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Flex36 Hooklift Manual Revisions

Date of Revision

August 27, 2007

May 14, 2008

January 14, 2010

Description of Revision

Updated Reservoir Assembly Drawing (PN 35883) to reflect

engineering changes.

Updatted Base Assembly Drawing Drawings to reflect

engineering changes.

Updated Controller Assembly to reflect engineering

changes.

Section Revised

Chapter 6 - Installation

Chapter 7 - Assembly

Drawings

Chapter 6: Installation

Summary of Contents for Flex36 108-12

Page 1: ...0 321 3741 Fax 641 923 2811 www stellarindustries com Safety Operation Installation Maintenance OWNERS MANUAL FLEX36 HOOKLIFT Manual Part No 35551 Last Revision 01 14 10 Subject to Change without Noti...

Page 2: ...f Revision Updated Reservoir Assembly Drawing PN 35883 to reflect engineering changes Updatted Base Assembly Drawing Drawings to reflect engineering changes Updated Controller Assembly to reflect engi...

Page 3: ...lve All Models PN 37741 24 Reservoir Assembly PN 35883 25 Setting System Relief Pressure 26 Installation Instructions for the Power Beyond VDM8 Valve 28 Port Side Relief Installation 29 Controller Ass...

Page 4: ...Use only factory approved accessories options and parts on this equipment The rebuilding or remounting of this equipment requires the mounting procedures and retesting to be in accordance with factor...

Page 5: ...the unit A few notes on this manual A copy of this manual is provided with every hooklift and shall remain with the hooklift at all times Information contained within this manual does not cover all m...

Page 6: ...ng containers to dump bodies Two independently controlled cylinders operate all the functions of the Stellar Flex By varying the cylinder operation the Stellar Flex can be used to dump or unload a bod...

Page 7: ...fety devices Do not remove any decals Chapter 1 Safety General Safety It is the responsibility of the owner to instruct the operator in the safe operation of your equipment and to provide the operator...

Page 8: ...not attempt to lift fixed loads Know the weight of your load to avoid over loading the equipment Deduct the weight of the body from the maximum load rating to determine how much weight can be lifted...

Page 9: ...be fully extended before operating the lift cylinder to prevent damage to the latch systems 2 When the PTO is engaged do not run the engine over 1400 RPM 3 Do not hold the brakes while performing ope...

Page 10: ...location you wish to unload 2 Put the truck in neutral and engage the PTO Run RPM as needed 3 Locate the black control lever labeled tilt 4 Pull the tilt lever until the cylinder is fully extend ed th...

Page 11: ...needed 3 Locate the black control lever labeled tilt 4 Pull the tilt lever until the cylinder is fully extended thus releasing tabs 5 Locate the red lever labeled lift 6 Pull lift lever until the body...

Page 12: ...body you intent to pick up 2 Engage the hook to the body by maneuvering the hooklift with the red lift lever Run RPM as needed 3 Push the red lift lever until the main cylinder is fully retracted 4 P...

Page 13: ...o dump the load 2 Put the truck in neutral and engage the PTO Run RPM as needed 3 Locate the red lever labeled lift 4 Pull the lift lever to dump the body 5 Wait until dumping is complete then push th...

Page 14: ...8 Flex36 Owner s Manual...

Page 15: ...e first month of operation on new machines and then quarterly thereafter 2 Cylinders and valves for leaks 3 Lubrication 4 Tilt hook for cracks 5 Structural weldments for bends cracks or breaks 6 All p...

Page 16: ...erature Modified Sodium Based High Drop Point Transmission Semi Fluid Calcium Based Molybdenum Filled Lithium Based with 2 Molybdenum Disulfide Graphite Filled Sodium Based with 2 Graphite Block Greas...

Page 17: ...7kg A Dump Angle 54 53 54 50 B Lowest Hook Heigh 23 5 60cm 25 63 5cm 27 68 5cm 28 71cm C Effective Length 91 231cm 115 292cm 142 361cm 151 383 5cm D Truck Frame Height 34 86cm 36 91 5cm 36 91 5cm 36 9...

Page 18: ...revent exposure of cylinder rod to corrosive road salts Tilt Section Operation Hooklift must include a hydraulic lock out device to prevent operation of the tilt section while hooklift is in the dumpi...

Page 19: ...vent exposure of cylinder rod to corrosive road salts Tilt Section Operation Hooklift must include a hydraulic lock out device to prevent operation of the tilt section while hooklift is in the dumpin...

Page 20: ...pre vent exposure of cylinder rod to corrosive road salts Tilt Section Operation Hooklift must include a hydraulic lock out device to prevent operation of the tilt section while hooklift is in the du...

Page 21: ...vent exposure of cylinder rod to corrosive road salts Tilt Section Operation Hooklift must include a hydraulic lock out device to prevent operation of the tilt section while hooklift is in the dumpin...

Page 22: ...16 Flex36 Owner s Manual...

Page 23: ...tilt operation the possible consequences should the haz ard occur and how to avoid the hazard PN C0865 Operation Hazard Decal Location Truck Frame Function To inform the operator of the need for prop...

Page 24: ...18 Flex36 Owner s Manual Decal Kit Placement PN 35559 PN 35559...

Page 25: ...8 Mount hydraulic reservoir tank and valve bank 9 Mount PTO and Pump 10 Run hydraulic hoses 11 Connect suction and pressure to the reservoir tank and valve bank 12 Install mud flaps and fenders 13 Run...

Page 26: ...Place a tie down channel on either side of the base within 2 of the front plate c Place a tie down channel on either side of the base within 7 of the rear of the hooklift d The final channels should...

Page 27: ...TO and valve bank c Protect these lines with hose wrap when necessary d Keep these lines away from sharp edges e Keep these lines away from the exhaust or other temperature extreme items f Keep these...

Page 28: ...N 33320 ITEM PART DESCRIPTION QTY 1 D0143 TIE DOWN CHANNEL 8 2 C1025 CAP SCR 0 63 11X2 00 HHGR8 ZY 8 3 C1038 WASHER 0 63 FLAT 16 4 24868 NUT 0 63 11 HH NYLOC 8 5 D0045 BACKUP ALARM 97 DECIBAL 1 Mounti...

Page 29: ...E N N A H C N W O D E I T 3 4 1 0 D 1 2 1 Y Z 8 R G H H 0 0 2 X 1 1 3 6 0 R C S P A C 5 2 0 1 C 2 4 2 T A L F 3 6 0 R E H S A W 8 3 0 1 C 3 2 1 C O L Y N H H 1 1 3 6 0 T U N 8 6 8 4 2 4 1 L A B I C E...

Page 30: ...PLATE ROTARY VALVE ARM 1 10 0482 CAP SCR 0 25 20 X 3 00 HHGR5 2 11 0333 NUT 0 25 20 HHGR5 NYLOC 2 12 7350 FTG ST RUN TEE 8R5OLO 2 13 D1535 PLUG STR HOLLOW HEX 0 50 8 HP5ON 2 37741 Rotary Valve All Mod...

Page 31: ...X2 50 HHGR5 3 Y T Q N O I T P I R C S E D T R A P M E T I 13 C4227 FTG MF MSTR 90 8 12 C5OLO S 1 14 26731 HOSE 0 50 381 JC J9 8 8 8 18 0 1 15 0352 WASHER 0 50 USS FLAT ZINC 8 16 C6106 NUT 0 50 13 HHGR...

Page 32: ...e next page for details 4500 5500 6500 7500 8500 9500 10500 11500 12500 13500 14500 15500 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 SYSTEM RELIEF PRESSURE P S I LOADER CAPACITY...

Page 33: ...the system relief pressure using 4 mm allen wrench Clockwise increases pressure counter clock wise decreases pressure 5 Once system pressure is set tighten the jam nut to lock system pressure Permanen...

Page 34: ...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 Ins...

Page 35: ...IDE RELIEF MAIN RELIEF VALVE BANK For some options port side relief is required To install port side relief 1 Remove plug 2 Insert relief 3 Replace plug Relief can be installed on the retract or exten...

Page 36: ...NTROL CABLE 96 IN WESCON 2 3 14 37472 CONTROL CABLE 144 IN WESCON 2 3 14 37473 CONTROL CABLE 192 IN WESCON 2 3 17 20057 CAP SCR 0 31 18X6 50 HHGR5 3 Section Only 2 17 0491 CAP SCR 0 31 18X4 00 HHGR5 2...

Page 37: ...be located directly above dump light switch when secondary is in lowered position Screw in elevator bolt and adjust so that switch is engaged when secondary is in lowered position Install light in br...

Page 38: ...VB TO PORT TUBES C2773 HOSE 50 STELLAR 18169 471TC JC J9 8 8 8 60 60 00 FUNCTION MAIN CYLINDER C1558 QTY 2 C1559 C0562 HOSE 38 91 00 STELLAR 34646 471TC JC J9 8 6 6 91 FUNCTION TILT ROTARY VAVLVE TO...

Page 39: ...TO PORT TUBES C2773 HOSE 50 STELLAR 18169 471TC JC J9 8 8 8 60 60 00 FUNCTION MAIN CYLINDER C1558 QTY 2 C1559 C0562 HOSE 38 115 00 STELLAR 34648 471TC JC J9 8 6 6 115 FUNCTION TILT ROTARY VAVLVE TO CY...

Page 40: ...VB TO PORT TUBES C2773 HOSE 50 STELLAR 18169 HTB JC J9 8 8 8 60 60 00 FUNCTION MAIN CYLINDER C1558 QTY 2 C1559 C0562 HOSE 38 145 00 STELLAR 34649 471TC JC J9 8 6 6 145 FUNCTION TILT ROTARY VAVLVE TO C...

Page 41: ...6392 QTY 2 FUNCTION TILT VB TO PORT TUBES C2773 HOSE 50 STELLAR 18169 471TC JC J9 8 8 8 60 60 00 FUNCTION MAIN CYLINDER C1558 QTY 2 C1559 C0562 HOSE 38 150 00 STELLAR 34650 471TC JC J9 8 6 6 150 FUNC...

Page 42: ...36 Flex36 Owner s Manual multi lift only Subframe Model 60 8...

Page 43: ...Installation 37 Subframe Model 84 10...

Page 44: ...38 Flex36 Owner s Manual Subframe Model 108 12...

Page 45: ...Installation 39 Subframe Model 120 14...

Page 46: ...40 Flex36 Owner s Manual...

Page 47: ...01X3 50X2 88 2 Y T Q N O I T P I R C S E D T R A P M E T I 10 22764 COLLAR 2 01X3 00X1 00 2 11 0507 CAP SCR 0 50 13X4 50 HHGR5 2 12 C6106 NUT 0 50 13 HHGR5 NYLOC 2 13 C0953 CAP SCR 0 38 16X4 00 HHGR5...

Page 48: ...50 13X4 50 HHGR5 2 Y T Q N O I T P I R C S E D T R A P M E T I 10 C6106 NUT 0 50 13 HHGR5 NYLOC 2 11 0532 CAP SCR 0 38 16X3 75 HHGR5 2 2 C O L Y N H H 6 1 8 3 0 T U N 7 4 3 0 2 1 13 C0078 HOSE CLAMP...

Page 49: ...Y T Q N O I T P I R C S E D T R A P M E T I 2 0 0 1 X 0 0 3 X 1 0 2 R A L L O C 4 6 7 2 2 0 1 11 0532 CAP SCR 0 38 16X3 75 HHGR5 2 2 C O L Y N H H 6 1 8 3 0 T U N 7 4 3 0 2 1 13 0507 CAP SCR 0 50 13X4...

Page 50: ...2 9 Y T Q N O I T P I R C S E D T R A P M E T I 10 0532 CAP SCR 0 38 16X3 75 HHGR5 2 2 C O L Y N H H 6 1 8 3 0 T U N 7 4 3 0 1 1 12 C0078 HOSE CLAMP 8 RUBBER COATED 1 13 0479 CAP SCR 0 25 20X0 75 HHGR...

Page 51: ...5 25 1 4 2257 SNAP RING INSIDE 2 00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 0332 CAP SCR 0 31 18X1 75 HHGR5 2 7 23301 TAB LOADER BREAK AWAY 1 8 0506 CAP SCR 0 50 13X4 00 HHGR5 2 9 0333 NUT 0 25 20 H...

Page 52: ...X25 25 1 4 2257 SNAP RING INSIDE 2 00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 0332 CAP SCR 0 31 18X1 75 HHGR5 2 7 23301 TAB LOADER BREAK AWAY 1 8 0506 CAP SCR 0 50 13X4 00 HHGR5 2 9 0333 NUT 0 25 20...

Page 53: ...NG 32DXR32 2 00X2 00 GARLOCK 6 8 0332 CAP SCR 0 31 18X1 75 HHGR5 2 3 22227 PIN 2 00X25 25 1 9 0333 NUT 0 25 20 HHGR5 NYLOC 2 4 2257 SNAP RING INSIDE 2 00 2 10 C6106 NUT 0 50 13 HHGR5 NYLOC 2 5 33062 T...

Page 54: ...X25 25 1 4 2257 SNAP RING INSIDE 2 00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 23301 TAB LOADER BREAK AWAY 1 7 0506 CAP SCR 0 50 13X4 00 HHGR5 2 8 0332 CAP SCR 0 31 18X1 75 HHGR5 2 9 0333 NUT 0 25 20...

Page 55: ...DER ASM 27020 4 00X29 63 1 3 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 6 4 22286 PIN 2 00X16 00 1 5 2257 SNAP RING INSIDE 2 00 2 6 0068 BUSHING QSI 1618 24 4 7 0069 BUSHING QSI 1618 16 4 8 22285 PIN 1 00...

Page 56: ...USHING 32DXR32 2 00X2 00 GARLOCK 6 3 0069 BUSHING QSI 1618 16 4 4 3875 SNAP RING 1 00 INTERNAL 2 5 22285 PIN 1 00X15 00 1 6 22286 PIN 2 00X16 00 1 7 2257 SNAP RING INSIDE 2 00 2 8 0068 BUSHING QSI 161...

Page 57: ...HING 32DXR32 2 00X2 00 GARLOCK 6 3 0068 BUSHING QSI 1618 24 4 4 0069 BUSHING QSI 1618 16 4 5 3875 SNAP RING 1 00 INTERNAL 2 6 22285 PIN 1 00X15 00 1 7 22286 PIN 2 00X16 00 1 8 2257 SNAP RING INSIDE 2...

Page 58: ...USHING 32DXR32 2 00X2 00 GARLOCK 6 3 0068 BUSHING QSI 1618 24 4 4 0069 BUSHING QSI 1618 16 4 5 3875 SNAP RING 1 00 INTERNAL 2 6 22285 PIN 1 00X15 00 1 7 22286 PIN 2 00X16 00 1 8 2257 SNAP RING INSIDE...

Page 59: ...60 CYLINDER ASM 3 00X17 00 1 8 D0419 THRUST WASHER 2 3 0069 BUSHING QSI 1618 16 1 9 33104 COLLAR 1 03X2 00X1 00 2 4 0064 PIN 1 00X3 38 1 10 0339 CAP SCR 0 25 20X2 50 HHGR5 2 5 0110 SNAP RING 1 00 ID 7...

Page 60: ...SHER 2 7 33104 COLLAR 1 03X2 00X1 00 2 8 0339 CAP SCR 0 25 20X2 50 HHGR5 2 9 0333 NUT 0 25 20 HHGR5 NYLOC 2 10 c1592 ZERK 1 8 NPT STRAIGHT 4 11 35066 PIN 1 00X18 38 SR 1 12 0867 MACHY WASHER 1 00ID 14...

Page 61: ...ART DESCRIPTION QTY 1 3767 CYLINDER 3 00X17 00 1 2 0279 FTG ADAPT 6 F5OLO S 2 3 0068 BUSHING QSI 1618 24 2 Bushing shown as reference Tilt Cylinder Assembly All Flex36 Models PN 23460 Note This Tilt C...

Page 62: ...SHING 32DXR32 2 00X2 00 GARLOCK 4 3 15822 MANIFOLD DOUBLE T11A 5000 PSI 1 4 27117 TUBE ASM 0 50X11 94 2 5 19369 HOSE CLAMP 4 13 7 00 5416K38 2 6 18701 CLAMP PORT TUBE ZR518 2 7 D1290 FTG ADAPT 8 6 F5O...

Page 63: ...A G T F 9 7 2 0 2 3 D1290 FTG ADAPT 8 6 F5OLO S 5 4 15822 MANIFOLD DOUBLE T11A 5000 PSI 1 5 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 4 1 5 7 7 2 X 0 5 0 M S A E B U T 4 4 7 3 3 6 7 19369 HOSE CLAMP 4 13...

Page 64: ...T F 9 7 2 0 2 3 D1290 FTG ADAPT 8 6 F5OLO S 5 4 15822 MANIFOLD DOUBLE T11A 5000 PSI 1 5 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 4 1 3 1 0 4 X 0 5 0 M S A E B U T 0 5 7 3 3 6 7 19369 HOSE CLAMP 4 13 7 0...

Page 65: ...16 Cable Hook up Kit Snap Ring 2 00 External Snap Ring 2 00 Internal Snap Ring 1 00 Internal Grease Zerk 1 8 NPT Tab Alarm Proximity Switch Bosch Relay Seal Kit Rotary Valve Seal Kit Tilt Cyl Seal Ki...

Page 66: ...60 Flex36 Owner s Manual...

Page 67: ...hanged per the maintenance page of the Hooklift Owner s Manual Make sure the filter strainer of the hydraulic reser voir is not plugged Make sure that the hydraulic pump is operating at its rated flow...

Page 68: ...rized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar In th...

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