Stellar Industries SI-75, SI-60 User Manual
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SI-60 and SI-75 Models
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Subject to Change without Notification.
© 2012 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
Last Revision: 05/25/12
Stellar Cable Hoist Manual Revisions
Date of Revision Description of RevisionSection Revised
Table of Contents
Table of Contents
Introduction...............................................................................iii
Chapter 1 - Safety ...................................................................1
Chapter 2 - Operation.............................................................3
General Guidlines for Operation of the Cable Hoist ...........4
Loading Operation...................................................................5
Unloading Operation - O.R. and I.O. Models .......................6
Unloading Operation - Extendable Tail Models....................7
Correct Roll-Off Container Loads...........................................8
Unsafe Roll-Off Container Loads ............................................8
Hoist Prop Operation................................................................9
Chapter 3 - Maintenance .....................................................11
Maintenance Procedures .....................................................11
Daily Inspection ......................................................................11
Monthly Inspection .................................................................11
General Service ......................................................................11
Inspection of Sheaves ............................................................12
Cable Replacement ..............................................................13
Choice Lubricants for DX Bearings .......................................14
Chapter 4 - Specifications ....................................................15
Cable Hoist Dimensions .........................................................16
Container Subframe...............................................................17
Chapter 5 - Decals ................................................................19
Decal Kit Placement ..............................................................19
Safety Decals of Note............................................................20
Chapter 6 - Installation..........................................................21
General Install Guidelines ......................................................21
Truck Chassis Specifications ..................................................22
Step 1: Truck Frame Cut-Off ..................................................22
Dimensions: 174 Models .........................................................23
Dimensions: 182 Models .........................................................24
Dimensions: 194 Models .........................................................25
Step 2: Mount Hoist.................................................................26
Step 3: Mount Lift Cylinders ...................................................27
Step 4: Hydraulic Reservoir Installation ................................28
Step 5: Sub-Frame Front Clamp Installation ........................29
Step 6: Hydraulic Plumbing Installation................................29
Step 7: Hydraulic Relief Pressure Setting ..............................30
Step 8: Cable Control Installation.........................................30
Step 9: Pneumatic Control Installation ................................32
Step 10: Bumper Installation..................................................34
Heavy Duty ICC Bumper Installation....................................35
Step 11: Hoist Up Light Installation ........................................36
Step 12a: Fender Installation - Steel Tandem/Tri-Axle ........37
Step 12b: Fender Installation - Plastic Tandem/Tri-Axle......38
Step 13: Mid-Body Light Installation......................................38
Step 14a: Removable Stop Installation................................39
Step 14b: Intermediate Stop Installation .............................40
Step 15: Reflective Tape Installation ....................................41
Chapter 7 - Hydraulics - Electrical ......................................43
Hydraulic Schematic ..............................................................43
Hydraulic Routing - Standard Lift Cylinder ..........................44
Hydraulic Routing - Telescopic Lift Cylinder ........................45
Hydraulic Routing - Reverse Mount Lift Cylinder.................46
Reverse Mount Lift Cylinder Mounting Kit - PN 56094 ........47
Reverse Mount Lift Cylinder Mounting Kit - PN 56094 ........48
Hydraulic Routing - Reeving Cylinder ..................................49
Hydraulic Routing - Tail Extension IOX Cylinder Mount ......50
Hydraulic Routing - Tail Extension ORX Cylinder Mount .....51
Electrical Schematics .............................................................52
Chapter 8 - Assembly Drawings...........................................53
Cable Controls........................................................................53
Air Controllers Assembly 1......................................................54
Air Controllers Assembly 2......................................................55
Main Hoist Assembly ...............................................................56
Reeving Cylinder Assembly - PN 60219................................57
Reeving Cylinder Assembly - PN 60221................................57
Chassis Mounted Parts ...........................................................58
Chassis Mounted Parts ...........................................................59
Mounting Kit (Forward Mount) - PN 55261...........................60
Mounting Kit (Reverse Mount) - PN 56094 ...........................61
Mounting Kit (Telescopic) - PN 55265...................................62
Cab Guard - PN 47263...........................................................63
Under Body Tool Box - PN 46579 ...........................................64
Reservoir Assembly - PN 46133 ..............................................65
2 Section Valve Bank Reservoir - PN 45710 ..........................66
3 Section Valve Bank Reservoir - PN 46642 ..........................67
Reservoir Mounting Bracket for PN 45710............................68
Standard Lighted Bumper - PN 45887 ..................................69
Pintle Bumper - PN 46818.......................................................70
ICC Wide Bumper - PN 53397 ...............................................71
ICC Heavy Duty Bumper - PN 46809 ....................................72
ICC Bumper Weldment - PN 45574.......................................73
ICC Standard Narrow Bumper - PN 48848...........................74
ICC Narrow Bumper - PN 48846............................................75
ICC Extendable Bumper - PN 62663.....................................76
Tri-Axle Fenders - PN 46299 ....................................................77
Tandem Fenders - PN 46122 ..................................................78
Tandem Fenders - PN 46122 Continued... ...........................79
Tandem Poly Fenders - PN 45795..........................................80
Tri-Axle Poly Fenders - PN 45893 ............................................81
Telescopic Lift Cylinder - PN 51078 .......................................82
Standard Lift Cylinder - PN 55262 .........................................82
Long Reeving Cylinder - PN 51201 .......................................83
Standard Reeving Cylinder - PN 51080 ................................83
Tail Extension Cylinder - PN 51203.........................................84
Tail Extension Cylinder - PN 51202.........................................84
Ratchet Strap Kit - PN 63150..................................................85
Bolted Hold Down (Optional) - PN 42918 ............................86
Chapter 9 - Replacement Parts..........................................875
Stellar Cable Hoist 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 CABLE HOIST 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 cable hoist. 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 cable
hoist. You shall make these available and known to all personnel working with and
around the equipment, so that all of you will take the necessary and required safety precautions.
FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
It is also your responsibility to operate and maintain your cable hoist with caution, skill,
and good judgment. Following the recognized safety procedures will help you avoid
accidents. Modification to any part of his cable hoist can create a safety hazard and
therefore shall not be made without the manufacturer’s written approval. Use only factory approved accessories, options, and parts on this equipment. The rebuilding or remounting of this equipment requires the mounting procedures and retesting to be in accordance with factory instructions. Safety covers and devices must remain installed and
maintained in proper working condition. Safety decals must be maintained, be completely legible, and be properly located. If safety covers, devices, or decals are missing,
they must be replaced with the proper designated Stellar part.
Be capable, careful, and concerned! Make safety your everyday business!
Attention!
According to Federal Law (49 cfr part 571),
each final-stage manufacturer shall complete the vehicle in such a manner that it
conforms to the standards in effect on the
date of 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 cable hoists
is considered one of the manufacturers of
the vehicle. As such a manufacturer, 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.
Please reference the Code of Federal
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.
Introduction
Introduction
Stellar Cable hoists are designed to provide
safe and dependable service for a variety
of operations. With proper use and
maintenance, these cable hoists 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 cable hoist.
Once you feel comfortable with the
material contained in this manual, strive to
exercise your knowledge as you safely
operate and maintain the cable hoist. 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
cable hoist and shall remain with the cable
hoist 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 manufactured cable hoists 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 cable hoist.
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
& Stellar Cable Hoist Owner’s Manual
Chapter 1 - Safety
Safety
Please Read the Following Carefully!
This portion of the manual contains information regarding all Stellar manufactured
Cable Hoists. 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 Cable Hoist prior to putting the unit into operation.
Please take note that Stellar Industries, Inc.
is not liable for accidents incurred by the
Cable Hoist 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.
Trainees or untrained persons shall be under
the direct supervision of qualified persons.
Always wear the prescribed personal safety
devices.
Always wear approved accident-prevention clothing such as: protective helmets,
anti-slip shoes with steel toes, protective
gloves, anti-noise headphones, protective
glasses, breathing apparatus, and reflective
jackets. Consult your employer regarding
current safety regulations and accidentprevention 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 Cable
Hoist.
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 Cable
Hoist operating area.
Do not operate equipment under the
adverse influence of alcohol, drugs, or
medication.
Read all safety decals on the equipment
and understand their meaning.
Personal Safety
Keep clear of all moving parts.
Never allow anyone under any portion of
the hoist unless the hoist is firmly resting in
the hoist props.
Never allow anyone to ride the Cable Hoist
or load.
Operation Safety
Never operate the hoist unless the hydraulic
system, including the cylinders and lines, are
full of oil and free of air.
Check the area for power lines and overhead obstructions.
Do not load, dump or unload a container
on uneven ground.
Stellar Cable Hoist Owner’s Manual
Do not move the truck while the hoist and
container are raised. A raised load creates
a top heavy unstable load.
Do not use a chain between the reeving
cable and the container. A chain will not
withstand the force applied to the cable.
Do not use any method to hold a valve
open which will not let the valve close automatically when released.
Always keep the cable centered on the
hoist frame. Do not allow the cable to rub
on any surface when loading or unloading
a container.
Do not operate the reeving cylinders to
load or unload a container unless the front
of the hoist frame is above the top of the
truck cab.
Maintenance Safety
Never modify or alter any of the equipment,
whether mechanical, electrical, or
hydraulic, without Stellar Industries’
approval.
Be sure safety decals are clean and in
place.
Check the reeving cable for wear and fraying.
Do not perform any maintenance or repair
work on the Cable Hoist 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.
ATTENTION
Stellar Industries, Inc. is not liable for acci-
dents incurred by the Cable Hoist because
of the operator’s non-fulfillment of current
rules, laws and regulations.
Chapter 2 - Operation
Operation
Job-Site Set-Up
Thoroughly plan the lift before positioning
the vehicle. Consider the following:
1. The vehicle should be positioned in an
area free from overhead obstructions to
eliminate the need for repositioning.
2. Position the vehicle so that it is impossible
for any portion of the equipment to
come within the minimum required safe
distance of any power line. Maintain a
clearance of at least 10 feet between
any part of the Cable Hoist, 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 setup near power lines.
3. The vehicle should also be positioned on
a firm and level surface that will provide
adequate support for the body.
4. The parking brake must be removed to
allow the truck to roll under the body
while loading.
Cable Hoist Controls
1. Be familiar with the sequence and operation of the Cable Hoist controls.
2. Each individual Cable Hoist 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 Cable Hoist.
5. Be prepared before beginning operation
of the Cable Hoist:
• All protective guards must be in place.
• Be aware of the surroundings: low
branches, power lines, unstable ground.
• Be sure all safety devices provided are
in place and in good operating condition.
• Be prepared for all situations. Keep fire
extinguisher and first aid kit near.
• Be sure all regular maintenance has
been performed.
• Visually inspect all aspects of the Cable
Hoist for physical damage.
• Check for fluid leaks.
Operator Requirements
Operation is limited to the following people:
1. Qualified individual.
2. Trainees under direct supervision of the
qualified individual.
3. Test or maintenance individual.
4. Cable Hoist Inspector.
Operators must:
1. Demonstrate the ability to understand all
decals, the owner’s manual, and any
other information required for safe operation of the Cable Hoist.
2. Be able to demonstrate the ability to
safely control the Cable Hoist.
3. Know all safety regulations.
4. Be responsible for maintenance require-
ments.
5. Understand and be fully capable of
implementing all emergency procedures.
6. Understand the operating procedures as
outlined by this manual, ANSI B30.5 and
Federal/State Laws.
Operator Conduct
1. Operators will not engage in any operation that would cause them to divert
attention away from the operation of the
Cable Hoist.
2. Operators are responsible for all operations 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
proper care.
Stellar Cable Hoist Owner’s Manual
General Guidlines for Operation of the Cable Hoist
Loading a Container
1. Back the truck up to the container to be
loaded and align the hoist rails with the
container long sills. Caution: Be sure the
area in which the hoist is to be operated
is clear of personnel and obstacles overhead and on the ground.
2. Engage the PTO and raise the hoist until
the rear roller is on the ground.
3. Set the parking brakes and retract the
reeving cylinders to connect the cable
to the container. Caution: Do not
attempt to load a container with faulty
equipment. Check the condition of the
cable, cable end, and container cable
connection. Never lift a container heavier than the rated capacity of the hoist.
4. Relase the parking brake and allow the
truck to roll under the container. Extend
the reeving cylinders to pull the container
onto the hoist. The container long sills
must be kept on the hoist rollers.
5. Once the center of gravity of the container is in front of the rear hinge, the
hoist can be lowered until the front is just
above the top of the truck cab.
6. Continue pulling the container forward
until it is securely locked into the front
stops. Caution: Rear hold-down devices
are required on the hoist and the containers.
7. Lower the hoist to the full-down position
and disengage the PTO.
Dumping a Container
1. While the hoist is in the full-down position,
open the container door and secure it.
Caution: Be sure that the truck is on firm,
level ground before dumping. If one side
of the load breaks loose in this high center of gravity position, a truck on unstable
footing may roll over on its side.
2. Engage the PTO and raise the hoist until
the load slides out of the container.
Caution: Do not pull forward until the
hoist is lowered to the full-down position.
3. Lower the hoist to the full-down position
and disengage the PTO.
Unloading a Container (O.R. and I.O.)
1. Back the truck up in front of where the
container is to be spotted. Allow room
for the container to roll off of the hoist.
2. Raise the hoist and retract the reeving
cylinders. Allow gravity to pull the container to the ground.
3. Once the rear rollers are on the ground,
allow the truck to roll out from under the
container.
4. Once the container is on the ground,
lock the truck brakes and disconnect the
cable and secure it to the hoist.
5. Lower the hoist to the full down position.
Pull away from the container. Disengage
the PTO.
Unloading a Container (Extendable Tail)
1. Back the truck up in front of where the
container is to be spotted. Allow room
for the container to roll-off of the hoist.
2. Raise the hoist and retract the reeving
cylinders. Allow gravity to pull the container to the ground. Once the rear
rollers are on the ground, allow the truck
to roll out from under the container.
3. Alternate extending the cable and the
tail until the container is on the ground.
4. Lock the truck brakes and disconnect
the cable and secure it to the hoist.
5. Lower the hoist and retract the tail section. Disengage the PTO before driving
away.
Cable Hoist Check List
1. Check hydraulic oil level with all
cylinders retracted.
2. Grease all lubrication points.
3. All rollers and sheaves are free to
rotate.
4. Tires are properly inflated.
5. The container lock is free to move and
works properly.
Back the truck up to the container
to be loaded and align the hoist rails
with the container long sills.
1
Engage the PTO and raise the hoist
until the rear roller is on the ground.
Set the parking brakes and retract
the reeving cylinders to connect the
cable to the container.
Release the parking brake and allow
the truck to roll under the container.
Extend the reeving cylinders to pull
the container onto the hoist. The
container long sills must be kept on
the hoist rollers.
Once the center of gravity of the
container is in front of the rear hinge,
the hoist can be lowered until the
front is just above the top of the
truck cab.
Continue pulling the container
forward until it is securely locked into
the front stops. Caution: Rear
hold-down devices are required
on the hoist and the containers.
Lower the hoist to the full-down
position and disengage the PTO.
2
3
4
5
6
7
Operation
Loading Operation
Stellar Cable Hoist Owner’s Manual
Back the truck up in front of where the
container is to be spotted. Allow room
for the container to roll-off of the hoist.
1
Raise the hoist and retract the
reeving cylinders. Allow gravity to
pull the container to the ground.
Once the rear rollers are on the
ground, allow the truck to roll out
from under the container.
Once the container is on the ground,
lock the truck brakes and disconnect
the cable and secure it to the hoist.
Lower the hoist to the full down position.
Pull away from the container.
Disengage the PTO.
2
3
4
5
Unloading Operation - O.R. and I.O. Models
Operation
Back the truck up in front of where the
container is to be spotted. Allow room
for the container to roll-off of the hoist.
1
Raise the hoist and retract the
reeving cylinders. Allow gravity to
pull the container to the ground.
Once the rear rollers are on the
ground, allow the truck to roll out
from under the container.
Alternate extending the cable and
the tail until the container is on the
ground.
Lock the truck brakes and disconnect
the cable and secure it to the hoist.
Lower the hoist and retract the tail
section. Disengage the PTO before
driving away.
2
3
4
5
Unloading Operation - Extendable Tail Models
Stellar Cable Hoist Owner’s Manual
Correct Container Position
Correct Position
For Short Container
Note: Removable front stops must
be used and rear hold downs must
match on container and roll-off
hoist.
The Container is Too Long
Load Center is Too Far to the Rear
Front Axle May Be Too Light
Front Axle May Be
Overloaded
Frame may crack or bend.
Frame may crack or bend.
Frame may crack or bend.
Frame may crack or bend.
Frame may crack or bend.
Correct Roll-Off Container Loads
Unsafe Roll-Off Container Loads
Hoist Prop Operation
WARNING
BEFORE WORKING AROUND A
RAISED HOIST, THE HOIST
MUST BE SUPPORTED BY THE
HOIST PROP.
(SEE HOIST PROP OPERATIN G
INSTRUCTIONS)
FAILURE TO DO SO COULD RESULT IN
SERIOUS INJURY OR DEATH.
IF THE HOIST PROPS CANNOT BE
USED, CONSULT THE MAINTENANCE
SECTION OF THE OPERATION MANUAL
FOR THE PROPER PRECAUTIONS.
45553
Operation
Stellar Cable Hoist Owner’s Manual
Chapter 3 - Maintenance
Maintenance
Please read the following before performing any
maintenance on the Cable Hoist.
1. Only authorized service personnel are to perform
maintenance on the Cable Hoist.
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.
5. Keep the Cable Hoist clean and free from
grease build-up, oil and dirt to prevent slippery
conditions.
6. Perform all safety and maintenance checks
before each period of use.
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 Cable Hoist 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 Cable
Hoist is in use. For the duration of the usage,
inspect the Cable Hoist 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.
3. Hydraulic systems for proper operating pressure.
4. Main frame mount bolts.
5. Cylinders for:
A. Damaged rods.
B. Dented barrels.
C. Drift from oil leaking internally.
D. Leaks at rod seals or holding valves.
6. PTO and hydraulic pump(s) for leaks.
7. Hydraulic hose and tubing for evidence of damage such as blistering, crushing, or abrasion.
8. Presence of this owner’s manual.
Daily Inspection
Daily Inspection should occur each day before the
Cable Hoist is put into use. Each day, inspect the
Cable Hoist for all of the following:
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
operating decals and safety signs.
11. Inspect the wire rope for fraying or other wear.
Monthly Inspection
Monthly Inspection should occur at the beginning
of every work month. Each month, inspect the
Cable Hoist for all of the following:
1. Frame bolt tightness - turn barrel nuts and mount-
ing bolts during the first month of operation on
new machines and then quarterly thereafter.
2. Cylinders and valves for leaks.
3. Lubrication.
4. Structural weldments for bends, cracks, or breaks.
5. All pins and keepers for proper installation.
6. All control, safety, and capacity placards for
readability and secure attachment.
7. Inspect all electrical wires and connections for
worn, cut, or deteriorated insulation and bare
wire. Replace or repair wires as required.
8. Lubrication of all points requiring lubrication.
General Service
The following general suggestions should be helpful
in analyzing and servicing your Cable Hoist. 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 compo-
nents against the cost of parts and labor necessary to replace them.
6. Make the necessary repair.
7. Recheck to ensure that nothing has been over-
looked.
8. Functionally test the new part in its system.
Stellar Cable Hoist Owner’s Manual
Cross-sections illustrating three sheeve-groove conditions.
A is correct, B is too tight, and C is too loose.
Cross-sections illustrating three sheeve-groove conditions.
A is correct, B is too tight, and C is too loose.
Inspection of Sheaves
Under normal conditions, machines should
receive periodic inspections, and their overall condition recorded. Such inspections
usually include the sheaves, and any other
parts that may come into contact with the
wire rope and subject it to wear. As an
additional precaution, rope related working
parts, particularly in the area described
below, should be re-inspected prior to the
installation of a new cable.
The very first item to be checked when
examining the sheaves is the condition of
the grooves. To check the size, contour and
amount of wear, a groove gage is used. As
shown in the illustration to the right of this
paragraph, the gage should contact the
groove for about 150º of arc.
Two types of groove gages are in general
use and it is important to not e which of these
is being used. The two differ by their respective percentage over nominal.
For new or re-machine grooves, the groove
gage is nominal plus the full oversize percentage. The gage carried by most wire
rope representatives today is used for worn
grooves and is made nominal plus 1/2 the
oversize percentage.
The latter gage is intended to act as a sort
of “no-go” gage. Any sheave with a groove
smaller than this must be replaced or, in all
likelihood, the existing rope will be damaged.
Experience has clearly demonstrated that
the service life of the wire rope will be materially increased by strict adherence to these
standards.
Cable Replacement
5.0020.0020.00 20.00
B
C
DA
CABLE CLAMP DETAIL
CLAMP INSTRUCTIONS
INSTALL CLAMP "A" TORQUE NUTS TO 225 FT-LBS.
1.
INSTALL CLAMP "B" SNUG NUTS ON CABLE.
2.
INSTALL CLAMPS "C" & "D" AS SHOWN SNUG NUTS.
3.
APPLY TENSION TO CABLE.
4.
TORQUE NUTS ON "B", "C" & "D" TO 225 FT-LBS.
5.
CLAMP NUTS MUST FACE DOWN.6.
Important: Standard replacement cable must be 7/8” diameter 6 x 37 extra improved plow steel
with steel core (6 x 37 EXIWRC) with a 4.00” swaged button x 75’ (174” & 182” CT, or) 77 feet (194”
CT) in length.
1. Remove the cable clamps and discard the old cable.
2. Inspect all the sheaves (See Inspection of Sheaves on page 12).
3. Install cable end onto cable. Thread cable through sheaves and guides, etc. Loop cable
through cable anchor and install clamps following the diagram below. Torque all bolts evenly
to 225 ft. lbs.
Maintenance
Cleanliness
An important item in preserving the long life of the cable hoist is keeping
dirt, grime, and corrosive material out of the working parts. Thoroughly
wash and grease the cable hoist periodically.
Stellar Cable Hoist 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
Chassis C.T.: See chart on next page.
Frame Width: 35-1/2”
Minimum GVWR: 18,000 lbs. Front, 44,000 lbs. Rear
Frame Height: 43”
Sub-Frame: Full length 2 x 4 Tube
Load Rating: 60,000 lbs., 75,000 lbs.
Dump Angle: 47º
Operating Pressure: 1,850 PSI (60,000 lbs), 2,150 PSI (75,000 lbs)
Gear Pump: 35 GPM @ 1,500 RPM
Operation: Inside Cab Cable Controls Standard
Weight: 6,400 lbs. - 7,400 lbs.
Cylinders: Twin Double Acting
6 x 72 Lift Model SI-60/75
7 x 80 Reeving Model SI-60/75
7 x 90 Reeving Model SI-60/75
Low Pressure Hydraulic System
Gear Driven Hydraulic Pump
Large 3” Rear Pivot Pin
Hold-down compatible with ANSI Z245.6 Type “U” Containers
Chapter 4 - Specifications
Specifications
Stellar Cable Hoist Owner’s Manual
*Autotarper installation requires 12” of unobstructed space behind the truck cab.
Specifications Chart
Models A B C D
CT (Cab to Trunnion)
w/o Autotarper w/ Autotarper
SI-60-174 OR/IO 281” 210” 174” 35.5” 174” 180”
SI-60-182 OR/IO 289” 218” 174” 35.5” 182” 188”
SI-60-194 OR/IO 301” 230” 186” 35.5” 194” 200”
Extended Tail Models A B C D
CT (Cab to Trunnion)
w/o Autotarper w/ Autotarper
SI-60-174 ORX 237” 210” 174” 35.5” 174” 180”
SI-60-182 ORX 245” 218” 174” 35.5” 182” 188”
SI-60-194 ORX 257” 230” 186” 35.5” 194” 200”
SI-60-174 IOX 278.5” 210” 174” 35.5” 174” 180”
SI-60-182 IOX 286.5” 218” 174” 35.5” 182” 188”
SI-60-194 IOX 298.5” 230” 186” 35.5” 194” 200”
*
Cable Hoist Dimensions
Container Subframe
PICKUP HOOK
SIDE VIEW
LEAD-IN-ROLLER
GROUND WHEEL
MIN. 6.00
MAX. 10.50
18.50MIN.
*SEE NOTE*
MAX. 24.00
MAX. 2.13
MAX. 3.63
MIN. 3.38
193.00
*LONG RAIL LENGTH*
TYPICAL REAR
GROUND WHEEL
GUIDE ROLLER
HOLDDOWN
2" X 6" STANDARD
STRUCTURAL TUBING
MAX. 3.63
MIN. 3.38
MAX. 41.00
FRONT OF LEAD-IN-ROLLER TO THE FRONT OF THE HOLDDOWN.
IF LONG RAIL LENGTH IS GREATER THAN OR EQUAL TO 18FT. AND LESS THAN
24FT, REAR HOLDDOWN DIMENSION IS 193.00 IN. PLUS 1 IN. MINUS 0 IN. FROM
FRONT VIEW
*NOTE*
IF LONG RAIL LENGTH IS GREATER THAN OR EQUAL TO 12FT. AND LESS THAN
18FT, REAR HOLDDOWN DIMENSION IS 147.50 IN. PLUS 1 IN. MINUS 0 IN. FROM
FRONT OF LEAD-IN-ROLLER TO THE FRONT OF THE HOLDDOWN.
NOTE:
ALL DIMENSIONS ARE IN ACCORDANCE WITH
ANSI Z245.60 TYPE "U" CONTAINER REQUIREMENTS
Specifications
Stellar Cable Hoist Owner’s Manual
16
12
7
18
14
16
10
1117
1913
16
24
3
Item PN Description Qty.
1 45702 TAPE CONSPICUITY YELLOW 9.00 IN
a
2
2 45701 TAPE CONSPICUITY RED 9.00 IN
b
2
3 16094 DECAL STELLAR LOGO5.00X13.00REFLECT 2
4 46657 DECAL TAIL 2
5 45981 DECAL WINCH 2
6 46071 DECAL HOIST 2
7 45553 DECAL WARNING RAISED HOIST 2
8 45807 VALVE PLATE
d
c
c
c
c
f
f
e
e
e
e
1
9 45691 DECAL HOIST INSTRUCTIONS 1
10 45692 DECAL WARNING CONTAINER 2
11 45693 DECAL CAUTION OPERATION 1
12 45694 DECAL PROP INSTRUCTIONS 2
13 45695 DECAL WARNING UNEVEN GROUND 2
14 45696 DECAL DANGER POWER LINES HOIST 2
15 45697 DECAL CAUTION PTO SPEED 1
16 25627 DECAL CRUSH POINT 6
17 45698 DECAL WARNING CABLE 2
18 45557 DECAL DANGER STAND CLEAR 2
19 C5942 PLATE SERIAL # STELLAR TRUCKS 1
20 45699 DECAL ICC BUMPER REQUIREMENT 1
21 45906 DECAL HOIST UP 1
22 49546 TAPE CONSPICUITY RED/WHITE 38.00FT 1
23 49547 TAPE CONSPICUITY WHITE 4.00FT 1
24 35234 DECAL STELLAR MADE IN THE USA 1
a
ON FRONT OF REAR FENDER (NOT SHOWN)
b
ON BACK OF REAR FENDER (NOT SHOWN)
c
IN CAB (NOT SHOWN)
d
ON TOP OF HYD. RSRVR (NOT SHOWN)
e
QTY 1 IN CAB (NOT SHOWN)
f
SEE PAGE 38 FOR PLACEMENT (NOT SHOWN)
Chapter 5 - Decals
Decal Kit Placement
Decals
Note: See page 41 for Reflective Tape Placement.
Stellar Cable Hoist Owner’s Manual
WARNING
CRUSHING HAZARD
Moving parts can
crush and cut.
Keep hands and
arms clear.
25627
DANGER
STAN D CLEAR
WHEN THIS UNIT IS IN OPERATION!
FAILURE TO DO SO COULD RESULT IN
SERIOUS PERSONAL INJURY.
45557
CAUTION
DO NOT ATT EMPT TO OPERATE
THIS EQUIPMENT WITHOUT PROPER TRAINING.
PERSONAL INJU RY AND EQU IPMENT DAMAGE
CAN OCCUR IF THIS EQUIPMENT IS USED IMPROPERLY.
REA D AN D UNDERSTAND THE OPERAT ION MANUAL.
45693
DANGER
BE AWARE OF POWER
LINES AND OVERHEAD
OBSTRUCTIONS.
CONTACT BY THE HOIST OR
CONTAINER COULD CAUSE
SERIOUS INJURY OR DEATH
TO THE OPERATOR AND
BYSTAN DERS.
45696
WARNING
45698
RAISE HOIST ABOVE THE TOP
OF THE TRUCK CAB BEFORE
LOADING OR UNLOADING A
CONTAI NER, UNLESS A CAB
GUARD IS INSTALLED.
CABLE FAILURE COULD RESULT
IN SERIOUS PERSONAL INJURY
AND EQUIPMENT DAMAGE.
WARNING
BEFORE WORKING AROUND A
RAISED HOIST, THE HOIST
MUST BE SUPPORTED BY THE
HOIST PROP.
(SEE HOIST PROP OPERATI NG
INSTRUCTIONS)
FAILURE TO DO SO COULD RESULT IN
SERIOUS INJURY OR DEATH.
IF THE HOIST PROPS CANNOT BE
USED, CONSULT THE MAINTENANCE
SECTION OF THE OPERATION MANUAL
FOR THE PROPER PRECAUTIONS.
45553
DO NOT ATTEMPT TO LOAD A CONTAINER
UNLESS THE HOIST AND CONTAINER ARE
CORRECTLY ALIGNED.
KEEP THE CONTAINER RAILS SAFELY
ENGAGED WITH THE HOIST RAILS AND
ROLLERS.
FAILURE TO DO SO COULD CAUSE THE
CONTAINER TO SLIDE OFF THE SIDE OF
THE HOIST OR JAM ON THE RAILS.
WARNING
45692
WARNING
DO NOT LOAD, UNLOAD OR
DUMP CONTAINER ON
UNEVEN GROUND.
A LOADED CONTAINER CREATES A TOP
HEAVY LOAD. USE CAUTION WHEN
DRIVING ON UNEVEN GROUND AND
TURNING CORNERS.
SERIOUS PERSONAL INJURY AND
EQUIPMENT DAMAGE COULD RESULT.
45695
CAUTION
45697
DO NOT EXCEED 1600 ENGINE
RPM WHEN OPERATING
POWER TAKE OFF!
Escaping fluid under pressure can penetrate the skin causing serious injury
or death. Relieve pressure before disconnecting hydraulic lines, tighten all
connections before applying pressure, and inspect all lines before
each use. See "Safety" section in operation manual for additional
information.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
few hours or gangrene may result.
45726
74-276
WARNING
Safety Decals of Note
Chapter 6 - Installation
General Install Guidelines
Installation
Cable Hoist Mounting and Assembly
Study names and locations of the parts and
familiarize yourself with the Cable Hoist
before starting the assembly . Reading the
step-by-step instructions that follow will be
helpful.
Safety
Read all of the safety notations in the
assembly instructions for your protection.
Accidents can be prevented by recognizing the cause of an accident before it can
happen.
Assembly
Select an area for assembly that will be
large enough to accommodate the completed unit. The surface of the work area
should be as level as possible. Use the
proper hand tools to ensure proper bolt
tightness. Refer to the chart below for the
recommended torque values for different
sizes of bolts.
Recommended Torque Values in Foot
Pounds
For SAE GRADE 2 and GRADE 5 coarse
thread cap screws and bolts shown are
suggested maximum for fasteners, carrying
only the residue oil of the manufacturer.
Proper Bolt Use
Do not use these values if a different torque
value or tightening procedure is given for a
specific application. Torque values listed
are for general use only. Check tightness of
fasteners periodically.
Sheer bolts are designed to fail under predetermined loads. Always replace shear
bolts with identical grade.
Fasteners should be replaced with the
same or higher grade. If higher grade fas-
teners are used, these should only be tightened to the strength of the original.
Tighten plastic insert or crimped steel-type
lock nuts to approximately 110 percent of
the dry torque values shown in the chart
below, applied to the nut, not to the bolt
head. Tighten toothed or serrated-type
lock nuts to the full torque value.
Note: “Lubricated” means coated with a
lubricant such as engine oil, or fasteners
with phosphate and oil coatings. “Dry”
means plain or zinc plated without lubrication. Tighten lubricated bolts to approximately 80% of dry bolts.
Grade 8 Grade 9
Plated
Plain
25
44
70
105
155
220
375
605
910
(Ft-Lb)
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
(Ft-Lb)
1290
1815
2380
3160
Plated
(Ft-Lb)
22
39
63
96
139
192
340
549
823
1167
1646
2158
2865
Size
(DIA-TPI)
5/16-18
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
1 1/8-7
1 1/4-7
1 3/8-6
1 1/2-6
Bolt DIA
(Inches)
0.3125
0.3750
0.4375
0.5000
0.5625
0.6250
0.7500
0.8750
1.000
1.1250
1.2500
1.3750
1.500
Grade 5
Plain
(Ft-Lb)
17
31
49
75
110
150
265
395
590
795
1120
1470
1950
Plated
(Ft-Lb)
13
23
37
57
82
115
200
295
445
595
840
1100
1460
Model Number
Know the model number of the Stellar
Cable Hoist being mounted. Use this model
number whenever referring to the assembly
or parts listing pages. The number is
stamped on the name plate which is located on the front frame member.
Right and Left sides can be established by
standing behind the truck frame and looking towards the front, or the direction of
travel.
Stellar Cable Hoist Owner’s Manual
Minimum Axle Rating:
Front: 18,000 lbs.
Rear: 44,000 lbs. with walking beam type suspension
Frame Strength:
Total RBM per frame rail = 2,400,000 in-lbs. (both channels)
Section Modulus (minimum) = 32 in
3
for 36,000 PSI steel
Section Modulus (minimum) = 24 in
3
for 55,000 PSI steel
Important: If your truck chassis height exceeds the 45” dimension, or tire dimension is
greater than 102”, the O.R.X. or I.O.X. hoist should be considered.
Relocate the rear axles as required.
Stellar Autotarper must have 10”
to 12” unobstructed space behind
cab for installation.
Model
Cab to Trunnion
w/o Tarper With Tarper
SI60-174 174 Inches 180 Inches
SI60-182 182 Inches 188 Inches
SI60-194 194 Inches 200 Inches
6-9/16
FRAME RAIL
11-3/4
Cab Boundary
Refer to dimensional drawings on the following pages
for placement of step cut in relation to cab boundary.
Truck Chassis Specifications
See the illustrations on pages 15-17 at the front of this manual for specific details.
1. Thoroughly check the truck requirements to ensure proper clearance and frame
strength before mounting the hoist. Note: The rear cab boundary is the rearmost
unremovable protrusion behind the cab and above the chassis frame.
2. The CT, from the rear of the cab boundary to the center of the walking beam suspension, is shown in the table below:
Step 1: Truck Frame Cut-Off
Measure and mark the truck frame as shown below. Use the dimensional drawings on
the following pages to determine where to mark the first vertical cut on the frame rail.
Measure assembled hoist to be sure that adequate room is available behind truck cab;
between bumper and tires; and between fender and tires. This verifies that a measurement error has not been made either in the CT (Cab to Trunnion) or cut-off dimension.
After double checking your measurements, step-cut the truck frame as shown below.
8 - 9/16
55
14
Rearmost Axle
To First Cut
43
Chassis Frame Height
174
C.T.
11
2 - 1/4
9 - 9/16
- 3/421
- 15/16
87
24
26 - 5/8
- 1/2
- 7/1686
9
206
25 - 13/16
281 - 1/4
Dimensions To Chassis Frame Rail
Forward Mount
Reverse Mount
Telescopic Mount
11 - 9/1692
- 1/4
8 - 9/16
55
14
Rearmost Axle
To First Cut
Chassis Frame Height
43
174
C.T.
Dimensions To Chassis Frame Rail
281 - 1/4
176
206 - 15/16
21 - 3/4
- 7/8107
68 - 7/8
9
26 - 5/8
- 3/4
25 - 13/16
112 - 9/169 - 9/16
8 - 9/16
C.T.
55
14
Rearmost Axle
to First Cut
174
43
Chassis Frame Height
Dimensions to Chassis Frame Rail
2 - 3/4
9
- 15/16139
- 3/421 - 13/1625
- 1/455
206 - 15/16
281 - 1/4
Dimensions: 174 Models
Installation
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