stellar labs ECCR User manual

Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com Last Revision: 05/12/09
Subject to Change without Notification.
© 2009 Stellar Industries, Inc.
Safety • Operation • Parts
OWNERS’ MANUAL
CONTAINER CARRIER

BECCR Owner’s Manual
Stellar ECCR Manual Revisions
Date of Revision Description of RevisionSection Revised

Table of Contents i
Table of Contents

ii ECCR 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 MANUAL BY ANYONE WHO WILL OPERATE, SERVICE, OR WORK
AROUND THIS CONTAINER CARRIER 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 container carrier. 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 container
carrier. 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 pre-
cautions.
FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
It is also your responsibility to operate and maintain your container carrier with caution,
skill, and good judgment. Following the recognized safety procedures will help you avoid
accidents. Modification to any part of his container carrier 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 miss-
ing, 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 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 container
carriers is considered one of the manufactur-
ers of the vehicle. As such a manufacturer,
the installer is responsible for compliance
with all applicable federal and state regula-
tions. 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.

iii
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 Container carriers are designed to
provide safe and dependable service. With
proper use and maintenance, these
container carriers 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 container carrier.
Once you feel comfortable with the material
contained in this manual, strive to exercise
your knowledge as you safely operate and
maintain the container carrier. 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
container carrier and shall remain with the
container carrier 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 container carriers 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].
Introduction
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
container carrier.

iv ECCR Owner’s Manual
sbl000,8yticapacgnitfiL
sbl000,8yticapacgnipmuD
Transporting capacity 8,000lbs, no driving restriction, using safe driving pracitices.
dy01-2seziSreniatnoC
Type of containers Front and rear load containers
Rotation Worm/turntable gear bearings
Stacking capability 2-8yd.
Operating pressure 4,500psi
21MPG
nollag01knatciluardyH
Recommended CA 84" min.
slortnocedistuo&edisnIslortnoC
Bushings and Grease Zerks At all pivot and rotation points
Container Bumpers Molded rubber
epytnotsipsixatneBpmuPciluardyH
Vdellortnocelbacloops-2knaBevla
Specifications
Center of gravity of container is located approximately 43”
behind rear axle. For “moment” calculations, subtract 740 lbs.
from the weight of container.
Base Frame
Lift Frame
Inner
Lift Frame
Fork Frame
ECCR Nomenclature
ECCR Specifications

Safety 1
Chapter 1 - Safety
Please Read the Following Carefully!
This portion of the manual contains
information regarding all Stellar
manufactured container carriers. 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 container carrier before putting the unit
into operation.
Please take note that Stellar Industries, Inc. is
not liable for accidents incurred by the
container carrier 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.
Do not operate equipment under the
adverse influence of alcohol, drugs, or
medication.
Read all Danger and Caution decals on the
equipment and understand their meaning.
Personal Safety
Keep 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, 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 container
carrier.
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
container carrier operating area.
Never allow anyone to ride the container
carrier or load.
Maintenance 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 container carrier 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

2ECCR Owner’s Manual
safety devices. Do not remove any decals.
Replace any decals that are missing,
damaged, or not
legible.
The safety instruction plates, notices, load
charts and any other sticker applied to the
container carrier must be kept legible and in
good condition. If necessary, replace them.
Keep all surfaces of the container carrier free
of oil and grease to avoid slippery surfaces
and aid in inspections.
Stability
Know the container carrier components and
their capabilities and limitations.
Do not move the truck while the mast and
container are raised. A raised load creates a
top heavy unstable load.
Overloading the container carrier 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
Move the control lever slow and smooth for
steady oil flow.
Avoid jerky or sudden movement of the
controls.
Be constantly aware of the container carrier
position when operating the controls.
Do not attempt to lift fixed loads.
Deduct the weight of the body from the
maximum load rating to determine how
much weight can be lifted.
Keep everyone clear when loading,
unloading, and dumping.
Do not push on fixed objects or bodies with
the forks of the container carrier.
Do not permit loose objects on the container
carrier.
Use a qualified person to assist in loading
when the load is not visible to the operator.
Do not leave container carrier unattended
with suspended load.
Take care when operating in areas
supported by vehicle tires, because of the
cushioning effect of springs and tires.
Never use the drivetrain of the chassis to
assist the hydraulics in loading
Environment
Do not operate the container carrier 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 container
carrier because of the operator’s
non-fulfillment of current rules, laws
and regulations.

Safety 3
1
9
2
8BOTH SIDES
BOTH SIDES
3
8
BOTH SIDES
7BOTH SIDES
5
ITEM PART DESCRIPTION QTY.
1 45976 DECAL DNGR WATCH ELEC LINES 1
2 45726 DECAL WARNING HYDRAULIC SAFETY 1
3 45974 DECAL CAUTION-OPERATING INST. 1
4 45906 DECAL HOIST UP (IN TRUCK CAB) 1
5 45975 DECAL CAUTION-FORK CARRIAGE (QTY 1 IN TRUCK CAB) 2
7 C5910 DECAL STELLAR LOGO 4.00X9.50 2
8 25627 DECAL CRUSH POINT 4
9 45971 DECAL DNGRSTAND CLEAR 2
10 45697 DECAL CAUTION PTO SPEED (IN TRUCK CAB) 1
11 45973 DECAL CARRIER CNTRLS (IN TRUCK CAB) 1
12 45972 DECAL CAUTION-LATCH (QTY 1 IN TRUCK CAB) 2
Decal Placement

4ECCR Owner’s Manual

5Operation 5
Chapter 2 - 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 container
carrier, 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 set-
up near power lines.
3. The vehicle should also be positioned on a
firm and level surface that will provide ade-
quate support.
Container Carrier Controls
1. Be familiar with the sequence and operation
of the container carrier controls.
2. Each individual container carrier function
should have control function decals. Replace
them immediately if they are missing or illegi-
ble.
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 container carrier.
5. Be prepared before beginning operation of
the container carrier:
• 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 extin-
guisher and first aid kit near.
• Be sure all regular maintenance has been
performed.
• Visually inspect all aspects of the container
carrier 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 quali-
fied individual.
3. Test or maintenance individual.
4. Container carrier 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
container carrier.
2. Be able to demonstrate the ability to safely
control the container carrier.
3. Know all safety regulations.
4. Be responsible for maintenance requirements.
5. Understand and be fully capable of imple-
menting all emergency procedures.
6. Understand the operating procedures as out-
lined 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 container car-
rier.
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.
Container Carrier Check List
1. Check hydraulic oil level with all
cylinders retracted.
2. Grease all lubrication points.
3. Fork stop pins are securely in place.
4. Mast safety latch and trunnion bar stop
are free to move and work properly.
5. Tires are properly inflated.
6. Truck is fully operational: Brakes, Lights,
etc.

6ECCR Owner’s Manual
Raise
Lift Frame
Lower
Forks
Tilt
Forks
1. If the forks are in the stored position,
manually rotate them to the extended
position and lock in place with the fork
stop pin.
CAUTION: : Be sure that the area in which the container carrier is
to be operated is clear of personnel and obstacles overhead,
and on the ground.
2. Engage the pump and raise the lift frame up
a minimum of 2” to disengage the automatic
safety latch.
Note: Safety latch may be set so that it does not automatically
engage by raising the latch and inserting the pin to hold it up.
When transporting a container, the pin should be removed so
that the safety latch will engage.
3. Fully extend the inner lift frame. 4. Tilt the forks so that they are aligned with the
container pockets.
12
4
3
Extend
Inner
Lift Frame
Lifting a Front Load Container

Operation 7
Back
to Container
Tilt
Forks
Raise
Lift Frame
5. Back the truck up to the container to be lifted
and align the forks with the container pockets.
Continue backing until the forks extend through
the pockets and container is against fork frame.
6. Raise the lift frame and tilt the forks up until
the container clears the ground.
7. Fully retract the inner lift frame and lower
the the lift frame.
8. To transport the container, lower the inner lift
frame completely down and tilt the forks all
the way up, so that full contact is made with
all rest pads.
56
8
7
Lower
Lift Frame
Retract
Inner
Lift Frame
Lifting a Front Load Container Continued...

8ECCR Owner’s Manual
4. Slowly pull the truck forward until the forks
are out of the container pockets.
3. Lower the lift frame until the container is
fully rested on the ground. Tilt the forks
down just enough to clear the container
pockets.
1. Back the truck up close to where the container
will be placed. From the transport position, the
inner lift frame must be raised up a minimum of
2”, before tilting the forks, to disengage the
automatic safety latch.
12
Raise
Lift Frame Extend
Inner
Lift Frame
Tilt
Forks
Lower
Lift
Frame
2. Fully extend the inner lift frame and tilt the
forks down.
Tilt
Forks
3
Forward
Back
4
6. Lower the lift frame completely down and
disengage the pump.
5. Fully retract the inner lift frame and tilt the
forks all the way up so that full contact is
made with the rest pads
6
Tilt
Forks
5
Lower
Lift Frame
Retract
Inner
Lift Frame
Placing a Front Load Container

Operation 9
Lifting a Rear Load Container
4. Line up and back to the container.
Raise the lift frame until the trunnion
bars are securely located in the slots and
tilt the forks up to make the rubber bumpers
contact the container. Put both trunnion
bar stops in the ‘locked’ position.
3. Fully extend the inner lift frame and tilt the
forks into a position that will allow for
attachment to the container.
1. If the forks are in the extended position,
manually rotate them to the stored position
and lock in place with the fork stop pin. Make
sure both trunnion bar stops are in the
‘unlocked’ position.
12
2. Engage the pump and raise the lift frame up a
minimum of 2” to disengage the automatic
safety latch.
3
Raise
Lift
Frame
Back
4
Note: Failure to lift forks before tilting mast will result in overloading
and possibly damage to the safety latch.
Tilt
Forks
Extend
Inner
Lift Frame
6. Fully retract the inner lift frame.
To transport the container, lower the lift frame
completely down and tilt the forks up so that
full contact is made with all rest pads.
Disengage the pump before driving away.
6
5
Retract Inner
Lift Frame
5. Raise the lift frame and tilt the forks to lift
the container.
Raise
Lift
Frame
Lower
Lift
Frame
Tilt
Forks

10 ECCR Owner’s Manual
Placing a Rear Load Container
4. Fully retract the inner lift frame and
tilt the forks back into the stored position
(full contact is made with the rest pads).
3. Lower the lift frame to clear the container
trunnion bars and slowly pull the truck forward
until clear of the container.
1. Back the truck up close to where the container
will be placed. Set both trunnion bar stops to
‘unlocked’ position. From the transport position,
the lift frame must be raised up a
minimum of 2”, before tilting the forks or
extending the inner lift frame, to disengage
the automatic safety latch. Fully extend the
inner lift frame.
12
2. Back the truck up until the container is
centered over the area where you want
to set it. Slowly lower the lift frame and
tilt the forks to keep the container level until
the container bottom is in full contact with
the surface where it will set.
34
5
5. After the last container has been placed, lower
the lift frame completely down so that full contact
is made with the rest pads. Disengage the pump.
Lower
Lift
Frame
Extend
Inner
Lift Frame
Tilt
Forks
Retract Inner
Lift Frame
Back
Forward
Raise
Lift
Frame
Tilt
Forks

Operation 11
Trunnion
Stop
Unlocked
Position
Locked
Position
Trunnion
Stop
Important Notes:
Do not lift a container heavier than 8,000 lbs. max
Do not rotate fork carriage with forks in stored posi-
tion. Possible damage to fork carriage may result.
Do not use rotator with rear load container.
Directions
1. Tilt forks up ap-
proximately 15º
before rotating the
container.
2. Slowly rotate fork
carriage to empty
container.
Container
Weight
<8,000 lbs.
Trunnion Bar Stops
Operation of Rotator
CAUTION
Failure to tilt forks up before rotating container may result in container sliding
off of forks with possible damage to equipment and injury to personnel

12 ECCR Owner’s Manual
Warning! Cylinder Collision Point
CYLINDER COLLISION POINT
Do not fully extend the tilt cylinder when the inner lift frame is
fully retracted. Equipment damage WILL result.

Installation 13
Container Carrier Mounting and Assembly
Study names and locations of the parts and
familiarize yourself with the container carrier
before starting the assembly . Reading the
step-by-step instructions that follow will be
helpful.
Safety
Read all of the safety notations in the assem-
bly instructions for your protection.
Accidents can be prevented by recognizing
the cause of an accident before it can hap-
pen.
Assembly
Select an area for assembly that will be
large enough to accommodate the com-
pleted unit. The surface of the work area
should be as level as possible. Use the prop-
er hand tools to ensure proper bolt tightness.
Refer to the chart below for the recom-
mended torque values for different sizes of
bolts.
Recommended Torque Values in Ft-Lbs
For SAE GRADE 2 and GRADE 5 coarse
thread cap screws and bolts shown are sug-
gested 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 fas-
teners periodically.
Sheer bolts are designed to fail under prede-
termined 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.
The stadard container carrier weighs approx-
imately 2,000 lbs. with rotator 2,500 lbs.
Make sure that all chains and handling
equipment are adequately rated for this
weight.
Model Number
Know the model number of the Stellar
Container Carrier 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.
Chapter 4 - Installation

14 ECCR Owner’s Manual
Truck Chassis
The Stellar Container Carrier will mount on any dual rear wheel chassis, one ton or larger,
that meets minimum dimensional requirements. (See Figure 1 below.)
Center of grav-
ity of container
is located
approximately
74” behind rear
axle. For “mo-
ment” calcu-
lations, add
300 pounds to
weight of con-
tainer at this
location.
Chassis
GVW Rating
of 30,000 lbs.
or more is
recommended.
84” Minimum
Cab-to-Axle
(Recommended)
60” Cab-to-Axle mini-
mum is possible with re-
duced capacity rating.
Clearance Height:
10” Minimum Fork Tip
186” Maximum Mast Top
32”
Aft of Axle
CG
74”
Rotator Frame: 27.75” Inside, 33.75” Outside Capacity: 2 through 10 cubic yard containers
Figure 1
1. Cut the truck frame off a minimum of 1”
behind the rear spring shackle. Note: Make
sure not to cut rear of frame off shorter than 32”
from center of axle to end of frame. See Figure
above.
2. The container carrier must mount on a good
supporting surface. If there are any rivets or
other obstructions on the top of the truck frame,
a 1/2” x 3” x 84” bar with clearance holes drilled
at each rivet location should be welded to the
truck frame or bottom of the container carrier.
If the truck frame has a hump above the rear
axle, spacers must be placed under container
carrier at each U-Bolt location to level it.
3. Stellar offers an offset pintle hitch accessory
shown in the figure to the right. See the next
page for pintle hitch detail.
Figure 2
Truck Preparation