Stellar X-Tra-Lift Pro User Manual

Owner’s Manual

Serial No. __________________________

Patent No. 6,435,806

Stellar Industries, Inc.

190 State Street • PO Box 169 • Garner, IA 50438

800-321-3741 • 641-923-3741 • Fax: [phone]

[e-mail] • www.xtralift.com

®

Manual Part No. 26339
Updated: 11/16/07
XtraliftPRO

If you have questions about your Stellar equipment, please contact one of

the individuals below.

Part Orders, Technical Questions, and Information:

Jeff Horstman Ext. 353 [e-mail]

Randy Milhan Ext. 224 [e-mail]

Brian Goll Ext. 357 [e-mail]

Warranty and Returned Goods:

Lisa Piklapp Ext. 351 [e-mail]

Customer Service Manager:

800-321-3741

800-321-3741

800-321-3741

Dave Schwichtenberg Ext. 227 [e-mail]

Contact Lisa Piklapp before returning goods

to:

Stellar Industries, Inc.

Return Goods

190 Bush Ave

Garner, IA 50438

Introduction

Stellar Industries, Inc. products are designed to
provide many years of safe, trouble-free,
dependable service when properly used and
maintained. This manual provides installation
and operating procedures to help you obtain
efficient and dependable use from your Stellar
X-Tra-Lift. This manual also contains mainte­nance information, safety suggestions, optional
items, and other general information.

It is specifically recommended that all operating
and service personnel consider this manual as
mandatory reading material before installing,
operating, or servicing the X-Tra-Lift. Keep this
manual with the X-Tra-Lift at all times for easy
reference. If at any time you have questions,
please contact your X-Tra-Lift dealer or the
Stellar Industries, Inc. Customer Service
Department.

This manual does not cover all maintenance,
operating, or repair instructions pertinent to all
possible situations. This manual is not intended
as a training manual for beginners or unskilled
operators. It offers guidelines for correct and
safe usage of the X-Tra-Lift, maintenance
guidelines, basic installation, and troubleshoot­ing guidelines. If you require additional informa­tion, please contact Stellar Industries, Inc. at
800-321-3741.

Stellar Industries, Inc. reserves the right to
update this material without notice or obligation.

X-Tra-Lift Capacity: Not to
Exceed 1300 LBS (590 KG)

WARNING!

X-Tra-Lift is not rated for roll bar

application.

Table of Contents

Chapter 1 - Operation & Safety 1-1

Chapter 2 - Maintenance 2-1

Chapter 3 - Installation 3-1

Chapter 4 - Wiring and Hydraulic Controls 4-1

Chapter 5 - Safety Decals 5-1

Chapter 6 - Assembly Drawings 6-1

Chapter 7 - Options 7-1

Chapter 8 - Troubleshooting 8-1

Mounting instructions specific to vehicle year, make,

and model will be found in mounting kit shipped with

each X-Tra-Lift.

Chapter 1 - Operation & Safety

IMPORTANT SAFETY INFORMATION. DO

NOT OPERATE THIS UNIT WITHOUT

FIRST READING THIS MANUAL.

Congratulations on your purchase of this
exciting new X-Tra-Lift Pro. We are sure you
will enjoy many years of satisfying use from
this high quality product. This manual con­tains very important safety and maintenance
information. Failure to read and understand
the information contained in this manual will
expose you to unnecessary risk. This is a
safe and reliable product when used as
intended. As with any product, intentional
misuse or failure to operate in a safe and pre­scribed manner is potentially dangerous.

OPERATING THE LIFT:

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

2. Set the parking brake.

3. Lower the tailgate.

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

Unload

Load

Control Pendant

PN: 24387

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 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.

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.

NOTICE!

Maintain good visual sight lines when
operating the lift.

Be aware of

potential conflicts during operation.

any

Chapter 1 - Operation

& Safety

1-1

9. Load your cargo safely. Remember to bind
top-heavy loads with a minimum of two ratchet
straps, suitable chain-binders, 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 secure it to the con­tainer by means of an appropriately rated 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 sure there are no obstructions in
the path of the lift. Once the lift reaches its
stowed position, release the “load” button and
safely stow or remove the control pendant. Never
leave the pendant in a position for others to oper­ate it without your control or consent.

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

WARNING!

Never use the lift to move people. It
is not designed as a personnel lift
and should never be used in this
manner.

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

If you desire to load or unload small boats or
personal watercraft, it is permissible to sub­merge the X-Tra-Lift container in water.
Remember to set your parking brake fully
when using the lift adjacent to a body of
water. The lift and its container may become
slippery when their surfaces are wet. Use
caution during these circumstances to avoid
slips and falls. If you use the lift frequently in
this manner, you may want to attach “no-slip”
tape strips to various places around the lift to
increase wet operation safety. These can be
found at area hardware or building supply
stores.

Secure the load extending out the back

Chapter 1 - Operation

1-2

ra-Lift is submersible

X-T

NOTE: If you are submerging you X-Tra-Lift
and carrier into salt water, Stellar Industries
recommends you thoroughly wash the lift
and carrier after each submersion.

& Safety

DETACHING THE CONTAINER:

Electrical Power Line

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.

9. Press “load” button on the control pendant,
until the lift structure, minus the carrier, is in the
fully retracted position.

Precautions

Death or serious injury can occur
when operating near power lines or
during electrical storms.

Allow extra space for swaying powerlines in
windy conditions.

Keep a minimum of ten feet between any por­tion of the X-Tra-Lift and an electrical line. Add
an additional 12" for every additional 30,000
Volts or less.

WARNING!

Never operate your vehicle unless
the lift is in the sto
with or without the container. The
only exception occurs during step
#8 of Detaching the Container.

Never use the lift for pulling against
fixed or imbedded objects. It is only
for movement of cargo and/or recre­ational vehicles.

Do not modify or alter the struc­ture of the lift in any way. Limited
changes, additions, or modifications
to the container are acceptable.
(Examples include adding additional
tie-downs, no-slip tape, cycle
chocks, etc.)

wed position,

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

Chapter 1 - Operation

1-3

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

Do not walk under suspended loads.

.

& Safety

Chapter 2 - Maintenance

Do not operate the lift if the fluid level is exces-

It is recommended to inspect and
service the X-Tra-Lift periodically.
Please use the following recom­mendations to ensure long and
trouble-free service from your X­Tra-Lift.

INSPECTION

sively low. This will risk introducing air into the
hydraulic system which requires a lengthy bleed­out process and potential seal damage.

Inspect the lift structure and frame cross-member
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.

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.

factory-approved distributor immediately and
do not use the lift until repaired.

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. Over­tightening will only worsen a hydraulic leak. Do
not over-tighten fittings.

Inspect the fluid level of the hydraulic reservoir
weekly. It should be filled to the recommended
level. Do
approved hydraulic fluid. Stellar recommends
Mobil 13 fluid or equivalent.

Report any failure to the factory or a

not overfill the reservoir. Use only

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

Do not modify or alter the
structure of the lift in any way.
Limited changes, additions or
modifications to the container
are acceptable (Examples
include adding additional tie­downs, no-slip tape, cycle
chocks, etc.).

Chapter 2 - Maintenance

2-1

Chapter 3 - Installation

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 installation
process, feel free to con­tact Stellar Customer
Service at 800-321-3741.

Plan the installation carefully.

1. Set parking brake on the truck and chock the wheels.

2. Disconnect the battery.

Parking Brake

Battery

Chapter 3 - Installation

3-1

9. Run electrical wiring harnesses.

10. Place lift carefully inside the truck box.

11. Drill holes per mounting kit instructions. See

specific mounting kit diagrams on pages
3-4 (Chevy) and 3-5 (Ford) for details.

Wiring Harnesses

Drill Holes

Mounting Hardware

12. Put mounting hardware in place and tighten.

Chapter 3 - Installation

3-2