stellar labs AutoTarper User manual

AutoTarper
Hydraulic Tarping System
Owner’s Manual
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Subject to Change without Notication.
© 2016 Stellar Industries, Inc. Last Revision: 1/21/16
Parts • Installation • Operation • Maintenance
Notice: A copy of this manual must remain with the equipment at all times.
For a printable download copy, please visit: www.stellarindustries.com

Page ii | Stellar®AutoTarper Owner’s Manual
AutoTarper Manual Revisions
Date of Revsion Section Revised Description of Revision
MODEL NO.SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENT INFORMATION
http://www.stellarindustries.com/ip
Serial Tag
Location
MODEL NO. SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENT INFORMATION
http://www.stellarindustries.com/ip

Stellar®AutoTarper Owner’s Manual | Page iii
Table of Contents
Introduction ............................................................iv
Chapter 1 - Assembly Drawings .................................1
Mounting Assembly - PN 79444 .............................1
Slide Arm Assembly Drawing - PN 79445 ..............2
Slide Arm Assembly Bill - PN 79445 ........................3
Gantry Assembly - PN 79446 ..................................4
Chapter 2 - Installation Procedure .............................5
General Installation ................................................5
Installer Notice .....................................................5
Torque Data Chart ..............................................6
Step 1: Assemble upper gantry. ............................7
Step 2: Install gantry cylinder. ................................8
Step 3: Install upper gantry. ...................................9
Step 4: Set gantry base onto truck frame. .........10
Step 5: Bolt gantry to mounting brackets. .........11
Step 6: Drill holes into the frame rail....................11
Step 7: Bolt gantry to the truck frame. ...............12
Step 8: Install bumper. ..........................................12
Step 9: Install rear mounting tubes. ....................13
Note: Installation on non-Stellar products ......14
Step 10: Slide fender onto rear tube. .................15
Step 11: Bolt slide weldment to rear tube. .........15
Step 12: Bolt slide weldments to bumper. ..........16
Step 13: Slide the bracket into position. .............17
Step 14: Assemble side mount tube. ..................17
Step 15: Weld side mount tube. ..........................18
Step 16: Drill holes into frame rail. .......................19
Step 17: Bolt frame rail bracket to frame rail. ....19
Step 18: Install slide cylinder mount. ...................20
Step 19: Install slide. ..............................................21
Step 20: Install slide cylinder. ...............................21
Step 21: Install arm lift cylinder. ...........................22
Step 22: Install lower arm weldment. .................22
Step 23: Install roller assembly. ............................23
Step 24: Install torsion bar.....................................23
Step 25: Install ratchet stop assembly. ...............24
Step 26: Attach upper arm weldments. ............25
Step 27: Install tarper arm deectors. .................25
Step 28: Install hydraulic kit. .................................26
Step 29: Install ttings. ...........................................27
Step 30: Prep valve bank. ....................................29
Hydraulic Safety ................................................30
Step 31: Route hydraulics. ...................................31
Hose Kit ...............................................................33
Hose Kit ...............................................................36
Hose Kit ...............................................................39
Step 32: Bleed air from hydraulics. .....................40
Step 33: Move arms to the rearmost position. ..40
Step 34: Attach tarp to gantry. ...........................41
Step 35: Attach tarp to roller. ..............................42
Step 36: Pre-load the tarp roller spring. ..............43
Step 37: Set hydraulic relief pressure. .................43
Step 38: Install Decal Package - PN 47490 ........44
Step 39: Install Reective Tape ............................45
Step 40: Install Serial Plate ....................................45
Chapter 3 - Operation ...............................................46
General Operation ...............................................46
Operator Requirements .......................................46
Pre-Operation Inspection ....................................47
Job Site Setup .......................................................47
Operation Checklist .............................................47
Cylinder Rephase Procedure ..............................48
Tarping Step 1: Rephase cylinders. .....................49
Tarping Step 2: Arms up. Slide forward...............49
Tarping Step 3: Raise the gantry. ........................50
Tarping Step 4: Rotate arms and slide back. ....51
Tarping Step 5: Lower tarp. ..................................51
Untarping Step 1: Raise gantry. Raise arms. ......52
Untarping Step 2: Move tarp to front. ................52
Untarping Step 3: Lower gantry. .........................53
Untarping Step 4: Set tarp roll on gantry. ...........53
Chapter 4 - Maintenance..........................................54
Basic AutoTarper Inspection Schedule ..............54
General Maintenance Guidelines ......................55
Hydraulic Oil/Filter Maintenance ........................55
PTO and Pump Maintenance .............................55
Choice Lubricants for DX Bearings .....................56
Face Seal/O-Ring Size Chart ...............................57

Page iv | Stellar®AutoTarper Owner’s Manual
Introduction
The Stellar®AutoTarper is designed to provide safe and dependable service for a variety
of operations. With proper use and maintenance, the AutoTarper 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
AutoTarper.
Once you feel comfortable with the material contained in this manual, strive to exercise
your knowledge as you safely operate and maintain the AutoTarper. 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 AutoTarper and can be found in the hard
plastic manual case that is installed on the chassis. A copy of this manual shall remain with
the AutoTarper at all times.
Throughout the manual, three signal words will be used to bring attention to important
items:
A NOTICE signal word indicates a practice not related to physical injury.
A WARNING signal word indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
A DANGER signal word indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
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 AutoTarpers in general
and may or may not apply to your specic model.
This manual is not binding. Stellar Industries, Inc. reserves the right to change, at any
time, any or all of the items, components, and parts deemed necessary for product
improvement or commercial/production purposes. This right is kept with no requirement or
obligation for immediate mandatory updating of this manual.
In closing:
If more information is required or technical assistance is needed, or if you feel that any
part of this manual is unclear or incorrect, please contact the Stellar Customer Service
Department by phone at 800-321-3741 or email at [email protected].
WARNING
NOTICE
DANGER

Stellar®AutoTarper Owner’s Manual | Page 1
Chapter 1 - Assembly Drawings
15
14
3
14
13
8
2
5
16
17
17
18
19
21
21
19 19 20
19
22
10
11
7
11
12
4
1
6
9
ITEM PART DESCRIPTION QTY.
179415 SLIDE WLDMT SIAT SS I BEAM 1
279800
TUBE 3.00X3.00X0.25WX35.59 W/HOLES 2
346906
BRKT GANTRY MNT KPAC 2
479801
WLDMT TUBE 2.50X2.50X0.25WX35.00 2
579855
GUSSET 0.25X3.38X10.00 W/HOLE 2
679414
SLIDE WLDMT SIAT CS I BEAM 1
747208
PLATE 1.00X2.50X2.50 SPACER KP60 2
847209
BRKT FENDER KP60 2
980141
CHANNEL FORMED 0.25X2.00X3.63X11.00 W/HOLES 2
10
C0966 CAP SCR 0.63-11X5.00 HHGR5 2
11
C1038 WASHER 0.63 USS FLAT 4
12 2826
NUT 0.63-11 HHGR5 NYLOC 2
13
C1026 CAP SCR 0.63-11X2.50 HHGR8 10
14
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 20
15 24868
NUT 0.63-11 HHGR8 NYLOC 10
16
C0954 CAP SCR 0.38-16X4.50 HHGR5 4
17 0346
WASHER 0.38 USS FLAT 8
18 0347
NUT 0.38-16 HHGR5 NYLOC 4
19 0352
WASHER 0.50 USS FLAT 16
20 0501
CAP SCR 0.50-13X2.00 HHGR5 4
21
C6106 NUT 0.50-13 HHGR5 NYLOC 8
22 0507
CAP SCR 0.50-13X4.50 HHGR5 4
PN 79444
Mounting Assembly - PN 79444

Page 2 | Stellar®AutoTarper Owner’s Manual
A
14
18
29
19 6
33
34
8
15
27
12
35
17
17
16
16
19
18
23 18
19
22
22
22
22
22
2
5
13
26
10 26
3
1
7
4
36
25
9
11
28
24
20
20
35
DETAIL A
10
26
*
31
*
21
30
32
26
13
18
Slide Arm Assembly Drawing - PN 79445
Note: Lift and Slide Cylinders use Seal Kit PN 81299

Stellar®AutoTarper Owner’s Manual | Page 3
ITEM
PART
DESCRIPTION
QTY.
179436
TUBE 3.00X1.50X0.19WX60.44 TARPER BOLT ON CS VER
T
1
279427
WLDMT TORSION BAR TARPER
1
379435
ARM WLDMT UPPER SS TARPER BOLT ON VERT
1
479424
ARM WLDMT LOWER SS TARPER GEN
2
1
542395
ASM TARP ROLLER KPAC
1
6
46002PC
WLDMT CYL MNT LUG KPAC
2
779425
ARM WLDMT LOWER CS TARPER GEN2
1
879413
WLDMT SLIDE TARPER
2
979431
BRKT CYL MNT TARPER SLIDE
2
10
C0946
CAP SCR 0.38-16X2.25 HHGR
5
2
11
C1002
CAP SCR 0.50-13X6.00 HHGR
5
8
12 0420
CAP SCR 0.31-18X0.75 HHGR5
6
13 0529
CAP SCR 0.38-16X2.50 HHGR
5
9
14 56515
PIN 1.00X4.94 SHOULDER SR
2
15
13400CR
PIN TEAR DROP 1.00X4.3
8
6
16 79409
WEAR PAD TARPER SLIDE TO
P
4
17 79408
WEAR PAD TARPER SLIDE BTTM
8
18 0867
MACHY WASHER 1.00ID 14GA
7
19 0110
SNAP RING 1.00 ID 7200-10
0
6
20
C5902
WASHER 0.63 SAE FLAT YELLOW GR8
10
21 79727
BOLT SHOULDER 0.63X0.75 0.50-13X0.75
1
22 47090
SCREW SELF TAP 0.25X0.75 HWHH
5
23
79728ZP
PIN 1.00X2.75 SR
2
24
C6106
NUT 0.50-13 HHGR5 NYLOC
8
25 72435
CAP SCR 0.63-11X5.00 HHGR8 RED PATCH
4
26 0347
NUT 0.38-16 HHGR5 NYLOC
11
27 0343
WASHER 0.31 USS FLAT
6
28 0352
WASHER 0.50 USS FLAT
8
29 0424
MACHY WASHER 1.00ID 10GA
2
30 79722
PLATE GEAR RATCHET STOP SIAT NYLATRON
1
31 79723
LEVER GEAR RATCHET STOP SIAT NYLATRON
1
32 79724
COLLAR GEAR RATCHET STOP SIAT NYLATRO
N
1
33 79407
CYLINDER 2.00X42.00
2
34 79406
CYLINDER 2.00X30.00
2
35 c1592
ZERK 1/8 NPT STRAIGHT
4
36 24868
NUT 0.63-11 HHGR8 NYLOC
4
PN 79445
Slide Arm Assembly Bill - PN 79445

Page 4 | Stellar®AutoTarper Owner’s Manual
17 16 3
15
4
20
19
19 18
8
9
7
10
8
9
6
13
14
13
12
5
13
11 12
1
2
2
ITEM PART DESCRIPTION QTY.
179438 WLDMT GANTRY GUIDE SIAT GEN2 1
256500
WLDMT GANTRY SLIDE TUBE SIAT 2
379441
WLDMT GANTRY RACK SIAT GEN2 1
446001
TUBE EX HEAVY TARP KPAC 1
546906
BRKT GANTRY MNT KPAC 2
646240
PIN 1.00X5.50 CLEVIS ZINC 1
747091
PIN 1.00X6.00 CLEVIS ZINC 1
80424
MACHY WASHER 1.00ID 10GA 3
947093
COTTER PIN .188X1.50 2
10 45305
CYLINDER 2.00X48.00 KPAT 1
11
C1026 CAP SCR 0.63-11X2.50 HHGR8 6
12 24868
NUT 0.63-11 HHGR8 NYLOC 10
13
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 20
14
C1025 CAP SCR 0.63-11X2.00 HHGR8 4
15
C0946 CAP SCR 0.38-16X2.25 HHGR5 2
16 0346
WASHER 0.38 USS FLAT 2
17 0347
NUT 0.38-16 HHGR5 NYLOC 2
18 0500
CAP SCR 0.50-13X1.75 HHGR5 4
19 0352
WASHER 0.50 USS FLAT 8
20
C6106 NUT 0.50-13 HHGR5 NYLOC 4
PN 79446
Gantry Assembly - PN 79446
Note: Gantry Cylinder
uses Seal Kit PN 59511

Stellar®AutoTarper Owner’s Manual | Page 5
Installer Notice
According to Federal Law (49 cfr part 571), each nal-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 nal completion, or a date between
those two dates. This requirement shall, however, be superseded by any conicting
provisions of a standard that applies by its terms to vehicles manufactured in two or more
stages.
Therefore, the installer of a Stellar®AutoTarper 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 Trafc and Motor Vehicle Safety Act.
Please reference the Code of Federal Regulations, title 49 - Transportation, Volume 5 (400-
999), for further information, or visit http://www.gpoaccess.gov/nara/index.html for the full
text of Code of Federal Regulations.
General Installation
Every AutoTarper installation is unique. However, certain guidelines exist that apply to
every install. Listed below is a general set of chronlological steps that may be followed
when installing a Stellar® AutoTarper. If any questions arise during the installation process,
feel free to contact your local dealer or Stellar Customer Service at 800-321-3741.
AutoTarper Mounting and Assembly
Study names and locations of the parts and familiarize yourself with the AutoTarper before
starting the assembly. The assembly drawings located at the end of this manual will be
helpful with this process.
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.
Chapter 2 - Installation Procedure

Page 6 | Stellar®AutoTarper Owner’s Manual
When using the torque data in the
chart, the following rules should be
observed:
• Bolt manufacturer’s particular
specications should be consulted
when provided.
• Flat washers of equal strength
must be used.
• All torque measurements are
given in foot-pounds. To convert
to inch-pounds, multiply by 12.
• Torque values specied are for
bolts with residual oils or no special
lubricants applied. If special
lubricants of high stress ability,
such as Never-Seez compound
graphite and oil, molybdenum
disulphite, colloidal copper or white lead are applied, multiply the torque values in the
charts by the factor .90. The use of Loctite does not affect the torque values listed above.
• Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
• Do not use these values if a different torque value or tightening procedure is given for
a specic application. Torque values listed are for general use only. Check tightness of
fasteners periodically.
• Shear 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 fasteners
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.
Size Bolt DIA Plain Plated Plain Plated Plated
(DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb)
5/16-18 0.3125 17 13 25 18 22
3/8-16 0.3750 31 23 44 33 39
7/16-14 0.4375 49 37 70 52 63
1/2-13 0.5000 75 57 105 80 96
9/16-12 0.5625 110 82 155 115 139
5/8-11 0.6250 150 115 220 160 192
3/4-10 0.7500 265 200 375 280 340
7/8-9 0.8750 395 295 605 455 549
1-8 1.000 590 445 910 680 823
1 1/8-7 1.1250 795 595 1290 965 1167
1 1/4-7 1.2500 1120 840 1815 1360 1646
1 3/8-6 1.3750 1470 1100 2380 1780 2158
1 1/2-6 1.500 1950 1460 3160 2370 2865
GRADE 5 GRADE 8 GRADE 9
Torque Data Chart

Stellar®AutoTarper Owner’s Manual | Page 7
Assemble the rest of the gantry as shown:
17 16
15
4
3
2
20
19
19
18
ID QTYPART DESCRIPTION
256500 WLDMT GANTRY SLIDE TUBE SIAT 2
379441
WLDMT GANTRY RACK SIAT GEN2 1
446001
TUBE EX HEAVY TARP KPAC 1
15
C0946 CAP SCR 0.38-16X2.25 HHGR5 2
16 0346
WASHER 0.38 USS FLAT 2
17 0347
NUT 0.38-16 HHGR5 NYLOC 2
18 0500
CAP SCR 0.50-13X1.75 HHGR5 4
19 0352
WASHER 0.50 USS FLAT 8
20
C6106 NUT 0.50-13 HHGR5 NYLOC 4
Step 1: Assemble upper gantry.

Page 8 | Stellar®AutoTarper Owner’s Manual
9810
6
ID QTYPART DESCRIPTION
6 46240 PIN 1.00X5.50 CLEVIS ZINC 1
8 0424
MACHY WASHER 1.00ID 10GA 2
9 47093
COTTER PIN .188X1.50 1
10 45305
CYLINDER 2.00X48.00 KPAT 1
Step 2: Install gantry cylinder.

Stellar®AutoTarper Owner’s Manual | Page 9
Slide the upper gantry into the lower gantry and attach the gantry cylinder as shown:
8
9
7
8
9
ID QTYPART DESCRIPTION
747091 PIN 1.00X6.00 CLEVIS ZINC 1
80424
MACHY WASHER 1.00ID 10GA 1
947093
COTTER PIN .188X1.50 1
Step 3: Install upper gantry.

Page 10 | Stellar®AutoTarper Owner’s Manual
Center the gantry base on the truck frame as shown:
Requires 12” clear truck frame
behind chassis cab.
Requires 20” clear truck frame
behind chassis cab when
installing a bulkhead reservoir.
NOTICE
Step 4: Set gantry base onto truck frame.

Stellar®AutoTarper Owner’s Manual | Page 11
Once centered, bolt the gantry mounting bracket to the gantry as shown:
14
13
13
12
5
ID QTYPART DESCRIPTION
546906 BRKT GANTRY MNT KPAC 2
12 24868
NUT 0.63-11 HHGR8 NYLOC 4
13
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 8
14
C1025 CAP SCR 0.63-11X2.00 HHGR8 4
Step 5: Bolt gantry to mounting brackets.
Drill three (3) 11/16” holes through the gantry mounting bracket and truck frame as shown:
11/16"
SUGGESTED BOLT PATTERNSUGGESTED BOLT PATTER
Step 6: Drill holes into the frame rail.

Page 12 | Stellar®AutoTarper Owner’s Manual
Secure the gantry base to the truck frame by using the hardware shown below:
13
11
13
13
11
12
13
ID QTYPART DESCRIPTION
11 C1026 CAP SCR 0.63-11X2.50 HHGR8 6
12 24868
NUT 0.63-11 HHGR8 NYLOC 6
13
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 12
Step 7: Bolt gantry to the truck frame.
Bolt the bumper to the cable hoist subframe apron as shown:
2
3
3
4
1
1NA BUMPER 1
211693
CAP SCR 0.63-11X1.75 6
3
C5902 WASHER 0.63 USS FLAT 12
4
24868 NUT 0.63-11 6
ID QTYPART DESCRIPTION
Step 8: Install bumper.

Stellar®AutoTarper Owner’s Manual | Page 13
Bolt the bumper to the cable hoist subframe apron as shown (both sides):
4 79801 WLDMT TUBE 2.50X2.50X0.25WX35.00 2
7 47208
PLATE 1.00X2.50X2.50 SPACER KP60 2
10
C0966 CAP SCR 0.63-11X5.00 HHGR5 2
11
C1038 WASHER 0.63 USS FLAT 4
12 2826
NUT 0.63-11 HHGR5 NYLOC 2
12
11
1
1
10
2
0
2
2
12
11 7
11
10
4
ID QTYPART DESCRIPTION
Step 9: Install rear mounting tubes.

Page 14 | Stellar®AutoTarper Owner’s Manual
When installing the rear mounting tubes on non-Stellar products, please note the following
dimensional guidelines:
24.00
11.00
center of rear axle to
front of rear mounting tube
center of left rear mounting tube bolt hole to
center of right rear mounting tube bolt hole
top of truck frame to
top of rear mounting tube
39.00
Note: Installation on non-Stellar products

Stellar®AutoTarper Owner’s Manual | Page 15
Bolt the slide weldment to the rear mounting tube as shown below (both sides):
19
22
21
19
19
22
ID QTYPART DESCRIPTION
19 0352 WASHER 0.50 USS FLAT
8
21
C6106 NUT 0.50-13 HHGR5 NYLOC 4
22 0507
CAP SCR 0.50-13X4.50 HHGR5 4
Step 11: Bolt slide weldment to rear tube.
Remove set screw from fender and slide onto rear mounting tube. Center the fender
over the wheels and temporarily support the front of the fender. Once centered over the
wheels, tighten the set screw (both sides):
Stellar® Tandem
Steel Fender Shown
(Not Included with AutoTarper)
Step 10: Slide fender onto rear tube.

Page 16 | Stellar®AutoTarper Owner’s Manual
Step 12: Bolt slide weldments to bumper.
Bolt the slide weldment to the bumper as shown (both sides):
21
19
19
20
21
19
19
20
ID QTYPART DESCRIPTION
19 0352 WASHER 0.50 USS FLAT 8
20 0501
CAP SCR 0.50-13X2.00 HHGR5 4
21
C6106 NUT 0.50-13 HHGR5 NYLOC 4