Stellar X-Tra-Lift 2000 User Manual

Owner’s Manual

2000

Tra

-

Lift

Subject to Change without Notification.
© 2007 Stellar Industries, Inc.

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: [phone]

www.stellarindustries.com

www.xtralift.com

Manual Part No.
Last Updated: 07/23/07

39131

ii X-Tra-Lift 2000 Owner’s Manual

X-Tra-Lift 2000 Manual Revisions

Date of Revision Description of RevisionSection Revised

Table of Contents iii

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .iv

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

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

Operating the Lift . . . . . . . . . . . . . . . . . . .3

Detaching the Container . . . . . . . . . . . . .4

Chapter 3 - Maintenance . . . . . . . . . . . . . . .5

Chapter 4 - Safety Decals . . . . . . . . . . . . . .7

Decal Placement . . . . . . . . . . . . . . . . . . .8

Chapter 5 - Installation . . . . . . . . . . . . . . . .9

Hydraulic Schematic . . . . . . . . . . . . . . .13

The TR2P-PD Installation . . . . . . . . . . .14

Chapter 6 - Assembly Drawings . . . . . . . .17

Base Assembly . . . . . . . . . . . . . . . . . . . .17

Link & Cylinder Assembly . . . . . . . . . . .18

Front Arm Assembly . . . . . . . . . . . . . . . .19

Rear Arm Assembly . . . . . . . . . . . . . . . .20

Lift Frame Assembly . . . . . . . . . . . . . . .21

Chapter 7 - Troubleshooting . . . . . . . . . . .23

Warranty Statement . . . . . . . . . . . . . . . . . . .24

iv X-Tra-Lift 2000 Owner’s Manual

Introduction

Stellar X-Tra-Lifts are designed to provide
safe and dependable service for a variety
of operations. With proper use and
maintenance, these X-Tra-Lifts 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 X-Tra-Lift.

Once you feel comfortable with the
material contained in this manual, strive to
exercise your knowledge as you safely
operate and maintain the X-Tra-Lift. 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 X-Tra-Lift and shall remain with the lift
at all times. Information contained within
this manual does not cover all
maintenance, operating, or repair
instructions pertinent to all possible
situations.

Please be aware that some sections of this
manual contain information pertaining to
Stellar X-Tra-Lifts 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 [e-mail].

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 X-Tra-Lift.

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 [e-mail]

Order Parts [e-mail]

Warranty Information [e-mail]

Chapter 1 - Safety

Safety 1

Please Read the Following Carefully! This
portion of the manual contains information
regarding all Stellar manufactured X-Tra­Lifts. 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 X-Tra-Lift before
putting the unit into operation.

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

ATTENTION

Never allow anyone to ride the

X-Tra-Lift or load.

protective glasses, and reflective jackets
with breathing apparatus. Consult your
employer regarding current safety
regulations and accident-prevention
equipment.

Do not wear rings, wristwatch, jewelry,
loose-fitting 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 X-Tra­Lift.

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.

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 maintained 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.

PERSONAL SAFETY

Keep clear of all moving parts.

Always wear the prescribed personal safety
devices.

Always wear approved accident-

evention clothing such as: protective

pr
helmets, anti-slip shoes with steel toes,
protective gloves, anti-noise headphones,

Do not use controls and hoses as
handholds. These parts move and cannot
provide stable support.

Never allow anyone to ride the X-Tra-Lift or
load.

ATTENTION

Maintain good visual sight lines

when operating the lift. Be aware

of any potential conflicts during

operation.

MAINTENANCE SAFETY

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

Do not perform any maintenance or repair
work on the X-T

ra-Lift unless authorized and

2 X-Tra-Lift 2000 Owner’s Manual

trained to do so.

Release system pressure before attempting
to make any adjustments or repairs.

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
X-Tra-Lift or service body must be kept
legible and in good condition. If necessary,
replace them.

ATTENTION

LOAD SAFETY

Know the weight of the load being lifted.
Do not rely on the overload device to
determine maximum rated loads.

Do not leave a X-Tra-Lift load suspended or
unattended.

Do not walk under suspended loads.

Do not position any load over a person nor
should any person be permitted to place
him or herself under a load.

Do not use the lift to drag a load.

Do not use the X-Tra-Lift to push downward
onto anything.

ATTENTION

Do not position any load over a

person nor should any person be

permitted to place himself or her-

self under a load.

STABILITY

Know the X-Tra-Lift components and their
capabilities and limitations. Overloading
the X-Tra-Lift may result in serious injury to
self and others, and damage to the
equipment and immediate surroundings.

Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s
hydraulic, mechanical, and structural
design rather than stability.

The supporting surface under the truck must
be able to support the weight of the
machine and its load.

Never use the lift to move people. It

is not designed as a personnel lift

and should never be used in this

manner.

ENVIRONMENT

Do not operate the X-Tra-Lift during
electrical storms.

In dusty work areas, every effort must be
taken to keep dust and sand out of the
moving parts of the machinery.

In high humidity work areas, keep parts as
dry as possible and well lubricated.

ATTENTION

Know the X-Tra-Lift components

and their capabilities and

limitations. Overloading the X-Tra-

Lift may result in serious injury to self

Set the parking brake before operating the
lift.

and others, and damage to the

equipment and immediate

surroundings.

Chapter 2 - Operation

Operating the Lift

1. Prior to operating the lift, park on flat and
level ground.

Unload

2. Set the parking brake.

3. Lower the tailgate.

Operation 3

4. Check for overhead obstructions (i.e.
wires, limbs, building overhangs, etc.).

5. Check to make sure the area behind the
truck is clear, and free of people, pets or
any other obstructions.

6. Make sure control pendant wire is fully
extended and not tangled or wrapped
in the structure of the lift in any way.

7. Make sure the container is free of
obstructions, and is clear to lift from the
truck bed.

8. Press and hold the “unload” button to
cycle the lift out of the truck. The lift is sta­ble throughout the load/unload cycle. It
can be set on a higher platform or truck
bed safely for loading as long as the lift is
in complete contact with the mated sur­face. Continue through the “unload”
cycle until you have reached your

NOTE:

Once the lift is in the stowed position,
check the load and any load binding
devices to make sure they have not shift­ed or loosened during the lifting process.
When driving with a loaded container, be
aware that the bulk of the load may
obscure your vision from the cab. Also be

e that the weight of the load will

awar
affect your vehicle’s stopping distance
and center of gravity. Stop periodically to
inspect and/or tighten any load retaining
devices as necessary.

Load

Control Pendant

PN: 24387

desired loading surface. The lift will not
travel past its pre-set bottom point but
will stop travel at a designated level. Do
not continue to depress the “unload”
button when the lift “limits out” or makes
contact with a solid surface. Release the
“unload” button when the lift makes
complete contact with the ground,
loading dock, etc.

9. Load your cargo safely. Remember to
bind top-heavy loads with a minimum of
two ratchet straps, suitable chain­binders, or other appropriately rated
cargo retention devices. Load heavy
items into the center of the container
whenever possible. It is much safer and
will extend the life of your lift. If the load
extends beyond the length of the con­tainer, you must secur
er by means of an appr
ratchet-strap or chain binder.

10. To return the container to the truck bed,

press the “load” button on the pendant
control. Again, check to make sur
there ar
the lift. Once the lift reaches its stowed
position, release the “load” button and
safely stow or remove the control pen
dant. Never leave the pendant in a
position for others to operate it without
your control or consent.

e no obstructions in the path of

e it to the contain-

opriately rated

e

-

4 X-Tra-Lift 2000 Owner’s Manual

Detaching the Container

1. Park the truck on flat, level ground. This is
critical if you desire to remove the con­tainer.

2. Set the parking brake.

3. Lower the tailgate.

4. Check for obstructions, both on the
ground and above the lift.

5. Press and hold the “unload” button and
cycle the lift until it makes complete
contact with the ground.

6. Remove the two steel retaining pins
(one per side) at the forward end of the
container retention blocks. Keep them
in a safe place such as the console or
glove-box of the vehicle.

7. Press the “unload” button briefly until

both retention blocks drop free from the
carrier. Mark exactly where your vehicle
is parked. To reattach your carrier, it is
necessary to be at the correct distance
from the carrier to mate the retention
blocks to the container.

8. Release the parking break. Drive ahead
a few inches. Re-depress parking brake
fully.

9. Set the parking break.

10. Press “load” button on the control pen-

dant, until the lift structure, minus the
carrier, is in the fully retracted position.

ATTENTION

Never operate your vehicle unless

the lift is in the stowed position, with

or without the container. The only

exception occurs during step #8 of

Detaching the Container.

For further operating instructions, or for questions about operation, please contact your nearest X-Tra-Lift dealer or the manufacturer.

Chapter 3 - Maintenance

Inspect the fluid level of the hydraulic reser-

It is recommended to inspect and

service the X-Tra-Lift periodically.

Please use the following recom-

mendations to ensure long and

trouble-free service from your

X-Tra-Lift.

INSPECTION

Every six months, inspect the joints and pivot
points of your lift. Be alert for any cracks, rust,
or chipped paint in these areas as they may
indicate structural failure. If cracks are found,
take the lift out of service immediately. This is
a high-quality, well-built product. Such fail­ures are not anticipated, but should be
checked for regardless. Also inspect the car­rier at this interval for similar cracks.

any failure to the factory or a factory­approved distributor immediately and do
not use the lift until repaired.

Report

voir weekly. It should be filled to the recom­mended level. Do not overfill the reservoir.
Use only approved hydraulic fluid. Stellar rec­ommends Petro-Canada HYDREX 32 (ISO 32)
fluid or equivalent.

Do not operate the lift if the fluid level is
excessively low. This will risk introducing air
into the hydraulic system which requires a
lengthy bleed-out process and potential seal
damage.
Inspect the lift structure and frame cross­member bolts every six months. Re-torque
any loose bolts immediately. If bolts repeat­edly require tightening, report this situation to
the factory or a factory-approved distributor.

Inspect all wires and control pendant for
signs of fraying or exposed wiring monthly.

Maintenance 5

Inspect hydraulic hoses and fittings monthly
for signs of leakage. If leaks are found, call
the factory for replacement hoses and/or
appropriate fittings. Hoses are tightened to
approximately 45 in-lbs. at the factory. If
leaks are present, check to make sure hoses
are tightened to that specification with an
appropriate torque wrench. Over-tightening
will only worsen a hydraulic leak. Do not
over-tighten fittings.

ATTENTION

An important item in preserving

the long life of the X-Tra-Lift is

keeping dirt, grime, and corrosive

material out of the working parts.

Thoroughly wash and grease the

X-Tra-Lift periodically.

SERVICE

The following general suggestions should
be helpful in analyzing and servicing your
X-Tra-Lift. 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 r

6. Make the necessary repair.

7. Recheck to ensure that nothing has
been overlooked.

8. Functionally test the new part in its sys­tem.

eplace them.