Stellar labs Flex Series Manuale utente

Owner’s Manual

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA50438

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.

Stellar Flex Manual 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: Assembly

Drawings

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. DEATH OR SERIOUS INJURY

WILL RESULT FROM IMPROPER USE OR MAINTENANCE OF THIS MACHINE.

Occupational safety is a prime concern of Stellar Industries in the design and production of this

hooklift. Our goal in writing this manual was the safety of the operator and others who work

around this equipment.

It is your responsibility to know the specific requirements, governmental regulations, precautions

and work hazards that exist in the operation and maintenance of this hooklift. You shall make

these available and known to all personnel working with and around the equipment, so that all of

you will take the necessary and required safety precautions.

FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.

It is also your responsibility to operate and maintain your hooklift with caution, skill, and good

judgment. Following the recognized safety procedures will help you avoid accidents. Modification

to any part of his hooklift can create a safety hazard and therefore shall not be made without the

manufacturer’s written approval. 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 factory instructions. Safety covers and devices must

remain installed and maintained in proper working condition. Safety decals must be maintained,

be completely legible, and be properly located. If safety covers, devices, or decals are missing,

they must be replaced with the proper designated Stellar part.

Be capable, careful, and concerned! Make safety your everyday business!

Attention!

According to Federal Law (49 cfr part 571),

each final-stage manufacturer shall complete

the vehicle in such a manner that it conforms

to the standards in effect on the date of man-

ufacture of the incomplete vehicle, the date

of final completion, or a date between those

two dates. This requirement shall, however,

be superseded by any conflicting provisions

of a standard that applies by its terms to vehi-

cles manufactured in two or more stages.

Therefore, the installer of Stellar hooklifts is

considered one of the manufacturers of the

vehicle. As such a manufacturer, the installer

is responsible for compliance with all applica-

ble federal and state regulations. They are

required to certify that the vehicle is in com-

pliance with the Federal Motor Vehicle Safety

Standards and other regulations issued

under 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 full text of Code of Federal

Regulations.

Stellar Hooklifts are designed to provide safe

and dependable service for a variety of opera-

tions. With proper use and maintenance,

Stellar Hooklifts will operate at peak perform-

ance for many years.

This manual con-

tains information

vital to the safe use

and efficient opera-

tion of this unit.

Following the infor-

mation provided

within this manual

can ensure the

longevity of the

hooklift. Carefully

read and study the

operator’smanual

before using the

unit. Failure to

adhere to the

instructions could result in property damage or

even serious bodily injury to the operator or

others close to the hooklift.

Acopy of this manual is provided with every

hooklift and shall remain with the hooklilft at all

times. Information contained within this manu-

al does not cover all maintenance, operating, or

Introduction

repair instructions pertinent to all possible situ-

ations. 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 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 is not intended as a train-

ing manual for beginners or unskilled opera-

tors. This manual offers guidelines for correct

and safe usage of the hooklift, maintenance,

and troubleshooting. If more information is

required or technical assistance is needed,

please contact the Stellar Industries, Inc.

Customer Service Department.

Some sections of this manual contain informa-

tion pertaining to all Stellar manufactured hook-

lifts and may or may not apply to your specific

model.

If this manual becomes damaged, misplaced,

or unreadable at any point, or if you feel that

any part of this manual is unclear or incorrect,

please contact Stellar Customer Service

Department at 800-321-3741 or email at

[email protected]

Technical Questions, and Information [email protected]

Order Parts [email protected]

Warranty Information [email protected]

For Technical Questions, Information, Parts, or Warranty,

Call Toll-Free at

800-321-3741

Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST

Or email at the following addresses:

Table of Contents

Chapter 1 - Safety 1-1

Chapter 2 - Operation 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 - Replacement Parts 9-1

Chapter 10 - Troubleshooting 10-1

iii

Chapter 1 - Safety

1-1

Chapter 1 - Safety

GENERAL

It is the responsibility of the owner to instruct the

operator in the safe operation of your equipment

and to provide the operator with properly main-

tained equipment.

Trainees or untrained persons shall be under the

direct supervision of qualified persons.

Do not operate equipment under the adverse

influence of alcohol, drugs, or medication.

Read all Danger and Caution decals on the

equipment and understand their meaning.

PERSONAL SAFETY

Keep clear of all moving parts.

Always wear the prescribed personal safety

devices.

Always wear approved accident-prevention

clothing such as: protective helmets, anti-slip

shoes with steel toes, protective gloves, anti-

noise headphones, protective glasses, breathing

apparatus, and reflective jackets. Consult your

employer regarding current safety regulations

and accident-prevention equipment.

Do not wear rings, wristwatch, jewelry, loose-fit-

ting or hanging clothing such as ties, torn gar-

ments, scarves, unbuttoned jackets or unzipped

overalls, which could get caught up in the moving

parts of the hooklift.

Keep a first-aid box and a fire extinguisher read-

ily available 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 stable

support.

Do not allow unauthorized personnel or equip-

ment to enter within 10 feet of hooklift operating

area.

Never allow anyone to ride the hooklift or load.

MAINTENANCE SAFETY

Never modify or alter any of the equipment,

whether mechanical, electrical, or hydraulic, with-

out Stellar Industries’ approval.

Do not perform any maintenance or repair work

on the hooklift unless authorized and trained to

do so.

Please Read the Following Carefully!

This portion of the manual contains infor-

mation regarding all Stellar manufactured

hooklifts. Some items contained within this

chapter may not apply to your specific

equipment.

Safety should be the number one thought

on every Stellar hooklift operator’s mind.

Three factors should exist for safe opera-

tion: a qualified operator, well-maintained

equipment, and the proper use of this

equipment. The following information

should be read and understood completely

by everyone working with or near the hook-

lift before beginning.

Stellar Industries, Inc. is not liable for acci-

dents occurred during the usage of the

hooklift caused by non-fulfillment from the

operator’s side of current rules, laws and

regulations.

Chapter 1 - Safety

1-2

Release system pressure before attempting to

make adjustments or repairs.

Do not attempt service or repair when PTO is

engaged.

Decals are considered safety equipment. They

must be maintained, as would other safety

devices. Do not remove any decals. Replace

any decals that are missing, damaged, or not

legible.

The safety instruction plates, notices, load charts

and any other sticker applied to the hooklift must

be kept legible and in good condition. If neces-

sary, replace them.

Keep all surfaces of the hooklift free of oil and

grease to avoid slippery surfaces and aid in

inspections.

STABILITY

Know the hooklift components and their capabili-

ties and limitations. Overloading the hooklift may

result in serious damage of self, others, equip-

ment or the surroundings.

Never exceed manufacturer’s load ratings.

These ratings are based on the machine’s

hydraulic, mechanical, and structural design

rather than stability.

LOAD SAFETY

Full rated dump capacity assumes load will

decrease as dump angle increases. Do not take

full rated capacity to full dump angle without

some unloading of weight as it may cause dam-

age to the chassis 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 controls.

Do not attempt to lift fixed loads.

Know the weight of your load to avoid overload-

ing the equipment.

Deduct the weight of the body from the maximum

load rating to determine how much

weight can be lifted.

Keep everyone clear when loading, unloading,

and dumping.

Do not push on fixed objects or bodies without

rollers with the hooklift.

Do not permit loose objects on the hooklift.

Use a qualified person to assist in loading when

the load is not visible to the operator.

Do not leave hooklift unattended with suspended

load.

Take care when operating in areas supported by

vehicle tires, because of the cushioning

effect of springs and tires.

Never use the drivetrain of the chassis to assist

the hydraulics in loading

ENVIRONMENT

Do not operate the hooklift during electrical

storms.

In extreme cold, allow adequate time to warm the

truck before engaging the PTO. Do not rev the

truck engine and over speed the hydraulic pumps

as permanent damage to the pumps may occur.

Follow the vehicle owner’s manual regarding

operating the vehicle in such adverse conditions.

In extreme cold, operate the controls slowly to

allow for viscosity changes.

Chapter 1 - Safety

1-3

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.

4. Be familiar with the control levers and how

they operate before attempting to operate the

hooklift.

5. Be prepared before beginning operation 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 operating condition.

• Be prepared for all situations. Keep fire

extinguisher and first aid kit near.

• Be sure all regular maintenance has been

performed.

•Visually inspect all aspects of the hooklift

for physical damage.

• Check for fluid leaks.

Stellar Industries, Inc. is not liable

for accidents occurred during the

usage of the hooklift caused by non-

fulfillment from the operator’s side of

current rules, laws, and regulations.

AATTTTEENNTTIIOONN!!

2-1

Chapter 2 - Operation

Job-Site Set-Up

Thoroughly plan the lift before positioning

the vehicle. Consider the following:

1. The vehicle should be positioned in an area

free from overhead obstructions to eliminate the

need for repositioning.

2. Position the vehicle so that it is impossible for

any portion of the equipment to come within the

minimum required safe distance of any power

line. Maintain a clearance of at least 10 feet

between any part of the hooklift, load line, or

load, and any electrical line or apparatus carrying

up to 50,000 volts. One foot additional clearance

is required for every additional 30,000 volts or

less. Remember to allow for winds that cause

power lines to sway. It is recommended that a

signal person be used when the vehicle is set-up

near power lines.

3. The vehicle should also be positioned on a firm

and level surface that will provide adequate sup-

port for the body.

4. The parking brake must be removed to allow

the truck to roll under the body while loading.

Unloading Operation

1. Stop the truck at the location 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 red lever labeled lift.

6. Pull lift lever until the body is on the ground and

can be detached. Return the hooklift to the stored

position and disengage the PTO.

Caution!

1. When loading and unloading, the tilt cylin-

der must 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

operations.

Loading Operation

1. Perform the steps for unloading a container.

2. Engage the hook to the body by maneuvering

the loader with the red(lift) lever.

3.Push the red(lift) lever until the main cylinder is

fully retracted.

4. Push the black(tilt) lever until the tilt is fully

retracted.

5. Disengage the PTO.

Dumping Operation

1. Stop the truck at the location 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 lever to dump the body.

5.Wait until dumping is complete, then push the

red(lift) lever until the main cylinder fully retracts.

6. Disengage the PTO.

Operation Overview

Chapter 2 - Operation

2-2

1. Stop the truck at the location you wish to

unload.

2. Put the truck in neutral and engage 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 ground

and can be detached. Return the hooklift to

the stored position and disengage the PTO.

Unloading Operation

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