Stellar Slider65 User Manual

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Page 1

OWNER’S MANUAL

Safety, Installation, Maintenance, and Operation

Stellar Slider65 Hooklift

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. 40241 Last Revision: 9/20/07

Page 2

Slider65 Hooklift Manual Revisions

Date of Revision Description of RevisionSection Revised

Page 3

Table of Contents

Table of Contents i

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Loader Nomenclature . . . . . . . . . . . . . . . . iv

Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . 1

General Safety. . . . . . . . . . . . . . . . . . . . . . . 1

Personal Safety . . . . . . . . . . . . . . . . . . . . . . 1

Maintenance Safety . . . . . . . . . . . . . . . . . . 1

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Load Safety . . . . . . . . . . . . . . . . . . . . . . . . . 2

Environment . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 2 - Operation . . . . . . . . . . . . . . . . . 3

Operator Requirements . . . . . . . . . . . . . . . 3

Operator Conduct . . . . . . . . . . . . . . . . . . . 3

Job-Site Set-Up. . . . . . . . . . . . . . . . . . . . . . . 3

Operation Overview . . . . . . . . . . . . . . . . . . 4

Hooklift Controls. . . . . . . . . . . . . . . . . . . . . . 4

Unloading Operation . . . . . . . . . . . . . . . . . 5

Loading Operation . . . . . . . . . . . . . . . . . . . 6

Dumping Operation . . . . . . . . . . . . . . . . . . 7

Chapter 3 - Maintenance. . . . . . . . . . . . . . . 9

Maintenance Procedures . . . . . . . . . . . . . 9

Periodic Inspection

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 9

Monthly Inspection . . . . . . . . . . . . . . . . . . . 9

General Service . . . . . . . . . . . . . . . . . . . . . . 9

Choice Lubricants for DX Bearings . . . . . 10

Chapter 4 - Specifications . . . . . . . . . . . . . 11

Stellar Slider65 Hydraulic Hooklift

Specifications . . . . . . . . . . . . . . . . . . . . . 12

Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . 13

Decals of Note. . . . . . . . . . . . . . . . . . . . . . 13

Decal Kit Placement - PN 31827 . . . . . . . 14

. . . . . . . . . . . . . . . . . . . 9

Chapter 6 - Installation . . . . . . . . . . . . . . . . 15

Basic Installation Overview. . . . . . . . . . . . 15

Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installation Steps - Basic Guidelines . . . . 16

Mounting Kit - PN 40017 . . . . . . . . . . . . . . 18

Reservoir Assembly - PN 40022. . . . . . . . . 19

Setting System Relief Pressure . . . . . . . . . 20

Installation Instructions for the Power

Beyond VDM8 Valve . . . . . . . . . . . . . . . 22

Dump Light Kit Installation . . . . . . . . . . . . 23

Controller Assembly - PN 38841 . . . . . . . . 24

STOP System Overview - PN 40029 . . . . . 25

STOP System - Push/Pull Switch

(PN C0868) . . . . . . . . . . . . . . . . . . . . . . . 26

STOP System - Limit Switch

(PN 10953) . . . . . . . . . . . . . . . . . . . . . . . . 27

STOP System - Unloader Manifold

(PN 10953) . . . . . . . . . . . . . . . . . . . . . . . . 28

Hydraulic Schematic - PN 38955 . . . . . . . 30

Wiring Schematic - PN 41133 . . . . . . . . . . 31

Chapter 7 - Assembly Drawings

Base Assembly - PN 34135 . . . . . . . . . . . . 33

Dump Assembly - PN 34137 . . . . . . . . . . . 34

Roller Assembly - PN 38766. . . . . . . . . . . . 35

Secondary Assembly - PN 34139 . . . . . . . 36

Main Cylinder Assembly - PN 39043 . . . . 37

Jib Assembly - PN 34142 . . . . . . . . . . . . . . 38

Jib Cylinder Assembly - PN 38729 . . . . . . 40

Chapter 8 - Replacement Parts . . . . . . . . . 41

Chapter 9 - Troubleshooting. . . . . . . . . . . . 43

Warranty Information. . . . . . . . . . . . . . . . . . 44

. . . . . . . . 33

Page 4

ii Slider65 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 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 requir

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

ed safety precautions.

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 standar date of manufacture 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 vehicles 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

ds in ef

fect on the

, the

installer is responsible for compliance with all applicable federal and state regulations. They are required to certify that the vehicle is in compliance with the Federal Motor Vehicle Safety Standards and other regulations issued under the National Traffic and Motor Vehicle Safety Act.

ence the Code of Federal

Please r Regulations, title 49 - Transportation, Volume 5 (400-999), for further information, or visit www.gpoaccess.gov/nara/index.html for the full text of Code of Federal Regulations.

efer

Page 5

Introduction

iii

Stellar Hooklifts are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, these hooklifts will operate at peak performance for many years.

To promote this longevity, carefully study the information contained in this manual before putting the equipment into service. Though it is not intended to be a training manual for beginners, this manual should provide solid guidelines for the safe and proper usage of the hooklift.

Once you feel comfortable with the material contained in this manual, strive to

cise your knowledge as you safely

exer operate and maintain the hooklift. This process is vital to the proper use of 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 maintenance, operating, or repair instructions pertinent to all possible situations.

Please be awar manual contain information pertaining to

e that some sections of this

Stellar manufactured hooklifts in general and may or may not apply to your specific model.

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 purposes. This right is kept with no requirement or obligation for immediate mandatory updating of this manual.

In closing:

If more information is required or technical assistance is needed, or if you feel that any part of this manual is unclear or incorrect, please contact the Stellar Customer Service Department by phone at 800-321-3741 or email at [email protected].

ATTENTION

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.

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:

Technical Questions, and Information [email protected]

Order Parts [email protected]

Warranty Information [email protected]

Page 6

iv Slider65 Owner’s Manual

Loader Nomenclature

The Stellar Slider is a hydraulic, body-loading device when mounted on a truck chassis. It can handle a multitude of bodies ranging from flatbeds to recycling containers and dump bodies.

Two independently controlled cylinders operate all the functions of the Slider. By varying the cylinders operations, the Slider can be used to dump or unload a body.

The Slider consists of four basic parts: the base, dump, secondary, and jib sections. Please take the time to familiarize yourself with the various components. Knowing the proper terminology is necessary to get the full benefit of this manual.

Page 7

Chapter 1 - Safety

Safety 1

Please Read the Following Carefully! This portion of the manual contains information 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 operator’s mind. Three factors should exist for safe operation: 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 hooklift before putting the unit into operation.

Please take note that Stellar Industries, Inc. is not liable for accidents incurred by the hooklift because of non-fulfillment from the operator’s side of current rules, laws, and regulations.

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 with properly maintained equipment.

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, loosefitting or hanging clothing such as ties, torn garments, 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 readily 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 equipment to enter within 10 feet of hooklift operating area.

Never allow anyone to ride the hooklift or load.

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 pr devices.

Always wear appr clothing such as: protective helmets, antislip shoes with steel toes, protective gloves,

escribed personal safety

oved accident-prevention

Maintenance Safety

Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without Stellar Industries’ approval.

Do not perform any maintenance or repair work on the hooklift unless authorized and trained to do so. 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.

Page 8

2 Slider65 Owner’s Manual

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 necessary, 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 capabilities and limitations. Overloading the hooklift may result in serious damage of self, others, equipment 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 damage 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.

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.

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 overloading the equipment.

Deduct the weight of the body from the maximum load rating to determine how much

ATTENTION

Stellar Industries, Inc. is not liable

for accidents incurred by the

hooklift because of the

operator’s non-fulfillment of

current rules, laws and

regulations.

Page 9

Chapter 2 - Operation

Operation 3

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 support for the body.

Operator Requirements

Operation is limited to the following people: A. Qualified individual. B. Trainees under direct supervision of the

qualified individual. C. Test or maintenance individual. D. Hooklift Inspector.

Operators must: A. Demonstrate the ability to understand

all decals, the owner’s manual, and any other information required for safe operation of the hooklift.

B. Be able to demonstrate the ability to

safely control the hooklift. C. Know all safety r D. Be responsible for maintenance require-

ments.

E. Understand and be fully capable of

implementing all emergency proce-

dures. F. Understand the operating procedures as

outlined by this manual, Ansi B30.5 and Federal/State Laws.

egulations.

4. The parking brake must be removed to allow the truck to roll under the body while loading.

CAUTION

When loading and unloading, the jib clinder must be fully retracted 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.

Operator Conduct

1. Operators will not engage in any operation that would cause them to divert attention away fr the hooklift.

2. Operators are responsible for all opera tions under their direct control.

3. Operators will not leave a suspended load unattended.

4. Operators will be familiar with the equipment and the maintenance required for

oper care.

om the operation of

Page 10

4 Slider65 Owner’s Manual

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 pr

•

• Be sure all safety devices provided are

• Be prepared for all situations. Keep

• Be sure all regular maintenance has

• Visually inspect all aspects of the

• Check for fluid leaks.

otective guards must be in place. Be aware of the surroundings: low branches, power lines, unstable ground.

in place and in good operating condition.

fire extinguisher and first aid kit near.

been performed.

hooklift for physical damage.

Operation Overview

Unloading Operation

. 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 jib.

4. Pull jib lever until the jib cylinder is fully retracted, 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.

Loading Operation

1. Perform the steps for unloading a container.

2. Engage the hook to the body by maneuvering the hooklift with the red(lift) lever.

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

4. Push the black(jib) lever until the jib is fully extended.

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.

ait until dumping is complete, then push the

5. ed(lift) lever until the main cylinder fully r

6. Disengage the PTO.

etracts.

Page 11

Unloading Operation

Operation 5

1. Stop the truck at the location you wish to unload.

3. Locate the black control lever labeled jib.

2. Put the truck in neutral and engage the PTO.

4. Pull jib lever the jib cylinder is fully retracted, thus releasing tabs.

5. Locate the r

ed 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.

Page 12

6 Slider65 Owner’s Manual

Loading Operation

1. Position the truck in line with the body you intent to pick up.

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

2. Engage the hook to the body by

maneuvering the hooklift with the red(lift)

lever and the black (jib) lever.

4. Push the black(jib) lever until the jib is fully extended.

5. Disengage the PTO.

Page 13

Dumping Operation

Operation 7

1. Stop the truck at the location you wish to dump the load.

3. Locate the red lever labeled lift.

2. Put the truck in neutral and engage the PTO.

4. Pull the lift lever to dump the body.

5. Wait until dumping is complete, then push the ed(lift) lever until the main cylinder fully r

etracts.

6. Disengage the PTO.

Page 14

8 Slider65 Owner’s Manual

Page 15

Chapter 3 - Maintenance

9Maintenance 9

Please read the following before performing any maintenance on the hooklift.

1. Only authorized service personnel are to perform maintenance on the hooklift.

2. Disengage the PTO before any service or repair is performed.

3. Do not disconnect hydraulic hoses while there is still pressure in those components.

4. Before disconnecting hydraulic components, shut off the engine, release any air pressure on the hydraulic reservoir, and move control levers repeatedly through their operating positions to relieve all pressures. Keep the hooklift clean and free from grease

5. build-up, oil and dirt to prevent slippery conditions.

6. Perform all safety and maintenance checks

e each period of use.

befor

7. Replace parts with Stellar Industries, Inc. approved parts only.

8. Immediately repair or have repaired any components found to be inadequate.

Maintenance Procedures

1. Position the hooklift where it will be out of the way of other operations or vehicles in the area.

2. Place all controls in the off position and secure operating features from inadvertent motion.

3. Relieve hydraulic oil pressure from all hydraulic circuits before loosening 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 the hooklift for all of the following:

1. Loose bolts and fasteners.

2. All pins, bushings, shafts, and gears for wear, cracks, or distortion to include all pivot points, and bushings.

Hydraulic systems for pr

4. Main frame mount bolts.

5. Cylinders for:

A. Damaged rods. B. Dented barrels. C. Drift fr D. Leaks at rod seals or holding valves.

6. PTO and hydraulic pump(s) for leaks. Hydraulic hose and tubing for evidence of damage

7. such as blistering, crushing, or abrasion.

esence of this owner’s manual.

8. Pr

Daily Inspection

Daily Inspection should occur each day before the hooklift is put into use. Each day, inspect the hooklift for all of the following:

om oil leaking inter

oper operating pr

nally.

essur

1. Hydraulic oil level.

2. Loose parts or damage to structures or weld.

3. Cylinder movement due to leakage.

4. Hoses for evidence of oil leaks.

5. Controls for malfunction or adjustment.

6. Parking brake operation.

7. All securing hardware such as cotter pins, snap rings, hairpins, and pin keepers for proper installation.

8. All safety covers for proper installation.

9. Cylinder holding valves for proper operation.

10. Equipment for missing, illegible, or defaced operat-

ing decals and safety signs.

Monthly Inspection

Monthly Inspection should occur at the beginning of every work month. Each month, inspect the hooklift for all of the following:

1. Frame bolt tightness - turn barrel nuts and mounting

bolts during the first month of operation on new machines and then quarterly thereafter.

2. Cylinders and valves for leaks.

3. Lubrication.

4. Jib hook for cracks.

5. Structural weldments for bends, cracks, or breaks.

6. All pins and keepers for proper installation.

7. All contr

ability and secure attachment.

8. Inspect all electrical wires and connections for worn,

cut, or deteriorated insulationand bare wire. Replace or repair wires as required.

10. Lubrication of all points requiring lubrication.

General Service

The following general suggestions should be helpful in analyzing and servicing your hooklift. Using the following systematic approach should be helpful in finding and fixing problems:

1. Determine the problem.

2. List and record possible causes.

3. Devise checks.

4. Conduct checks in a logical order to determine the

cause.

5. Consider the remaining service life of components

against the cost of parts and labor necessary to replace them.

6. Make the necessary repair.

7. Recheck to ensur

8. Functionally test the new part in its system.

ol, safety, and capacity placards for read-

e that nothing has been overlooked.

Cleanliness

An important item in preserving the

long life of the hooklift is keeping dirt,

grime, and corrosive material out of the working parts. Thoroughly wash

and grease the hooklift periodically.

Page 16

10 Slider65 Owner’s Manual

Choice Lubricants for DX Bearings

Greases Recommended

Type of Grease Description

Premium Quality Multi-Purpose

Multi-Purpose Calcium Based, for General Automotive and Industrial Use

Anti-Friction Bearing Calcium Based with EP Additives

Extreme Pressure (EP) Lithium Based with EP Additives

High Temperature 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 Grease Sodium Based Solid Grease White Grease Aluminum Complex Based with Anti-Oxidant & Rust

Silicone Lithium Based with Silicone Oil Lubricant

Stabilized, Anti-Oxidant Lithium Base Lithium Base with 3% Molybdenum Disulfide High Drop Point

Calcium Grease, Water Stabilized, High Drop Point

Lithium Based Sodium Based

Calcium Based with EP Additives

Inhibitors & Zinc Oxide Additives

Greases Not Recommended

Type of Grease Description

Cup Grease Light Service Calcium or Sodium Based Grease Graphite Filled Greases with More than 10% Graphite

Molybdenum Filled Greases with More than 10% Molybdenum Disulfide Fluorocarbon Low Molecular Weight Chlorofluoroethylene Polymer

with Inert Thickeners

White Grease Calcium Based, Zinc Oxide Filled

Page 17

Chapter 4 - Specifications

• Will accommodate bodies from 16-feet up to 22-feet (4877mm to 6706mm) long and still attain the maximum dump angle on a 41-inch (1041mm) high frame truck. Longer bodies may be accommodated with reduced dumping capabilities.

•

Transmission-mounted PTO and hydraulic pump required to power

the Hooklift loader.

• 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.

• Twentyfive (25) gallon (95L.) frame-mounted oil tank.

• Operating pressure is 4,500psi. (31Mpa)

• Hydraulic flow required is 20-gallons (76L.) per minute.

• Patented dump/load interface as featured on most Stellar Shuttle Hooklift loaders.

11Specifications 11

Lifting Capacity Dumping Capacity Dump Angle

Lowest Hook Height

fective Length

ruck Frame Height

Hooklift Height

Hooklift Length

Hooklift Center of Gravity

Chassis Cab to T

Max. Height When Loading Longest Body to Dump

Max. Height When Dumping

Maximum Operating Pr

Shipping W Min. Truck GVWR (pounds) Load Angle w/ Shortest Body Length Recommended Container Lengths* Recommended Flatbed Lengths**

*(Assumes 3ft. overhang from center of rear roller pin)

(Bumper typically 12” fr

**(Assumes 5ft. overhang from center of rear roller pin)

(May require bumper and latch options)

runion

essur

eight (pounds)

om center of r

oller pin)

• Hydraulic locks to prevent cylinder collapse in case of hose failure.

• Slide through rear body tie-down latches.

• Hydraulic lock-out valve to prevent front jib movement when the dump frame is raised.

• Permanently lubricated and greaseable bushings used throughout.

54” Hook Height

52,000lbs. (23,587kg) 65,000lbs. (29,484kg) 50°

(1,131mm)

44.51" 193" to 224" (4,902mm to 5,690mm) 41" (1,041mm)

53.44" (1,357mm) 227" (5,766mm) 103" (2,616mm) 174" to 190"(4,420mm to 4,826mm) 175" (4,445mm) 24' (7,315mm) 259" (6,579mm) 4,500psi (31Mpa) 6,600lbs. (2,994kg) 54,000lbs. (2,4494kg) 40° 16' to 22' 16' to 24' (4877mm to 7315mm)

(4877mm to 6706mm)

61.75” Hook Height

65,000lbs. (29,484kg) 65,000lbs. (29,484kg) 50°

(967mm)

38" 193" to 224" (4902mm to 5,690mm) 41" (1041mm)

53.44" (1,357mm) 227" (5766mm) 103" (2616mm) 174" to 190" (4,420mm to 4826mm) 179" (4547mm) 24' (7315mm) 264" (6706mm) 4,500psi (31Mpa) 6,600lbs. (2,994kg) 54,000lbs. (2,4494kg) 37° 16' to 22' 16' to 24' (4877mm to 7315mm)

(4877mm to 6706mm)

Page 18

12 Slider65 Owner’s Manual

Stellar Slider65 Hydraulic Hooklift Specifications

54" H.H.(1372mm): Max. Lifting Capacity: 52,000lbs. (23,587kg), evenly distributed in, or on the body.

4" H.H.(1372mm): Max. Dumping Capacity: 65,000lbs. (29,484kg), evenly distributed in, or on the body.

Operating Pressure: 4,500psi (31Mpa)

61.75"(1568mm): Max. Lifting Capacity: 65,000lbs. (29,484kg) evenly distributed in, or on the body.

1.75"(1568mm): Max. Dumping Capacity: 65,000lbs. (29,484kg) evenly distributed in, or on the body.

Operating Pressure: 4,500psi (31Mpa)

Max. Dump Angle: 50 degrees.

Hook Height: Adjustable hook height to handle 54" (1372mm) or 61.75" (1568mm) hook height bodies.

Shiping Weight: Not to exceed 6,600lbs. (2,994kg.)

ydraulic Gear Pump: Correctly sized direct-coupled piston type pump.

Hydraulic Control Valve: Correctly sized hydraulic valve mounted directly on top of oil reservoir.

Controls: Dual manual levers with sealed cable actuators mounted in the cab to allow full feathering of all hooklift functions.

Must also have center lock out to meet OSHA 1926.601(b)(11).

Sliding Jib Assembly: Hooklift must have sliding jib, to provide a low loading/unloading height of 179" (4,547mm), based on a 41"

(1,041mm) chassis frame height. Inner and outer jib booms must be hexangular shaped to reduce flexing, add to structural integrity, and ease wear pad replacement. The sliding jib assembly must be able to hydraulically slide the body/container horizontally without the use of wear pads for the body skid to slide on. Rollers will only be accepted, no wear pads accepted.

Jib Cylinder: Single 5" (127mm) bore with 2.5" (66mm) diameter rod cylinder. Cylinder must be double acting and include dual

pilot operated counter-balance valves to prevent cylinder collapse in case of hose failure. Cylinder is sized for rated capacity.

Jib/Dump Operation:

LIFT/Dump Cylinders:

Jib/Dump Interlock: Dumping must be accomplished through a rear pivot. Jib and dump sections must lock together to support the full

Rear Body Hold-downs: Slide through hold-downs devices mounted on the dump section to secure the rear of body through out a wide

Rear Hinge Pin: 3 1/2" diameter (89mm), type 17-4 stainless steel.

Hooklift must include a hydraulic lock-out device to pr

Dual 7" (178mm) bor pilot operated counter rated capacity.

length of the container/body. This must be accomplished without the use of springs, latches, hydraulic/air cylinders, gravity, to change mode of operation. The dump/jib interlock should be accomplished by means of tabs on jib boom which then slide under the dump to form support under the full length of the container and change the pivot point for dumping to the rear of the hooklift.

range of body lengths through the entire transportation and dump mode operation. Hooklift must be compatible with containers manufactured to ANSI Z245.60 standards for waste containers.

e with 3" (64mm) diameter rod cylinder. Cylinders must be double acting and include dual

-balance valves to prevent cylinder collapse in case of hose failure. Cylinders are sized for

event operation of the sliding jib while in the dump mode.

Pins: All pins to be made of 17-4 stainless steel.

Bushings: All bushings are to be a permanently lubricated and greaseable type.

Hoses and Fittings: All hoses and fittings are to SAE metrics are not allowed. O-ring face seal fittings are to be utilized

wherever possible.

Finish Paint Coating: Hooklift weldments must be finished painted with DuPont® Imron 5000 paint.

gin of Manufacturer: Hooklift must be designed and manufactured in the United States of America.

Page 19

Chapter 5 - Decals

Decals of Note

13Decals 13

Electrocution Hazard Decal

Location: On each side of the jib base. Function: To inform the operator of the hazard

associated with electrocution, the possible consequences should the hazard occur, and how to avoid the hazard. PN: C1179

Hands Clear Decal

Location: On each side of the jib base. Function: To inform the operator of the

hazard associated with jib 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 proper training, familiarity with safe operating pr possible consequences without training. PN: C4540

ocedures and , the

Operation Hazard Decal

Location: Truck Frame Function: To inform the operator and other

personnel in the work area of the hazard associated with improper maintenance and unauthorized modifications, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 4190

Page 20

14 Slider65 Owner’s Manual

PN 31827

Decal Kit Placement - PN 31827

Page 21

Chapter 6 - Installation

1/2” Plate

16.00

2-1/2” Pin

Bent 60°

12.00

41.63

Place at 45° Angle

8.25 Max

7.75 Min

Back of lift bar to rear of A-Frame

3/8” Plate

197.25

Body Length

3/8” Plate

6.00

3.00

Body Tie Downs

3/4 x 4 x 4 Plate

2.00

Note: Cap all tube ends.

Drawing for Dimensional Purposes Only

Minimum recommended rail construction

per number of rear rollers on loader.

190-24-60 6 x 3 x 3/8 & 1/2 x 3 Plt 6 x 3 x 3/8 & 1/2 x 3 Plt

Single Double

61.75

To Bottom

of Hook

Every hooklift installation is unique. However, certain guidelines exist that apply to every model. Listed below is a general set of chronlological steps that may be followed when installing a Stellar Hooklift. If any questions arise during the installtion process, feel free to contact your local dealer or Stellar Customer Service at 800-321-3741.

Basic Installation Overview

1. Clear the truck frame.

2. Set the Slider on the truck frame.

3. Shorten the truck frame to within 2” from the rear of the loader.

4. Install bumper.

5. Weld mounts to the base. (See Mounting Kit PN 40017)

6. Drill mounting holes.

7. Install tie-downs.

8. Install tarper tower (If applicable).

9. Mount hydraulic reservoir tank and valve bank.

10. Mount PTO and Pump.

11. Run hydraulic hoses.

12. Connect suction and pressure to the reservoir tank and valve bank.

13. Install cab and PTO controls.

14. Install mud flaps and fenders.

15. Run Slider.

15Installation 15

Subframe

Page 22

16 Slider65 Owner’s Manual

Installation Steps - Basic Guidelines

1. Clear the truck frame.

2. Set the Slider on the truck frame.

a. The front plate of the base needs to be at least 2” behind the cab or any equip-

ment mounted behind the cab.

b. Be sure to square the Slider on the truck frame and make certain that the jib cylin-

ders are fully extended for proper measurement.

c. Take a visual and look for any potential issues. For example: Clearance problems,

cross members extending too high, insufficient room in front of the Slider for tarpers, exhaust manifolds, etc, or insufficient room in the rear to allow for bumper selection.

3. Shorten the truck frame to within 2” from the rear of the loader.

4. Install bumper.

a. See Gover

nment Regulations for acceptable placement.

5. Weld mounts to the base. (See Mounting Kit PN 40017)

a. Move any thing that may be in your way.

Remove any bolts or hucks to be drilled later in the mounting angles.

b. c. The two (2) 20” long angle mounts must be welded on opposite sides under the

very front of the base. This angles can not be shortened in length.

d. Two (2) 18” angle mounts must be welded on opposite sides directly under the

rear pivot point. e. You will need to raise the base up above the truck frame. Use 1-1/4” spacers. f. Two (2) 18” angle mounts must be welded on opposite sides under the very rear

of the base, within 6” from the end of the truck frame. g. The other four (4) 18” angle mounts should be welded at even intervals on oppo-

site sides under the base, when possible. h. Note: Symmetry is not crucial. Adjustments can be made to make way for

braces, chassis additions, air tanks, etc. Otherwise, the mounts can be notched

for such allowances.

6. Drill mounting holes.

a. Using the mounting channels as a guide, drill (4) 1-1/16” holes through each of the

front two (2) mounts and truck frame. b. For the rest of the mounts, drill two (2) 1-1/16” holes through each of the mounts

and truck frame.

7. Install tie-downs.

a. Using 1” bolts (3” long), washers, and nuts, secure all mounts to the truck frame

and the Slider. b. Grease all bolts. c. Torque every bolt to 680 ft-lbs.

Page 23

Installation 17

8. Install tarper tower (If applicable).

a. See brand specific installation instructions.

9. Mount hydraulic reservoir tank and valve bank.

a. Make sure the tank isn’t too far away if cables are being used. b. Don’t raise the tank above the frame height. c. See Power Beyond Installation guide for valve bank details. d. See Reservoir Assembly Drawing PN 40022 for details.

10. Mount PTO and Pump.

a. Be sure to check the rotation of the pump to ensure proper installation. b. Use brand specific installation instructions.

11. Run hydraulic hoses.

a. Run hoses between the pump and reservoir tank. b. Run hoses between the PTO 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.

Keep these lines away from the driveshaft or other moving items.

f. g. See hydraulic schematics for details.

12. Connect suction and pressure to the reservoir tank and valve bank.

a. Fittings on the valve bank should be 3” lower than the long sills. b. Fill reservoir to site gauge, within 3” from the top (Roughly 25 Gallons). c. Petro-Canada Hydrex 32 (ISO 32) hydraulic oil is recommended. d. When connections are secure, turn reservoir on.

13. Install cab and PTO controls.

a. Use PTO brand specific installation instructions. b. See Controller Assembly Drawing (PN 38841) for details. c. See Stop System Drawing (PN 40029) for details. d. See Dump Light Kit Installation

14. Install mud flaps and fenders.

15. Run Slider.

a. Bleed the air out of the hydraulic system (instructions/diagram?) b. Check the oil level and add oil if needed. c. Calibrate stop system. d. Calibrate dump light system. e. Be sure to check all clearances. f. Set/check relief pressure no higher than 4500 PSI (see chart/diagram).

Page 24

18 Slider65 Owner’s Manual

THE TWO FRONT MOUNTS EACH USE FOUR BOLTS (5199).

QNOITPI

RCSE

TRA

ETI

156R

AOL43

1 240018 ANGLE 4.00X6.00X.50WX20.00 10

1EMARF KCURT2-710043 45199 CAP SCR 1.00X8X3.00 HHGR8 ZY 26 56538 WASHER 1.00 SAE FLAT YELLOW GR8 48 66294 NUT 1.00 HHGR8 NYLOC 24

PN 40017

Mounting Kit - PN 40017

20” long angle mount at front of base.

18” angle mount at pivot point.

Angle mount notched for frame bolt.

Page 25

YTQNOITPIRCSED

TRAPMETI

126510 RSRVR ASM 25GAL K MODEL 1

27353 NIPPLE 2.00 HEX PIPE 2FF 1

KLB GED 09 52.1 LE TS496

1KLB 00.41X52.1 ELPPIN4

200D

5C6228 FILTER HEAD SF120-25 1.3 1

101-ES EGRAL RETL

IF5226C

100.

2 LLAB EVLAV0

574C

100.2 BRAB E

SOH GTF0374C

18MDV NOITCES-2 BV11

642

KCOL 52.0 REHSAW12500

11 0339 CAP SCR 0.25-20X2.50 HHGR5 3

12 C5968 FTG MF/MSTR 90 8-12 C5OLO-S 1

.YT

QNOITPIRCSEDTRAPMETI

13 26737 HOSE 0.75(471TC-JC-J9-12-12-12-24) 1

14 0352 WASHER 0.50 USS FLAT ZINC 24

15 C6106 NUT 0.50-13 HHGR5 NYLOC 12

16 0501 CAP SCR 0.50-13X2.00 HHGR5 6

17 27119 HOSE 0.75(78C-12-JC-JC-12-12-12-120) 1

18 10094 GAUGE OIL LF 2.5" 0-500 BM 1

-02

-2010 UDER G

TF5732

C91

S-OLF 21 TPADA G

TF2

594C0

21 16145 GAUGE PRES FILTER SERVICE CI20 1

400.2

PMALC ESOH918

TF01 00

.2 TCUS ESOH6677132

24 25630 FTG ADAPT 10-1/4 F5OG 1

.YT

OITPIRCSEDTRAPME

25 d1435 FTG ADAPT O'RING 12-10 1

26 c4903 FTG SL LOK SWIVEL 12-C6LO-S 1

-OLO5F

-01 TPADA GTF2516172

28 C2252 FTG ADAPT 8-10-F5OLO-S 2

29 41129 BRKT RSRV HANGER 25GAL 2

30 0505 CAP SCR 0.50-13X3.50 HHGR5 6

PN 40022

Reservoir Assembly - PN 40022

Installation 19

Page 26

20 Slider65 Owner’s Manual

Setting System Relief Pressure

Instruction Overview:

See next page for details.

1. Engage the PTO

2. Push the red (lift) lever until the boom bottoms out. Keep pushing the lever forward until the pressure is set.

3. Release the jam nut using a 13 mm wrench.

4. Adjust the system relief pressure using 4 mm allen wrench.

Never Exceed the Maximum Pressure of 4500 psi.

Never adjust System Relief Pressure to allow Loader

Capacity to exceed chassis GVW and always per-

form a weight distribution before installation and

after System Relief Pressure adjustments to confirm

Loader Capacity and chassis compatibility.

5. Once system pressur

e is set, tighten the jam nut to lock system pressure. No permanent thread lock may be used

Page 27

Setting System Relief Pressure Continued

21Installation 21

1. Engage the PTO. Run the PTO at 1200 RPM.

3. Release the jam nut using a 13 mm wrench.

2. Push the red (lift) lever until the boom bottoms out. Keep pushing the lever forward until steps 3-5 are complete.

4. Adjust the system relief pressure using 4 mm allen wrench. Clockwise increases pressure, counter clockwise decreases pressure.

5. Once system pressure is set, tighten the jam nut to e. Permanent thread lock should

lock system pr not be used.

essur

6. Release all functions and disengage the PTO. Snap tamper cap into position over the jam nut. The br away clip will be destroyed if the cap is removed.

eak

Page 28

22 Slider65 Owner’s Manual

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.

1. Remove cover/access plug to reveal the power

beyond access point. Can also be used as the Return/Tank port.

3. The Power Beyond feature is now activated and will

divert oil to alternate system via the port shown.

2. Install a 3/8” straight thread pipe plug into lower portion of cavity to activate the power beyond feature. Use thread sealer (tape sealers not recommended.

Note:

1. The return/tank line must be connected to the top or the side port, labeled “T”.

2. Using the return line to run auxillary equipment will directly result in a failure and will not in any circumstance be covered under warranty.

3. A standard Stellar hooklift will have 6 hydraulic lines attached to the valve. A Stellar hooklift with Power Beyond will have 7 hydraulic lines attached to the valve.

Page 29

Installation 23

• 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.

• Screw in elevator bolt, and adjust so that switch is engaged when secondary is in lowered position.

• Install light in bracket provided with control console.

• Complete the wiring; following instructions provided with dump light kit.

Elevator bolt

L-bracket

Dump light switch

Detail A Scale 1 : 8

Dump Light Kit Installation

Page 30

24 Slider65 Owner’s Manual

CONTROLLER CABLES TO VALVE BANK

.YTQNOITPIRCSEDTRAPMETI 137474 CONTROLLER CTR LOCK RIGHT BEND 1 237475 CONTROLLER CTR LOCK LEFT BEND 1

1TNM MRALA BAT ETALP392623 437470 VALVE CTRL CONSOLE 2LEVER RVC 1 50491 CAP SCR 0.31-18X4.00 HHGR5 2 60343WASHER 0.31 USS FLAT ZINC 4

2COLYN HH 81-13.0 TUN24307 826031 BACKUP ALARM PIEZO JAMECO 123537 1 926135 DECAL NOTICE FIX TABS 1

10 D1711 CAP SCR #10-24X0.50 BTNHD SS 1 11 C6072 RELAY BOSCH 20-30 AMP 1 12 26288 LIGHT INDICATOR RED FORCE PTO 1 13 31806 DUMP UP LIGHT KIT BUYERS SK10 1 15 25933 BRKT CONTROLLER DECAL 1

1 COLYN HH 42-01# TUN4306261

18 37469 CABLE CONN. KIT FOR VD8A/VDM8 2

28MDV TCES-2 BV1164291

20 26291 WIRE HARNESS TAB ALARM 1 21 26289 WIRE HARNESS PROXIMITY SWITCH 1 17 37471 CONTROL CABLE 96" WESCON 2

NOTE: CONTROL LEVER, HANDLES, CONSOLE, AND CONTROLLER CABLES ARE INCLUDED WITH THE HYDRAULIC CONTROL VALVE.

PN 38841

Controller Assembly - PN 38841

Page 31

Unloader Manifold

See page 28 and 29 for breakdown. NOTE: Unloader manifold is attached to a bracket on the reservoir assembly. See page 29 for details.

Limit Switch

See page 27 for breakdown.

Push Pull Switch

See page 26 for breakdown.

Controller Assembly

STOP System Overview - PN 40029

The STOP system must be hooked up properly for the loader to operate.

The loader is equipped with a STOP (Stellar Tab Operation Protection) system. It is designed to protect the loader and operator from damage caused by improper loader operation. It will cut hydraulic power to the jib cylinder when the jib is raised for loading or dumping.

25Installation 25

Page 32

PN C0868 Push/Pull Switch

PN D1698 Indicator Light

26 Slider65 Owner’s Manual

STOP System - Push/Pull Switch (PN C0868)

Make sure to disconnect the batteries!

A decal mounting bracket (standard cab controls only) has been provided that will allow for mounting of the push/pull switch (PN C0868) and indicator light (PN D1698). The switch and light may be mounted in any easily accessible position if needed. See the electrical schematics on page 31 for details.

Page 33

DETAIL A

Limit Switch PN 10953

shown with installation assembly

NOTE: UNLOADER MANIFOLD IS ATTACHED TO A BRACKET ON THE RESERVOIR ASSEMBLY

.YTQNOITPIR

CSED

TRAPMETI 510953 SWITCH LIMIT OMRON 52F4219 NO/NC 1 640025 BRKT STOP SYSTEM 190-24-65S BTM 1 740026 BRKT STOP SYSTEM 190-24-65S TOP 1 8 0479 CAP SCR 0.25-20X0.75 HHGR5 2 9 0437 CAP SCR 0.25-20X1.25 HHGR5 2

8TALF 52.0 REHSAW043001 11 0333 NUT 0.25-20 HHGR5 NYLOC 4 12 41132 UNLOADER INSTALL KIT SLIDER65 1

STOP System - Limit Switch (PN 10953)

Installation 27

Page 34

28 Slider65 Owner’s Manual

DETAIL A

Unloader Manifold PN 41132

shown with fittings and

installation assembly

Limit Switch PN 10953

shown with installation assembly

5 10953 SWITCH LIMIT OMRON 52F4219 NO/NC 1 6 40025 BRKT STOP SYSTEM 190-24-65S BTM 1 7 40026 BRKT STOP SYSTEM 190-24-65S TOP 1 8 0479 CAP SCR 0.25-20X0.75 HHGR5 2 9 0437 CAP SCR 0.25-20X1.25 HHGR5 2

11 0333 NUT 0.25-20 HHGR5 NYLOC 4 12 41132 UNLOADER INSTALL KIT SLIDER65 1

A NOTE: Unloader manifold is attached to a bracket on the reservoir assembly. See page 29 for details.

ITEM PART DESCRIPTION

139337 MANIFOLD ASM UNLOADER 2 C2252 FTG ADAPT 8-10-F5OLO-S 312153 PLUG STR HOLLOW HEX 0.63 10-HP5ON

QTY

1 4 4 2 8 4 1 2

4 C0933 CAP SCR 0.31-18X

4.50 HHGR5 50343 WASHER 0.31 USS FLAT ZINC 60342 NUT 0.31-18 HH NYLOC 741130 BRKT DUMP VAVLE SLIDER65 80488 CAP SCR 0.31-18X2.00 HHGR5

STOP System - Unloader Manifold (PN 10953)

Page 35

Installation 29

JIB EXTEND

JIB RETRACT

PLUG

P/N 17482

P/N 38988

P/N 19292

Unloader Manifold Location on the Reservoir Assembly

STOP System - Unloader Manifold Details

Install the four equal length hoses between the unloader manifold and the tank mounted valve bank. The unloader See the following pages and the hydraulic schematics on page 30 for details.

manifold is attached to a bracket on the reservoir assembly.

Page 36

30 Slider65 Owner’s Manual

PN 38955

Hydraulic Schematic - PN 38955

Page 37

PN 41133

Wiring Schematic - PN 41133

Installation 31

Page 38

32 Slider65 Owner’s Manual

Page 39

Chapter 7 - Assembly Drawings

.YTQNOITPIRCSEDTRAPMETI

156REDILS ESAB631431

260.4XDO "4 RELLOR896832 3 2227 BUSHING 48DXR48 GARLOCK 2 4 0865 BUSHING 48DXR32 GARLOCK 2

RS 65.51X00.3 NIP99683

5 638830 PIN 3.50X42.00 .5DIA D&T 1 718373 BUSHING 48DXR48 GARLOCK 2

261-5323-ISQ GNIHS

UB91

888

9 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2

10 21493 PIN TEAR DROP 2.00X8.00 2 11 0352 WASHER 0.50 USS FLAT ZINC 2 12 8457 CAP SCR 0.50-13X1.00 SS 2

400.3 GNIR PANS690231

14 1589 MACHY WASHER 3.00ID 14GA 4 15 0377 MACHY WASHER 2.00ID 10GA 6 16 c1592 ZERK 1/8 NPT STRAIGHT 2 17 21586 COLLAR 2.01X3.00X1.00 UHMW 4 18 12922 THRUST WASHER 0.64x4.00x0.125 2 19 8597 PIN CAP 0.69x4.00x0.25 SS 2 20 12711 THRUST WASHER 0.63 DIA 2 21 12673 CAP SCREW 0.50-13 SHOULDER 2 22 21505 COLLAR 2.01X3.00X.63 UHMW 2 23 19361 MACHY WASHER 3.50ID 16GA 4

PN 34135

Base Assembly - PN 34135

33Assembly Drawings 33

Page 40

34 Slider65 Owner’s Manual

.YTQ

NOI

TPI

RCSE

PME

56RE

LS PM

8314

1 238698 ROLLER 4" ODX4.06 4 321505 COLLAR 2.01X3.00X.63 UHMW 8 4 8819 BUSHING QSI-3235-16 4 5 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 4 621493 PIN TEAR DROP 2.00X8.00 4 7 0352 WASHER 0.50 USS FLAT ZINC 4 8 8457 CAP SCR 0.50-13X1.00 SS 4 918373 BUSHING 48DXR48 GARLOCK 2

.YTQNOITPIRCSEDTRAPMETI

10 2227 BUSHING 48DXR48 GARLOCK 4

05.23X

00.3 NIP097

831

1 12 2200 SNAP RING INSIDE 3.00 3000-X300 2 13 21586 COLLAR 2.01X3.00X1.00 UHMW 4 14 38766 17758-ROLLER ASSEMBLY 1 15 0489 CAP SCR 0.31-18X2.50 HHGR5 1 16 0343 WASHER 0.31 USS FLAT ZINC 2 17 0342 NUT 0.31-18 HH NYLOC 1 18 8622 CLAMP HOSE/TUBE AG-2 1

PN 34137

Dump Assembly - PN 34137

Page 41

NOITPIRCS

DTRA

METI 1 38767 ROLLER CARRIAGE 190-24-65S 2 2 38768 PIN TEAR DROP 2.00X6.00 4 3 0350 CAP SCR 0.50-13X1.00 HHGR5 4 4 0352 WASHER 0.50 USS FLAT ZINC 4 5 0865 BUSHING 48DXR32 GARLOCK 4

205.21X00.3 NIP967836

460.4

DO "4 RELLOR

896

837

461-53

-IS

GNIHSU

91888

9 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 4

10 c1592 ZERK 1/8 NPT STRAIGHT 6 11 26168 COLLAR 3.01X4.00X1.00 4 12 C0954 CAP SCR 0.38-16X4.50 HHGR5 4 13 0347 NUT 0.38-16 HH NYLOC 4

PN 38766

Roller Assembly - PN 38766

35Assembly Drawings 35

Page 42

36 Slider65 Owner’s Manual

.YT

TPIRCSEDTRAP

134140 SECONDARY 190-24-65S 1 2 2227 BUSHING 48DXR48 GARLOCK 2 338738 PLATE WEAR PAD CAP 8 440019 CAP SCR 0.63-11X1.25 HHGR8 ZY 64 538739 WEAR PAD 190-24-65S 8

1RS 05.9X00.2

NIP047

836 70377 MACHY WASHER 2.00ID 10GA 2 8 0108 SNAP RING 2.00 7200-200 2 9 1546 THRUST WASHER 2.01DIA UHMW .12THK 2

10 c1592 ZERK 1/8 NPT STRAIGHT 2 11 39043 CYLINDER ASM

DUAL 65 SLIDER 1 12 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 66 13 8597 PIN CAP 0.69x4.00x0.25 SS 2 14 0356 CAP SCR 0.63-11X1.50 HHGR8 ZY 2

PN 34139

Secondary Assembly - PN 34139

Page 43

.YT

NOITP

IRC

SED

APMETI

252.17X00.7 REDNILYC741431

4S-OLO5F 8-01 TPADA GTF350132 339185 TUBE ASM 0.63 SLIDER SR RETRACT 1 439186 TUBE ASM 0.63 SLIDER SR EXTEND 1 539188 TUBE ASM 0.63X10.93 SLIDER SR 1

1OLO5R-01 EET NUR TS GTF2419

4S-

OL6C-01 TPAD

A G

66523

7 815995 MANIFOLD ASM DUAL T2A 5000PSI 1

1S-OLO5S-01 EET GTF512049

10 39187 TUBE ASM 0.63X79.19 SLIDER SR 1

2815RZ EBUT TROP PMALC1078111

12 19370 HOSE CLAMP 5.63-8.50 5416K39 2

2S-OLO5F-01 TPADA GTF25161

PN 39043

Main Cylinder Assembly - PN 39043

37Assembly Drawings 37

Page 44

38 Slider65 Owner’s Manual

.YTQNOIT

PIRCSED

TRAP

METI

138725 JIB BOTTOM 190-24-65S 1

1S56-42-091 POT BIJ627832 338727 PIN WLDMT 2.00X12.50 2 438732 WEAR PAD JIB 190-24-65S 2

1RS 83.11X00.2 NIP338835 60377 MACHY WASHER 2.00ID 10GA 2 70108 SNAP RING 2.00 7200-200 2 8 D0896 CAP SCR #10-24X0.75 FHSH SS 4 938729 CYLINDER ASM 5.00X39.00 1

10 40135 GAS SPRING CLOSE ASSIST 9502T7 1 11 40093 HANDLE JIB ADJUST SLIDER SR 1 12 40094 LINK JIB ADJUST SLIDER65 1 13 40021 PIN .25X2.50 QR W/ LANYARD 2 14 40193 GRIP 0.25X1.00 FLAT VINYL 9692K37 1 15 41080 BALL STUD 13MM BALL SLIDER 9512K64 1 16 0486 CAP SCR 0.31-18X1.50 HHGR5 2 17 0342 NUT 0.31-18 HH NYLOC 2 18 0343 WASHER 0.31 USS FLAT ZINC 4 19 C2225 WASHER 0.31 FENDER 1.25OD 2 20 27813 COLLAR 0.38X0.75X0.38 UHMW 1 21 38106 PIN 0.38 SQUARED RETAINER SNAP 1 22 41775 SPACER SLIDER65 ADJUST HH UHMW 1 23 14861 CABLE ASM .063X10.00 1

PN 34142

Jib Assembly - PN 34142

Page 45

.YTQ

OITPIRCSE

DTRAP

METI 10 40135 GAS SPRING CLOSE ASSIST 9502T7 1 11 40093 HANDLE JIB ADJUST SLIDER SR 1 12 40094 LINK JIB ADJUST SLIDER65 1 14 40193 GRIP 0.25X1.00 FLAT VINYL 9692K37 1 15 41080 BALL STUD 13MM BALL SLIDER 9512K64 1 16 0486 CAP SCR 0.31-18X1.50 HHGR5 2 17 0342 NUT 0.31-18 HH NYLOC 2 18 0343 WASHER 0.31 USS FLAT ZINC 4 19 C2225 WASHER 0.31 FENDER 1.25OD 2 20 27813 COLLAR 0.38X0.75X0.38 UHMW 1 21 38106 PIN 0.38 SQUARED RETAINER SNAP 1 22 41775 SPACER SLIDER65 ADJUST HH UHMW 1 23 14861 CABLE ASM .063X10.00 1

CONNECT WIRE, P/N 14861, THROUGH THE .19" HOLE IN LINK 40094 AND THROUGH THE HOLE IN PIN 38106.

Jib Assembly - PN 34142 Continued...

Page 46

40 Slider65 Owner’s Manual Assembly Drawings 40

ITEM PART DESCRIPTION QTY.

138730 CYLINDER 5.00X39.00 1

PN 38729

Jib Cylinder Assembly - PN 38729

Page 47

Chapter 8 - Replacement Parts

41Replacement Parts 41

Hydraulic System Component Parts

ART#

10094 16145 C6228 C6225 C6327 15463 15464 18552 15462 C1090 17482 29683 24611 C2028 C2029 32223 D1246 D1247 D1248 C6310 41038 39185 39186 39188 39187

ESCRIPTION

PRESSURE GAUGE - HYDRAULIC

GAUGE - FILTER SERVICE

FILTER HEAD

FILTER - HYDRAULIC

FILTER STRAINER - HYDRAULIC RESERVOIR

THERMO-SIGHT GUAGE - HYDRAULIC RESERVOIR

TANK COVER - 6" CLEAN OUT - HYDRAULIC RESERVOIR

CAP FILL ASM

CAP FILL ASM - HYDRAULIC RESERVOIR

C-BALANCE VALVE - LIFT & JIB CYLINDER

SOLENOID VALVE - STOP SYSTEM

SEAL KIT - VDM8 VALVE SECTION

VALVE BANK 2-SECTION VDM8

O RING (#6 FACE SEAL) (HYDRAULIC FITTINGS)

O RING (#8 FACE SEAL) (HYDRAULIC FITTINGS)

O RING (#10 FACE SEAL) (HYDRAULIC FITTINGS)

O RING (#6 SAE PORT SIDE) (HYDRAULIC FITTINGS)

O RING (#8 SAE PORT SIDE) (HYDRAULIC FITTINGS)

O RING (#10 SAE PORT SIDE) (HYDRAULIC FITTINGS)

SEAL KIT - LIFT CYLINDER (34147)

SEAL KIT - JIB CYLINDER K-0500-250-32 (38730)

TUBE ASSEMBLY ( LIFT CYLINDER ) Retract

TUBE ASSEMBLY ( LIFT CYLINDER ) Extend

TUBE ASSEMBLY ( LIFT CYLINDER ) 0.63 X 5.88

TUBE ASSEMBLY ( LIFT CYLINDER ) 0.63 X 65.19

Assembly Component Parts

PART# DESCRIPTION

0865 2227 4380 8819 18373 8597

BUSHING 3.00" X 2.00"

BUSHING 3.00" X 3.00"

BUSHING 2.00" X 1.50"

BUSHING 56D48

PIN CAP 0.69" X 4.00" X 0.25" SS

Assembly Component Parts

PART# DESCRIPTION

0356 8457 12673 40019 1546 0377 1589 19361 0108 2096 2200 21505 21586 26168 39345 C1592 38732 38739 40135 38698PC

CAP SCREW 0.63-11 X 1.50 GR8

CAP SCREW 0.50-13 X 1.00" SS

CAP SCREW 0.50-13 SHOULDER 0.63" X 0.50" SS

CAP SCREW 0.63-11 X 1.25 GR8

THRUST WASHER 2.01 DIAMETER UHMW .12

MACHINE WASHER 2.00 ID 14GA

MACHINE WASHER 3.00 ID 14GA

MACHINE WASHER 3.50 ID 16GA

SNAP RING 2.00"

SNAP RING 3.00"

SNAP RING 3.00" INTERNAL

COLLAR 2.01 X 3.00 X 0.63

COLLAR 2.01 X 3.00 X 1.00

COLLAR 3.01 X 4.00 X 1.00

COLLAR 4.75 X 0.63W X 1.25

GREASE ZERK 1/8 NPT STRAIGHT

WEAR PAD - JIB

WEAR PAD - SECONDARY

GAS SPRING

ROLLER 4.00"

Controller Assembly Parts

PART# DESCRIPTION

37474 37475 37471 37472 37473 37469 C0868 10953 26031 26288 C6072

CONTROLLER - CENTERLOCK RIGHT BEND

CONTROLLER - CENTERLOCK LEFT BEND

CONTROL CABLE - 96.00"

CONTROL CABLE - 144.00"

CONTROL CABLE - 196.00"

CABLE CONNECTOR KIT

SWITCH - PUSH / PULL 12V

LIMIT SWITCH

ALARM

INDICATOR LIGHT

RELA

Page 48

42 Slider65 Owner’s Manual

Page 49

Chapter 9 - Troubleshooting

43Troubleshooting 43

This chapter will list a number of

potential problems that may occur

while operating the Hooklift. Most

problems are easily solved using the

solutions portion of this chapter. If

problems persist, please contact

Customer Service at Stellar Industries

1-800-321-3741.

Problem: Hooklift will not operate or operates slow. Solutions:

• Make sure the PTO is engaged.

• Make sure the control lever/cable assem bly or air actuator are shifting the spool valves on the valve section

• Make sure that the hydraulic pump is operating at its rated flow or GPMs under load. Check the flow by using a flow meter to determine the GPMs. To find the

oper flow the equipment is to operate

pr at, see Chapter 6 of the Hooklift Owner’s Manual.

• Make sure the relief pressure is properly set per the specifications page of the hooklift owners manual.

• Make sure the spool valves on the valve bank are adjusted and operating smoothly.

Problem: Hydraulic system gets extremely hot. Solutions:

• Make sure the hydraulic filter has been changed per the maintenance page of the Hooklift Owner’s 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. See the Table on page 20 of Chapter 6: Installation for proper setting.

Problem: Hooklift will not lift or pickup a loaded container. Solutions:

• Make sure the container contents are evenly distributed.

• Make sure the container and its load does not exceed the rated capacity.

• Make sure the relief pressure is properly set per the Table on page 20 of Chapter 6: Installation for proper setting.

• Make sure the hydraulic pump is operat-

ing at its rated flow or GPMs. See Chapter 4: Specifications.

• Make sure that the container is not fixed

to the ground or frozen down.

Problem: Cylinders drift upward or downward while hydraulics are dis-engaged. Solutions:

• Make sure valve spools are shifting to three neutral position. Possible contamination keeping the hold-

• ing valve open.

• Possible internal piston seals rolled or damaged.

Problem: Lift cylinder operates, but the jib cylinder operates slow or does not operate at all. Solutions:

• Make sure the rotary valve arm is properly adjusted. See Rotary Valve Drawing in the Installation Chapter of this manual.

• Make sure the rotary valve arm is not damaged or has become disconnected.

Problem: Hooklift binds at pivot points. Solutions:

• Make sure the pivot points are lubricated.

• Make sure pivot pins are not seized to the bushing.

• Make sure the weldments or pins are not misaligned or bent.

Contact Customer Service at Stellar Industries: 1-800-321-3741

Page 50

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 from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture, Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of manufacture, and Thirty-six (36) month warranty on all Stellar Crane and Hooklift structural parts from the date recorded by Stellar as the in-service date, not to extend beyond forty-eight (48) months from date of manufacture.

The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, the factory ship date will be used.

Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option) of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24hours of notification by the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.

Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged parts must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of the warranty claim.

Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service provider.

All obligations of Stellar and its authorized 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 the case repair work is performed on a Stellarmanufactured product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any way not approved, in writing, by Stellar.

The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear, accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.

The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of delay, or for any special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use, wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.

All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not participate in, or obligate itself to, any such warranty.

Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products theretofore manufactured.

This warranty will apply to all Stellar Hooklifts, Stellar Service Trucks, & Truck-mounted Cranes shipped from Stellar’s factory after July 1, 2005. The warranty is for the use of the original owner only and is not transferable without prior written permission from Stellar.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Revision Date: February 2007 Document Number: 37040