Cable Control Installation

    Installation Cable Control Installation Important The standard cable controls supplied with Stellar equipment are a high-quality assem- A. A good cable path is essential for a bly which seal out moisture, are corrosion properly operating system. Keep bends protected, and engineered to minimize in the cable path to a minimum and as backlash (lost motion).
  • Page 28 ECCR Owner’s Manual Cable Control Installation Continued... Cable Connections 8. Remove the screw from the cable controller where the cable end will install. Do not remove the other screws passing through the cable control housing. 9. Screw the hex threaded...
  • Page 29 Installation Air Control Installation (V20) The optional air controller provided with 6. Apply a small bead of removable thread Stellar equipment are dual three-way regu- lock to the threads of the spool adapter lating valves. Output of the controllers is (item 1).
  • Page 30 ECCR Owner’s Manual Air Control Installation (V20) Continued... Pre-Assembled Air Control Tower Installation ators. (See Figure 15 on following page) 5. Connect the air lines to the elbow fittings 1. Determine a suitable location which is in in the air actuators.
  • Page 31 Installation Air Controls - PN 47144 PN 47144 ITEM PART DESCRIPTION 45307 CONTROL TOWER ASM 2SECT AIR 1 0345 CAP SCR 0.38-16X1.50 HHGR5 0347 NUT 0.38-16 HHGR5 NYLOC 0346 WASHER 0.38 USS FLAT ZINC...
  • Page 32 ECCR Owner’s Manual 3-Section Air Controls - PN 46152 PN 46152 ITEM PART DESCRIPTION QTY. 45244 CONTROL TOWER ASM 3SECT AIR K-PAC 0345 CAP SCR 0.38-16X1.50 HHGR5 0346 WASHER 0.38 USS FLAT ZINC 0347 NUT 0.38-16 HHGR5 NYLOC...
  • Page 33 Installation Hoist-Up Light Installation 1. Locate the switch mounting plate (PN light should fail, neither light would func- 44766) on the curb side base tube on the tion. carrier. See Figure 16 below. 7. Caution: The LED warning light is polarity sensitive.

  • Page 34: Fender Installation

    ECCR Owner’s Manual Hydraulic System Start-Up Procedure Caution: Do not operate the pump until the 3. Check the carrier for loose parts, tools, system is filled with oil. Damage to the clamps, or chains. pump bearing and shafts can occur.

  • Page 35: Hydraulic Schematic

    Installation Hose Kit - PN 49534 PN 49534 Hydraulic Schematic TILT CYLINDERS CONTROL VALVE LIFT CYLINDERS ROTATOR MOTOR ITEM PART DESCRIPTION QTY. 50636 HOSE .38X102.00 50643 HOSE .38X217.00...
  • Page 36 ECCR Owner’s Manual...

  • Page 37: Chapter 3 - Assembly Drawings

    Assembly Drawings 31 Chapter 3 - Assembly Drawings Base Assembly - PN 51313 PN 51313 21810 BUSHING BPC24DXR12 1.50X.75 23699 BUSHING BPC32DXR20 2.00X1.25 0108 SNAP RING 2.00 7200-200 0249 BUSHING BPC20DXR20 1.25X1.25 23462 CYLINDER ASM 4.00X26.50 51394 CYLINDER ASM 3.50X55.19 8622 CLAMP HOSE/TUBE AG-2 0347...
  • Page 38 ECCR Owner’s Manual Lift Cylinder Assembly - PN 23462 PN 23462 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK...
  • Page 39 Assembly Drawings 33 Tilt Cylinder Assembly - PN 51394 PN 51394...
  • Page 40 ECCR Owner’s Manual Lift Frame Assembly - PN 51385 PN 51385 52554PC PLATE WEAR PAD SUPPORT ECCR 30659 NUT 0.25-20 HH NYLOC SS C5902 WASHER 0.63 SAE FLAT YELLOW GR8 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 0108 SNAP RING 2.00 7200-200 23699 BUSHING BPC32DXR20 2.00X1.25...
  • Page 41 Assembly Drawings 35 Extension Cylinder Assembly - PN 51396 PN 51396...
  • Page 42 ECCR Owner’s Manual Inner Lift Frame Assembly - PN 51397 PN 51397 21810 BUSHING BPC24DXR12 1.50X.75 0249 BUSHING BPC20DXR20 1.25X1.25...
  • Page 43 Assembly Drawings 37 Fork Frame Assembly - PN 51308 PN 51308 ITEM PART DESCRIPTION QTY. 51205 FORK FRAME SICHR EXT 4032 BEARING SWING DRIVE 6000 51303 CARRIAGE FRAME WLDMT ROTATOR EXT 47489 PLATE SPACER FORK KPAC C5902 WASHER 0.63 SAE FLAT YELLOW GR8 0346 WASHER 0.38 USS FLAT ZINC 0343...
  • Page 44 ECCR Owner’s Manual Reservoir Assembly - PN 51433 PN 51433 24722 RSRVR ASM 10 GAL BULKHEAD MNT 48141 CAP SCR 0.50-13X8.50 HHGR5 0352 WASHER 0.50 USS FLAT ZINC C6106 NUT 0.50-13 HHGR5 NYLOC 1115 FTG NIPPLE HEX MALE 0101-20-20 C2282 FTG 1.25 NPT TO 1.25 BARB...
  • Page 45 Assembly Drawings 39 Reservoir Assembly - PN 24722 PN 24722 ITEM NO. PART NO. DESCRIPTION QTY. C5552 FILTER STRAINER TFS-1220-0 C2126 MAGNETIC PLUG DRAIN 3/4" 24723 RSRVR WLDMT HYD 10GAL 26HX19WX6D...

  • Page 46: Valve Bank Assembly

    ECCR Owner’s Manual Valve Bank Assembly ITEM PART DESCRIPTION QTY. 51513 VB 4-SECT VDM8 AIR CYL SPOOLS C2252 FTG ADAPT 8-10-F5OLO-S...
  • Page 47 Assembly Drawings 41 4 Section Control Tower Assembly - PN 51605 CAB FLOOR ITEM PART DESCRIPTION QTY. 51455 CONTROL TOWER ASM 4SECT AIR 0345 CAP SCR 0.38-16X1.50 HHGR5 0535 NUT 0.38-16 HHGR5 0346 WASHER 0.38 USS FLAT ZINC 45687 ELBOW ADAPTER MALE SWIVEL (NOT SHOWN IN DRAWING)

  • Page 48: Bumper Assembly

    ECCR Owner’s Manual Bumper Assembly ITEM PART DESCRIPTION QTY. 51618 PULL PLATE PINTLE 30K W/ BUMPER C4862 GROMMET FOR 2 CLEARANCE 30700 10334 GROMMET 4.00 ROUND LAMP (PETERSON) 27626 LIGHT BACKUP LED 62391 13143 LIGHT STOP/TURN/TAIL 4 RND LED 13145...

  • Page 50: Warranty Statement

    ECCR Owner’s Manual Warranty Statement...

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