stellar labs 108-12-36 Owner'S Manual Download

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Owner’s Manual

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Safety, Installation, Maintenance, and Operation

Stellar Flex™ Series Hooklift

FLEX36

60-8-36

84-10-36

108-12-36
120-14-36

Manual Part No. 35551
Last Revision: 4/25/06

Subject to Change without Notification.
© 2006 Stellar Industries, Inc.

Summary of Contents for 108-12-36

Page 1: ...00 321 3741 Fax 641 923 2811 www stellarindustries com Safety Installation Maintenance and Operation Stellar Flex Series Hooklift FLEX36 60 8 36 84 10 36 108 12 36 120 14 36 Manual Part No 35551 Last...

Page 2: ...anual Revisions Date of Revision April 25th 2006 Description of Revision Updated the Main Cylinder Drawing for the 84 10 108 12 120 14 to reflect the new tubing additions Section Revised Chapter 7 Ass...

Page 3: ...ry 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 factory instructions...

Page 4: ...s deemed necessary for product improvement or commercial production purpos es This right is kept with no requirement or obligation for immediate mandatory updating of this manual This product manual i...

Page 5: ...eration 2 1 Chapter 3 Maintenance 3 1 Chapter 4 Specifications 4 1 Chapter 5 Decals 5 1 Chapter 6 Installation 6 1 Chapter 7 Assembly Drawings 7 1 Chapter 8 Hydraulics Electrical 8 1 Chapter 9 Replace...

Page 6: ...e on the truck Regularly check to make sure the fire extinguisher is fully charged and the first aid kit is stocked Do not use controls and hoses as handholds These parts move and cannot provide stabl...

Page 7: ...assis and or the hooklift Move the control lever slow and smooth for steady oil flow Avoid jerky or sudden movement of the controls Be constantly aware of the hooklift position when operating the cont...

Page 8: ...peration of the hooklift 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 opera...

Page 9: ...cation you wish to unload 2 Put the truck in neutral and engage the PTO 3 Locate the black control lever labeled tilt 4 Pull this lever until full stroke is reached thus releasing tabs 5 Locate the re...

Page 10: ...the PTO 3 Locate the black control lever labeled tilt 4 Pull tilt lever until full stroke is reached thus releasing tabs 5 Locate the red lever labeled lift 6 Pull lift lever until the body is on the...

Page 11: ...ing a container 2 Engage the hook to the body by maneuver ing the loader with the red lift lever and the black tilt lever 3 Push the red lift lever until the main cylinder is fully retracted 4 Push th...

Page 12: ...ion you wish to dump the load 2 Put the truck in neutral and engage the PTO 3 Locate the red lever labeled lift 4 Pull the lift lever to dump the body 5 Wait until dumping is complete then push the re...

Page 13: ...Federal State Laws Operator Information Operator Conduct 1 Operators will not engage in any operation that would cause them to divert attention away from the operation of the hooklift 2 Operators are...

Page 14: ...osening or removing hydraulic components 4 Label or tag parts when disassembling Periodic Inspection Periodic Inspection should occur while the hooklift is in use For the duration of the usage inspect...

Page 15: ...e wire Replace or repair wires as required 10 Lubrication of all points requiring lubrication Service The following general suggestions should be helpful in analyzing and servicing your hooklift Using...

Page 16: ...ium 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 Grease Sodium Based Solid...

Page 17: ...Up to 9 000 54 23 5 91 34 39 5 99 25 43 60 104 120 141 See table 1 1 1 275 35 63 100 x 49 x 47 38 5 8 to 9 To 10 Up to 16 000 53 25 115 36 41 5 126 58 84 to 96 118 144 162 See table 1 1 1 360 35 63 12...

Page 18: ...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 dumping mode Lift Dump Cylinder C...

Page 19: ...r 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 dumping mode Lift Dump Cylinder...

Page 20: ...r 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 dumping mode Lift Dump Cylinder...

Page 21: ...r 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 dumping mode Lift Dump Cylinder...

Page 22: ...void the hazard PN 26134 Electrocution Hazard Decal Location Bottom of tilt Function To inform the operator of the hazard associated with electrocution the possible conse quences should the hazard occ...

Page 23: ...Chapter 5 Decals 5 2 Decal Placement PN 35559...

Page 24: ...sten 2 tie down channels together with the narrow faces towards each other do this with all 8 channels Note Use included spacers if necessary for clear ance Place the tie down channels in the approxim...

Page 25: ...a 13 mm wrench 4 Adjust the system relief pressure using 4 mm allen wrench 5 Once system pressure is set tight en the jam nut to lock system pres sure No permanent thread lock may be used 6 Release al...

Page 26: ...mplete 3 Release the jam nut using a 13 mm wrench 4 Adjust the system relief pressure using 4 mm allen wrench Clockwise increases pressure counter clock wise decreases pressure 5 Once system pressure...

Page 27: ...f 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 In...

Page 28: ...Mounting Kit P 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 D...

Page 29: ...M E T I 2 1 L 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...

Page 30: ...568 214 1 9 22449 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 Ro...

Page 31: ...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 HHGR5 NYLOC 8 18 D0549 FTG A...

Page 32: ...ould 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 i...

Page 33: ...Chapter 6 Installation 6 10 Subframe 60 8...

Page 34: ...Chapter 6 Installation 6 11 Subframe 84 10...

Page 35: ...Chapter 6 Installation 6 12 Subframe 108 12...

Page 36: ...Chapter 6 Installation 6 13 Subframe 120 14...

Page 37: ...8 HOSE CLAMP 8 RUBBER COATED 1 5 8819 BUSHING QSI 3235 16 2 16 0479 CAP SCR 0 25 20X0 75 HHGR5 1 6 24766 PIN 2 00X47 00 1 17 0333 NUT 0 25 20 HHGR5 NYLOC 1 7 23699 BUSHING 32DXR20 2 00X1 25 2 18 8622...

Page 38: ...UHMW 12THK 6 15 0333 NUT 0 25 20 HHGR5 NYLOC 1 5 8819 BUSHING QSI 3235 16 2 16 0427 MACHY WASHER 2 00ID 10GA 2 6 24766 PIN 2 00X47 00 1 17 0108 SNAP RING 2 00 7200 200 2 7 23699 BUSHING 32DXR20 2 00X1...

Page 39: ...THK 6 15 C0078 HOSE CLAMP 8 RUBBER COATED 1 5 8819 BUSHING QSI 3235 16 2 16 0479 CAP SCR 0 25 20X0 75 HHGR5 1 6 23699 BUSHING 32DXR20 2 00X1 25 2 17 0333 NUT 0 25 20 HHGR5 NYLOC 1 7 33741 PIN 2 00X10...

Page 40: ...THK 6 15 C0078 HOSE CLAMP 8 RUBBER COATED 1 5 8819 BUSHING QSI 3235 16 2 16 0479 CAP SCR 0 25 20X0 75 HHGR5 1 6 23699 BUSHING 32DXR20 2 00X1 25 2 17 0333 NUT 0 25 20 HHGR5 NYLOC 1 7 33741 PIN 2 00X10...

Page 41: ...PIN 2 00X25 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...

Page 42: ...PIN 2 00X25 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...

Page 43: ...4381 BUSHING 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...

Page 44: ...PIN 2 00X25 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...

Page 45: ...7116 CYLINDER 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 2228...

Page 46: ...2 4381 BUSHING 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 BUSHIN...

Page 47: ...2 4381 BUSHING 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 RIN...

Page 48: ...2 4381 BUSHING 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 RIN...

Page 49: ...2 2 23460 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...

Page 50: ...8 4 2 8 1 6 1 I S Q G N I H S U B 8 6 0 0 4 2 0 5 0 1 X 0 0 1 T M D L W N I P 3 0 1 3 3 5 T 9 1 4 0 D 6 2 R E H S A W T S U R H 2 0 0 1 X 0 0 2 X 3 0 1 R A L L O C 4 0 1 3 3 7 2 5 R G H H 0 5 2 X 0 2...

Page 51: ...rawings P N 23460 ITEM PART DESCRIPTION QTY 1 3767 CYLINDER 3 00X17 00 1 2 0279 FTG ADAPT 6 F5OLO S 2 3 0068 BUSHING QSI 1618 24 2 Tilt Cylinder 60 8 84 10 108 12 120 14 Note This Tilt Cylinder uses S...

Page 52: ...3 1 2 4381 BUSHING 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...

Page 53: ...F 6 T P A D 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 HO...

Page 54: ...T P A D 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 3 1 0 4 X 0 5 0 M S A E B U T 0 5 7 3 3 6 7 19369 HOSE C...

Page 55: ...Chapter 8 Hydraulics Electrical 8 1 P N 34616 PRESSURE FROM PUMP RETURN TO TANK Hose Kit 60 8 Chapter 8 Hydraulics Electrical...

Page 56: ...Chapter 8 Hydraulics Electrical 8 2 P N 34617 PRESSURE FROM PUMP RETURN TO TANK Hose Kit 84 10...

Page 57: ...Chapter 8 Hydraulics Electrical 8 3 P N 34618 PRESSURE FROM PUMP RETURN TO TANK Hose Kit 108 12...

Page 58: ...Chapter 8 Hydraulics Electrical 8 4 HOSE KIT P N 34619 PRESSURE FROM PUMP RETURN TO TANK Hose Kit 120 14...

Page 59: ...Chapter 8 Hydraulics Electrical 8 5 P N 26414 In Cab Installation At Valve Installation Part 1 Controller Assembly 60 8 84 10 108 12 120 14...

Page 60: ...NYLOC 4 18 26135 DECAL NOTICE FIX TABS 1 6 0528 CAP SCR 0 25 20X4 50 HHGR5 2 19 D1711 CAP SCR 10 24X0 50 BTNHD SS 1 7 0340 WASHER 0 25 FLAT 8 20 26034 NUT 10 24 HH NYLOC 1 8 0333 NUT 0 25 20 HHGR5 NYL...

Page 61: ...alami Cable Hook up Kit Salami 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 Cy...

Page 62: ...Manual Make sure the filter strainer of the hydraulic reservoir is not plugged Make sure that the hydraulic pump is operating at its rated flow or GPMs Make sure the relief pressure is set properly S...

Page 63: ...er than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar In the case repair work is performed on a Stellar manufactured product...

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