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: 641-923-2811
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 service@stellarindustries.com.
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 service@stellarindustries.com
Order Parts parts@stellarindustries.com
Warranty Information warranty@stellarindustries.com
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.
6 X-Tra-Lift 2000 Owner’s Manual
Safety Decals 7
Chapter 4 - Safety Decals
These decals are placed at various points on the X-Tra-Lift. Please read and follow all of
them. Replace decals if they are missing or illegible.
8 X-Tra-Lift 2000 Owner’s Manual
2
XTRA LIFT SHOWN AS REFERENCE
5
3
4
2
2
2
2
.
Y
TQ
NOI
TPIRCSEDTRAPM
E
T
I
1 37397 XTRA LIFT ASM 8FT SQUARE 2K OS 1
2
1TNIOP HS
URC LACED72652
2
2EDIS TFIL ART-X LACED214713
4 25624 DECAL DO NOT OPERATE ON INCLINE EU 2
5 39139 DECAL MAX. CAPACITY XTRA LIFT 2K 2
2
3
2
CONTAINER SHOWN AS REFERENCE
.YTQ
N
OITPIRCSEDTRAPMETI
1 38798 BODY ASM X-LIFT 8FT APL BODY 2K 1
2 25625 DECAL DO NOT RIDE IN CONTAINER 3
3 25623 DECAL STAY SAFE DISTANCE AWAY 2
Decal Placement
Chapter 5 - Installation
Read this Page Before Installation of the X-Tra-Lift
The following section is set up to
provide a basic guide to the installation of the X-Tra-Lift system. If any
questions occur during the installa-
tion process, feel free to contact
Stellar Customer Service at
800-321-3741
Installation 9
Plan the installation carefully.
1. Set parking brake on the truck
and chock the wheels.
Parking Brake
2. Disconnect the battery.
Battery
10 X-Tra-Lift 2000 Owner’s Manual
9. Run electrical wiring harnesses.
*See Wiring Instructions on page 14 for details.
Wiring Harnesses
10. Place lift carefully inside the
truck box.
11. Drill holes.
Drill Holes
12. Put mounting hardware in
place and tighten.
Mounting Hardware
Installation 11
*NOTE: On Ford F-Series trucks, installation requires partially extending
the lift prior to placing the forward two mount bolts.
14. Cycle the lift several times to insure everything is working properly.
12 X-Tra-Lift 2000 Owner’s Manual
Remote Signal
Ground
Hyd Solenoid
Remote Signal
Start Solenoid
Remote Signal
X-Tra-Lift Wiring Instructions
1. Connect the ignition wire to an ignition
hot wire. Consult your vehicle’s wiring
schematic to find an ignition hot wire.
2. Connect the optional light switches if
that option was purchased with the XTra-Lift.
Flood Lights
Wire Switch
Remote Start Supply Volt
Flood Signal ACC ON
GND Earth GND
Loadbed Lights
Wire Switch
Remote Start Supply Volt
LB Light Signal ACC ON
GND Earth GND
3. Connect the harness to the battery.
Connect the gr
ground, and connect the main power
circuit to the battery power.
ound circuit to the batter
5. If optional flood lights/load bed lights
are to be installed, connect the four pin
Packard connector to the light harness
included in the light kit. Connect both
right and left side.
6. Optional radio remote control. Wire the
remote as shown below:
7. Connect the wire control handle by
plugging in the thr
ee pin Packard.
4. Run the brake signal wire to the back of
the vehicle. The factory installed brake
signal wire will be located at the rear of
the vehicle.
8. See specific instructions in the power system manufacturer’s documentation for
details on connecting the hydraulic
motor to the solenoids.
Hydraulic Schematic
Installation 13
14 X-Tra-Lift 2000 Owner’s Manual
The TR2P-PD
Installation and Programming
Instructions
In the picture above there are a series of numbers that will be referenced
often in this installation process.
1. In the picture above, terminal #1 on the terminal strip will need to be
wired to the positive side of a 12 to 24V DC battery.
2. In the picture above, terminal #2 on the terminal strip will need to be
wired to the negative side of a 12 to 24V DC battery.
3. In the picture above, terminal #3 (Normally open output for channel one) on the terminal strip will
need to be wired to the power unit solenoid used for operating the power unit in the “up position.”
In most cases, this solenoid can be located on the solenoid valve block next to the “down position” solenoid. Once finding the solenoid, the connection of the wir
from the receiver unit into the wire coming from the hand-held controller already being used for
the “up” function.
4. Terminal #4 (normally open output for channel two) is not used in this procedure.
e is done by splicing the wire
5. Terminal #5 on the terminal strip is the common input for channel one. This connector should be
connected to a 12 to 24 volt positive source. The positive power that feeds the power unit is the
preferr
6. In the picture above terminal #6 (normally open output for channel two) on the terminal strip will
need to be wir
tion.” In most cases, this solenoid can be located on the solenoid valve bank next to the “up posi
tion” solenoid. Once finding the solenoid, the connection of the wire is done by splicing the wire
from the receiver unit to the wire coming from the hand-held controller already being used for the
down function.
7. Terminal #7 (solid state output) is to be connected to the motor solenoid (located on top of the
motor in most cases). The voltage of this output is deter
terminals (#5 and #8) and not to exceed 24V DC.
8. Terminal #8 on the terminal strip is the (common input) for channel two, this terminal should be connected to a 12 to 24 volt positive source. The positive power that feeds the power unit is the preferred choice.
Connect the antenna provided to the red connector on the end of the black wire located next to
9.
ter
ed choice.
ed to the power unit solenoid used for operating the power unit in the “down posi-
mined by the voltage on both common
minal #8.
-
10.Check over the unit to make sure it is wired correctly.
Take the wireless key chain remote and press button #1 and then button #2 making sure the up
11.
and down positions work. If the unit doesn’t operate properly, it will need to be programmed, look
at the provided information for programming.
Programming Instructions for the TR2P-PD
Mode switch (one per channel):
Mode Switch (one per channel):
Installation 15
Enter Programming Mode:
Learn Transmitter Code:
Clear Memory:
Press mode switch momentarily and
release:
LED Indicator (on per channel):
Steady ON:
Press and hold mode switch S1 or S2 for 3
seconds. LED will flash fast.
Within 15 seconds of entering programming mode press a transmitter button #1 or
#2. LED will flash 1 time when the button
has been programmed. Do this for both
buttons #1 to S1 and #2 to S2.
After entering programming mode, again
press and hold the switch for 3 seconds.
LED will flash twice to indicate memory
clear.
The LED will flash the number of remotes
that have been programmed to that
channel.
RF reception (receiver is receiving RF signal
from coded transmitter -- great for trouble
shooting).
Fast Flash:
One Flash:
Two Flashes:
Notes to remember:
1. Terminals #1 and #2 have to be wired directly to the battery, or through a safety switch
ectly to the battery. Do not wir
dir
unit itself.
2. Best location for the receiver unit is close to the battery under the hood.
3. Antenna needs to be outside of metal ground plane, i.e. not under the hood; outside in
the open is the best. Antenna needs to be at least one foot away from a power unit
motor.
e terminals #1 and #2 into the power on the power
In programming mode.
A transmitter code is programmed.
All programmed codes are cleared.
16 X-Tra-Lift 2000 Owner’s Manual
Assembly Drawings 17
1
4
5
6
7
5
4
2
3
8
.YTQ
N
OITPIRCSE
DT
RAPMETI
1 37384 BASE WLDMT X-TRA LIFT 8FT LC MM 2K 1
2 31129 WEAR PAD BASE SIDE MOD 2
3D0529 CAP SCR 0.25-20X1.50 BTNHD SS 4
2
1
SS T
ALF 52.0 REH
SA
W7190D4
530659 NUT 0.25-20 HH NYLOC SS 12
623639 WEAR PAD BASE SADDLES X-TRA LIFT 4
7C6022 CAP SCR 0.25-20X1.00 BTNHD SS 8
824688 PLATE SERIAL # XTRA LIFT 1
Chapter 6 - Assembly Drawings
Base Assembly
18 X-Tra-Lift 2000 Owner’s Manual
9
7
4
7
8
1
6
14
2
13
3
5
5
11
12
10
.YTQNOITPI
RC
SEDTR
AP
ME
TI
231.82X
05.
3 REDNILY
C
8337
31
237396 LINK LOWER XTRA LIFT 8FT PLT 2K 2
337395 LINK WLDMT UPPER XLIFT 8FT FLT 2K 2
437518 PIN TEAR DROP 1.00X5.25 XTRALIFT 2K 4
520362 BUSHING IGUS GFI-1618-08 8
4
61-81
61-ISQ GNIHSUB
960
06
61SS TALF 52.0 REH
SA
W7190D7
830659 NUT 0.25-20 HH NYLOC SS 12
9 C6022 CAP SCR 0.25-20X1.00 BTNHD SS 4
10 37678 PIN 1.00X4.19 SR RP XTRA LIFT 2
11 0867 MACHY WASHER 1.00ID 14GA 4
12 0110 SNAP RING 1.00 ID 7200-100 4
13 37679 SCREW #8-32X3.00 RNDHD SS 2
14 22186 NUT #8-32 HH NYLOC SS 2
Link & Cylinder Assembly
Assembly Drawings 19
1
3
4
3
4
10
9
8
9
10
5
6
2
6
7
.YTQNOITPIRCSEDTRAPMETI
1 37398 FRONT ARM WLDMT XTRA LIFT 8FT SQ 2K 2
237518 PIN TEAR DROP 1.00X5.25 XTRALIFT 2K 2
842-8161-ISQ GNIHSUB8600
3
461-8161-ISQ GNIHSUB96004
5C6022 CAP SCR 0.25-20X1.00 BTNHD SS 2
5SS TALF 52.0 REHSAW7190D6
730659 NUT 0.25-20 HH NYLOC SS 3
2
RS 91.4X0
0.1 NIP0867
3
8
90867 MACHY WASHER 1.00ID 14GA 4
10 0110 SNAP RING 1.00 ID 7200-100 4
Front Arm Assembly
20 X-Tra-Lift 2000 Owner’s Manual
3
1
4
5
6
2
3
.YT
QN
OITP
IR
CSEDT
RA
PMETI
137391 ARM WLDMT REAR XTRA LIFT 8FT SQ 2K 2
237518 PIN TEAR DROP 1.00X5.25 XTRALIFT 2K 2
842-8161-
ISQ GNIHS
U
B8600
3
4 C6022 CAP SCR 0.25-20X1.00 BTNHD SS 2
4SS TALF 52.0 REHS
A
W7190D5
630659 NUT 0.25-20 HH NYLOC SS 2
Rear Arm Assembly
Assembly Drawings 21
4
3
7
6
4
3
6
7
1
10
13
9
11
11
10
8
9
5
12
2
3
4
9
13
10
11
.YTQ
NO
ITPIRC
SED
TRA
P
METI
137423 LIFT FRAME WLDMT SQ 2K 1
2RS 60.11X00.1 NIP0257
3
2
30867 MACHY WASHER 1.00ID 14GA 12
40110 SNAP RING 1.00 ID 7200-100 12
2TFIL ART-X E
DIL
S
151
22
5
4R
S 60.5
X00.1 NIP
1257
3
6
720362 BUSHING IGUS GFI-1618-08 8
821514 WEAR PAD LIFT FRAME X-TRA LIFT 2
9C6022 CAP SCR 0.25-20X1.00 BTNHD SS 12
10 D0917 WASHER 0.25 FLAT SS 12
11 30659 NUT 0.25-20 HH NYLOC SS 12
12 0068 BUSHING QSI-1618-24 4
13 23638 WEAR PAD LIFT FRAME X-TRA LIFT 4
Lift Frame Assembly
22 X-Tra-Lift 2000 Owner’s Manual
Chapter 7 - Troubleshooting
Troubleshooting 23
This chapter will list a number of
possible problems that may occur
while operating the X-Tra-Lift. 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: X-Tra-Lift will not operate.
Solutions:
• Make sure that the parking break is fully
engaged.
• Check for poor safety switch grounds or
loose gr
clean ground connections and reattach.
ound connections. Thoroughly
Problem: X-Tra-Lift power unit operates, but
will not lift the rated load.
Solutions:
• Check the hydraulic fluid level. Add fluid
if necessary.
• Make sure that the pressure relief valve is
functioning properly. If it is faulty, call
Stellar Customer Service.
• Check the shaft and coupler between
the electric motor and hydraulic pump.
If one has broken, simply replace it.
• Make sure that the weight is evenly distributed across the carrier. Redistribute as
necessary.
Problem: X-Tra-Lift cylinder drifts.
Check to see if the electrical connec-
•
tions on the battery or power unit are
loose or corroded. Clean corroded
areas and tighten any loose connections.
• Make sure that the tailgate is lowered.
• If the tailgate is lowered and the X-Tra-Lift
still won’t operate, check the safety
switch to make sure it is functioning. If
the switch is faulty, simply replace it.
• Make sure the battery in the radio
remote is charged.
Problem: Brake light on lift is not illuminating.
Solutions:
• Check the bulb. If it is burned out, simply
replace it.
Solutions:
• Make sure the holding valves are operating properly. If they are not, contact
Stellar Customer Service
• Check for bad or worn out cylinder piston seals. Replace faulty seals with a seal
kit.
• Check for scratches or dents inside the
cylinder case wall. If such defects are
found, simply r
eplace the cylinder.
For problems not covered in
this section, please contact
Customer Service at
Stellar Industries
Check for loose or broken wires. Tighten
•
or replace wires as necessary.
1-800-321-3741
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
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