stellar labs Slider40 User manual

Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
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Last Revision: 10/07 /12
Subject to Change without Notification.
© 2012 Stellar Industries, Inc.

Slider40 Hooklift anual Revisions
Date of Revision Description of RevisionSection Revised

Table of Contents 
Introduction ...................................................................iii
Hooklift Nomenclature.................................................iv
Chapter 1 - Safety ........................................................1
General Safety ..............................................................1
Personal Safety..............................................................1
Maintenance Safety.....................................................1
Stability ..........................................................................2
Load Safety....................................................................2
Environment...................................................................2
Safety Decals of Note ..................................................3
Chapter 2 - Operation .................................................5
Operator Requirements ...............................................5
Operator Conduct........................................................5
Job-Site Set-Up ..............................................................5
Hooklift Controls ............................................................6
Hydraulic Hook Height Adjustment - Raise ................7
Hydraulic Hook Height Adjustment - Lower...............7
Loading Operation .......................................................8
Unloading Operation .................................................10
Dumping Operation ...................................................12
Chapter 3 - aintenance .........................................13
Maintenance Procedures..........................................13
Periodic Inspection .....................................................13
Daily Inspection...........................................................13
Monthly Inspection .....................................................13
Grease Zerk Locations................................................14
Choice Lubricants for DX Bearings ...........................15
Chapter 4 - Specifications.........................................17
Acceptable Subframe Dimensions for Bodies ........18
Acceptable Subframe Dimensions for Bodies ........19
Acceptable Subframe Dimensions for Bodies ........20
Acceptable Subframe Dimensions for Bodies ........21
Acceptable Subframe Dimensions for Bodies ........22
Chapter 5 - Installation ..............................................23
General Install Guidelines ..........................................23
Installation Note ..........................................................24
Step 1: Set the hooklift onto the truck frame. .........24
Step 2: Drill mounting holes........................................24
Step 3: Install bumper. ................................................24
Step 4: Install tie-downs..............................................24
Step 5: Install tarper tower (If applicable). ..............24
Mounting it - PN 57080 .............................................25
Step 6: Install hydraulic reservoir and valve bank. .26
Reservoir Assembly - PN 42426 ..................................26
Step 7: Install PTO and pump. ...................................27
Step 8: Route hydraulic hoses. ..................................28
Hose it - PN 59880 .....................................................28
(Fixed Hook Height Models) ......................................28
Hose it - PN 59881 .....................................................29
(Adjustable Hook Height Models) .............................29
Port Relief Location for Hoists with Inside Latches ..30
Power Beyond VDM8 Valve.......................................30
Step 9: Route Electrical Components ......................31
Step 10: Install cab and PTO controls.......................32
Air Control Routing......................................................33
Step 11: Install mud flaps and fenders. ....................33
Step 12: Install Hoist Up Light Sensor - PN 31806......34
Step 12: Apply Decals ................................................35
Step 13: Fill reservoir and activate hydraulic flow. .36
Step 14: Operate hooklift...........................................36
Setting System Relief Pressure....................................37
Chapter 6 - Assembly Drawings ...............................39
Base Assembly - PN 56080..........................................39
Dump Assembly - PN 56164 .......................................40
Secondary Assembly - PN 56774...............................41
Main Cylinder Assembly - PN 57019..........................42
Jib Assembly (62” Hook Height) - PN 56775.............43
Jib Assembly (54/62” Hook Height) - PN 58230 .......44
Jib Assembly (54/63” Hook Height) - PN 60111 .......45
Hose Track - PN 58142 ................................................46
Chapter 7 - Replacement Parts ................................49
Chapter 8 - Troubleshooting .....................................51
Table of Contents

 Slider40 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 opera-
tion of this equipment and to provide the operator with properly maintained equipment.
FAILURE TO READ THIS ANUAL BY ANYONE WHO WILL OPERATE, SERVICE, OR WORK
AROUND THIS HOOKLIFT IS A ISUSE OF THE EQUIP ENT. DEATH OR SERIOUS INJURY WILL
RESULT FRO I PROPER USE OR AINTENANCE OF THIS ACHINE.
Occupational safety is a prime concern of Stellar Industries in the design and production
of this hooklift. 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, pre-
cautions and work hazards that exist in the operation and maintenance of this hooklift.
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 hooklift with caution, skill, and
good judgment. Following the recognized safety procedures will help you avoid acci-
dents. Modification to any part of his hooklift 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! ake safety your everyday business!
Attention!
According to Federal Law (49 cfr part 571),
each final-stage manufacturer shall com-
plete 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 require-
ment shall, however, be superseded by any
conflicting provisions of a standard that
applies by its terms to vehicles manufac-
tured in two or more stages.
Therefore, the installer of Stellar hooklifts 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 regula-
tions 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.


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 [email protected]
Order Parts [email protected]
Warranty Information [email protected]
Stellar Hooklifts are designed to provide safe
and dependable service for a variety of
operations. With proper use and
maintenance, these hooklifts 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 hooklift.
Once you feel comfortable with the
material contained in this manual, strive to
exercise your knowledge as you safely
operate and maintain the hooklift. 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
hooklift and shall remain with the hooklift 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 hooklifts 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 [email protected].
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 hooklift.
Introduction

' Slider40 Owner’s Manual
Hooklift Nomenclature
BASE
HOOKLIFT
DUMP
JIB
SECONDARY
The Stellar Slider is a hydraulic, body-loading device when mounted on a truck chassis. It
can handle a multitude of bodies ranging from flatbeds to recycling containers and
dump bodies.
The Slider consists of four basic parts: the base, dump, secondary, and jib sections. Please
take the time to familiarize yourself with the various components. nowing the proper ter-
minology is necessary to get the full benefit of this manual.

Safety 
anti-noise headphones, protective glasses,
breathing apparatus, and reflective jackets.
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 hooklift.
eep 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 sta-
ble support.
Do not allow unauthorized personnel or
equipment to enter within 10 feet of hooklift
operating area.--
Never allow anyone to ride the hooklift or
load.
aintenance Safety
Never modify or alter any of the equipment,
whether mechanical, electrical, or hydraulic,
without Stellar Industries’ approval.
Do not perform any maintenance or repair
work on the hooklift 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.
Decals are considered safety equipment.
They must be maintained, as would other
safety devices. Do not remove any decals.
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.
Do not operate equipment under the
adverse influence of alcohol, drugs, or med-
ication.
Read all Danger and Caution decals on the
equipment and understand their meaning.
Personal Safety
eep clear of all moving parts.
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,
Please Read the Following Carefully! This
portion of the manual contains information
regarding all Stellar manufactured hooklifts.
Some items contained within this chapter
may not apply to your specific equipment.
Safety should be the n umber 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 hooklift before
putting the unit into operation.
Please take note that Stellar Industries, Inc.
is not liable for accidents incurred by the
hooklift because of non-fulfillment from the
operator’s side of current rules, laws, and
regulations.
Chapter 1 - Safety

Slider40 Owner’s Manual
Replace any decals that are missing, dam-
aged, or not
legible.
The safety instruction plates, notices, load
charts and any other sticker applied to the
hooklift must be kept legible and in good
condition. If necessary, replace them.
eep all surfaces of the hooklift free of oil
and grease to avoid slippery surfaces and
aid in
inspections.
Stability
now the hooklift components and their
capabilities and limitations. Overloading the
hooklift may result in serious damage of self,
others, equipment or the surroundings.
Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s
hydraulic, mechanical, and structural design
rather than stability.
Load Safety
Full rated dump capacity assumes load will
decrease as dump angle increases. Do not
take full rated capacity to full dump angle
without some unloading of weight as it may
cause damage to the chassis and/or the
hooklift.
Move the control lever slow and smooth for
steady oil flow.
Avoid jerky or sudden movement of the con-
trols.
Be constantly aware of the hooklift position
when operating the controls.
Do not attempt to lift fixed loads.
now the weight of your load to avoid over-
loading the equipment.
Deduct the weight of the body from the
maximum load rating to determine how
much weight can be lifted.
eep everyone clear when loading, unload-
ing, and dumping.
Do not push on fixed objects or bodies with-
out rollers with the hooklift.
Do not permit loose objects on the hooklift.
Use a qualified person to assist in loading
when the load is not visible to the operator.
Do not leave hooklift unattended with sus-
pended load.
Take care when operating in areas support-
ed by vehicle tires, because of the cushion-
ing effect of springs and tires.
Never use the drivetrain of the chassis to
assist the hydraulics in loading
Environment
Do not operate the hooklift during electrical
storms.
In extreme cold, allow adequate time to
warm the truck before engaging the PTO.
Do not rev the truck engine and over speed
the hydraulic pumps as permanent damage
to the pumps may occur. Follow the vehicle
owner’s manual regarding operating the
vehicle in such adverse conditions.
In extreme cold, operate the controls slowly
to allow for viscosity changes.
ATTENTION
Stellar Industries, Inc. is not liable
for accidents incurred by the
hooklift because of the
operator’s non-fulfillment of
current rules, laws and
regulations.

Safety 
Safety Decals of Note
DANGER
AN UNTRAINED OPERATOR
SUBJECTS HIMSELF AND
OTHERS TO
YOU MUST NOT OPERATE
THIS EQUIPMENT UNLESS
• You have been trained in the safe
operation of this equipment.
• You read, understand and follow the
safety and operating recommendations
contained in the equipment manufacturer’s
manuals, your employer’s work rules and
applicable government regulations.
C4540
DEATH OR SERIOUS INJURY
DANGER
FAILURE TO OBEY THE FOLLOWING
WILL RESULT IN
• Follow all recommended inspections and
maintenance practices listed in the equipment
manufacturer’s manuals. If manuals are
missing from this equipment, contact
manufacturer for replacement.
• Do not modify or alter this equipment without
written manufacturers approval. Use only
manufacturer approved attachments or parts
on this equiupment.
• Equipment must be mounted on factory
recommended chassis. If re-mounted or
rebuilt, the equipment must be re-certified.
4190
DEATH OR SERIOUS INJURY
DANGER
HOOK AND BAIL HEIGHTS
MUST MATCH
45955
74-490
OR LOAD WILL BE UNSTABLE
AND MAY FALL CAUSING
SERIOUS INJURY OR DEATH
TO OPERATOR AND/OR
BYSTANDERS.
WARNING
CRUSHING HAZARD
Moving parts can
crush and cut.
Keep hands and
arms clear.
25627
DANGER
THIS HOOKLIFT IS NOT INSULATED
will result from contact with the vehicle,
hooklift, or load should they become
electrically charged.
PN 55832
DEATH OR SERIOUS INJURY
ELECTROCUTION HAZARD
MAINTAIN A CLEARANCE IN ACCORDANCE WITH ANSI Z245.

Slider40 Owner’s Manual

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
in accordance with ANSI Z245.
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 should be removed to
allow the truck to roll under the body
while loading.
In some situations, the foot brake may be
used to position the body. If the container
will experience a significant restriction to
movement during unloading, the foot brake
must not be used.
Operator Requirements
Operation is limited to the following peo-
ple:
A. Qualified individual.
B. Trainees under direct supervision of the
qualified individual.
C. Test or maintenance individual.
D. Hooklift Inspector.
Operators must:
A. Demonstrate the ability to understand
all decals, the owner’s manual, and any
other information required for safe oper-
ation of the hooklift.
B. Be able to demonstrate the ability to
safely control the hooklift.
C. now all safety regulations.
D. Be responsible for maintenance require-
ments.
E. Understand and be fully capable of
implementing all emergency proce-
dures.
F. Understand the operating procedures as
outlined by this manual, ANSI Z245 and
Federal/State Laws.
Operator Conduct
1. Operators will not engage in any opera-
tion that would cause them to divert
attention away from the operation of
the hooklift.
2. Operators are responsible for all opera-
tions under their direct control.
3. Operators will not leave a suspended
load unattended.
4. Operators will be familiar with the equip-
ment and the maintenance required for
proper care.
Chapter 2 - Operation

Slider40 Owner’s Manual
Hooklift Controls
1. Be familiar with the sequence and operation of the hooklift controls.
2. Each individual hooklift function should have control function decals. Replace them
immediately if they are missing or illegible.
3. eep 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 hooklift.
5. Be prepared before beginning operation of the hooklift:
• 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. eep fire extinguisher and first aid kit near.
• Be sure all regular maintenance has been performed.
• Visually inspect all aspects of the hooklift for physical damage.
• Check for fluid leaks.
DANGER
Stellar®Slider Controls
55755
Be familiar with the control functions and
sequence of operation. See owner’s manual
for specific information regarding operation.
LIFT
SLIDE HOOK
HOOK AND BAIL
HEIGHTS MUST MATCH
OR LOAD WILL BE
UNSTABLE AND MAY
FALL CAUSING SERIOUS
INJURY OR DEATH
TO OPERATOR AND/OR
BYSTANDERS.

Operation 
With the hooklift in the stowed position
without a body, put the truck in neutral
and engage the PTO.
Hydraulic Hook Height Adjustment - Lower
Pull the control lever labeled ‘hook’
to raise the hook height. When
raised completely, release the lever
and disengage the PTO.
With the hooklift in the stowed position
without a body, put the truck in neutral
and engage the PTO.
Push the control lever labeled ‘hook’
to lower the hook height. When low-
ered completely, release the lever
and disengage the PTO.
Fully extend
hook height.
Fully retract
hook height.
PTO ON
PTO ON
PTO OFF
PTO OFF
Hydraulic Hook Height Adjustment - Raise

Slider40 Owner’s Manual
Loading Operation
PTO ON
Fully
retract jib
cylinder
Back truck
to body.
Maneuver the truck into a position to load the
body. Put the truck in neutral and engage the
PTO.
Pull the control lever labeled ‘Jib’ to slide the jib as far
back as it will go, effectively releasing the dump latches.
Slowly back up and attach
to the body by using the
‘Lift’ control lever as neces-
sary.
Extend lift
cylinder
Pull the control lever labeled ‘Lift’
until the hook is in a position to
attach to the body.
Note: Hook and bail heights must match.

Operation 
Loading Operation Continued...
PTO OFF
Fully
retract lift
cylinder
Fully
extend jib
cylinder
Once fully attached, push the ‘Lift’
control lever to load the body.
Note: ake sure the body is lining
up with the rear rollers while loading.
Finally, push the control
lever labeled ‘Jib’ to slide
the jib forward until the
body latches fully engage.
Disengage the PTO.
Note: If the container
will experience a signif-
icant restriction to
movement during load-
ing, the foot brake must
not be used. Allow the
truck to roll under the
load.
Note: Hook and bail heights must match.

 Slider40 Owner’s Manual
Unloading Operation
PTO ON
Put the truck in neutral and engage the PTO.
Pull the control level labeled
‘Jib’ to slide the jib as far
back as it will go, effectively
releasing the dump latches.
Pull the control lever labeled ‘Lift’
until the body is on the ground.
Fully
retract jib
cylinder
Note: If the container
will experience a signif-
icant restriction to
movement during
unloading, the foot
brake must not be
used. Allow the truck to
roll out from under the
load.
Extend lift
cylinder

Operation 
Unloading Operation Continued...
PTO OFF
Detach the hooklift from the container
by maneuvering the hook using the
‘Lift’ control lever and pulling the truck
forward.
Finally, push the control lever labled ‘Jib’ to slide
the jib forward into the stowed position.
Disengage the PTO.
Fully
extend jib
cylinder
Lift cylinder
fully retracted
Once fully detached, push the ‘Lift’
control lever until the lift returns to
the loading/unloading position.
Fully
retract lift
cylinder

 Slider40 Owner’s Manual
Dumping Operation
Put the truck in neutral and engage the PTO.
PTO ON
Pull the control lever labeled ‘Lift’ as desired
to dump the load. Be aware and avoid any
overhead obstructions during the entire
dump procedure.
Lift cylinder
fully extended
When dumping is complete, push
the ‘Lift’ control lever to return the
body to the stowed position.
Disengage the PTO.
PTO OFF

Maintenance 
aintenance Procedures
1. Position the hooklift 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 remov-
ing hydraulic components.
4. Label or tag parts when disassembling.
Periodic Inspection
eriodic Inspection should occur while the
hooklift is in use. For the duration of the usage,
inspect the hooklift 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 pres-
sure.
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 abra-
sion.
8. Presence of this owner’s manual.
Daily Inspection
Daily Inspection should occur each day before
the hooklift is put into use. Each day, inspect the
hooklift 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 dam-
age/wear.
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.
onthly Inspection
Monthly Inspection should occur at the begin-
ning of every work month. Each month, inspect
the hooklift for all of the following:
1. Frame bolt tightness - turn barrel nuts and
mounting bolts during the first month of opera-
tion on new machines and then quarterly
thereafter.
2. Cylinders and valves for leaks.
3. Jib hook for cracks.
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 insulationand bare
wire. Replace or repair wires as required.
8. Lubrication of all moving parts.
Please read the following before performing any
maintenance on the hooklift.
1. Only qualified service personnel are to perform
maintenance on the hooklift.
2. Disengage the PTO before any service or repair is
performed.
3. Do not disconnect hydraulic components while
there is any energy/pressure in the system.
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. eep the hooklift clean and free from grease
build-up, oil and dirt to prevent slippery condi-
tions.
6. Perform all safety and maintenance checks
before each period of use.
7. Immediately repair/replace damaged compo-
nents with Stellar Industries, Inc. approved
parts/repair procedures.
ATTENTION
Every six (6) months, remove the hydraulic
pump from the PTO and lubricate the splines
using Chelsea Lubricant #379831 or Stellar
PN 42042 (packet) or PN 20885 (tube).
Failure to lubricate shaft splines will cause
damage to the PTO and Hydraulic pump.
Chapter 3 - aintenance

Grease Zerk Locations
Slider40
Note: Grease After Every 100 Cycles.
QTY. (2) QTY. (2)
QTY. (2)
QTY. (2)
QTY. (2)
QTY. (2)
QTY. (2)
QTY. (2) BOTH ENDS OF CYLINDER
QTY. (2)