Stellar labs Flex series User manual

Owner’s Manual

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Safety, Installation, Maintenance, and Operation

Stellar Flex™ Series Hooklift

FLEX36

60-8-36

84-10-36

108-12-36

120-14-36

Manual Part No. 35551

Last Revision: 4/25/06

Subject to Change without Notification.

Stellar Flex Manual Revisions

Date of Revision

April 25th, 2006

Description of Revision

Updated the Main Cylinder Drawing for the 84-10,

108-12, 120-14 to reflect the new tubing additions.

Section Revised

Chapter 7: Assembly

Drawings

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 HOOKLIFT 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

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, precautions

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 accidents. 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! 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 man-

ufacture 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 vehi-

cles manufactured 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 applica-

ble federal and state regulations. They are

required to certify that the vehicle is in com-

pliance 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

http://www.gpoaccess.gov/nara/index.html

for the full text of Code of Federal

Regulations.

Stellar Hooklifts are designed to provide safe

and dependable service for a variety of opera-

tions. With proper use and maintenance,

Stellar Hooklifts will operate at peak perform-

ance for many years.

This manual con-

tains information

vital to the safe use

and efficient opera-

tion of this unit.

Following the infor-

mation provided

within this manual

can ensure the

longevity of the

hooklift. Carefully

read and study the

operator’smanual

before using the

unit. 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.

Acopy of this manual is provided with every

hooklift and shall remain with the hooklilft at all

times. Information contained within this manu-

al does not cover all maintenance, operating, or

Introduction

repair instructions pertinent to all possible situ-

ations. 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 purpos-

es. This right is kept with no requirement or

obligation for immediate mandatory updating of

this manual.

This product manual is not intended as a train-

ing manual for beginners or unskilled opera-

tors. This manual offers guidelines for correct

and safe usage of the hooklift, maintenance,

and troubleshooting. If more information is

required or technical assistance is needed,

please contact the Stellar Industries, Inc.

Customer Service Department.

Some sections of this manual contain informa-

tion pertaining to all Stellar manufactured hook-

lifts and may or may not apply to your specific

model.

If this manual becomes damaged, misplaced,

or unreadable at any point, or if you feel that

any part of this manual is unclear or incorrect,

please contact Stellar Customer Service

Department at 800-321-3741 or email at

[email protected]

Technical Questions, and Information [email protected]

Order Parts [email protected]

Warranty Information [email protected]

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:

Table of Contents

Chapter 1 - Safety 1-1

Chapter 2 - Operation 2-1

Chapter 3 - Maintenance 3-1

Chapter 4 - Specifications 4-1

Chapter 5 - Decals 5-1

Chapter 6 - Installation 6-1

Chapter 7 - Assembly Drawings 7-1

Chapter 8 - Hydraulics/Electrical 8-1

Chapter 9 - Replacement Parts 9-1

Chapter 10 - Troubleshooting 10-1

iii

Chapter 1 - Safety

1-1

Chapter 1 - Safety

GENERAL

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 main-

tained 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-fit-

ting or hanging clothing such as ties, torn gar-

ments, scarves, unbuttoned jackets or unzipped

overalls, which could get caught up in the moving

parts of the hooklift.

Keep a first-aid box and a fire extinguisher read-

ily 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 equip-

ment to enter within 10 feet of hooklift operating

area.

Never allow anyone to ride the hooklift or load.

MAINTENANCE SAFETY

Never modify or alter any of the equipment,

whether mechanical, electrical, or hydraulic, with-

out Stellar Industries’ approval.

Do not perform any maintenance or repair work

on the hooklift unless authorized and trained to

do so.

Please Read the Following Carefully!

This portion of the manual contains infor-

mation regarding all Stellar manufactured

hooklifts. Some items contained within this

chapter may not apply to your specific

equipment.

Safety should be the number one thought

on every Stellar hooklift operator’s mind.

Three factors should exist for safe opera-

tion: 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 hook-

lift before beginning.

Stellar Industries, Inc. is not liable for acci-

dents occurred during the usage of the

hooklift caused by non-fulfillment from the

operator’s side of current rules, laws and

regulations.

Chapter 1 - Safety

1-2

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. Replace

any decals that are missing, damaged, 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 neces-

sary, replace them.

Keep all surfaces of the hooklift free of oil and

grease to avoid slippery surfaces and aid in

inspections.

STABILITY

Know the hooklift components and their capabili-

ties and limitations. Overloading the hooklift may

result in serious damage of self, others, equip-

ment 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 dam-

age 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 controls.

Be constantly aware of the hooklift position when

operating the controls.

Do not attempt to lift fixed loads.

Know the weight of your load to avoid overload-

ing the equipment.

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 without

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 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 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.

Chapter 1 - Safety

1-3

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. 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

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. Keep 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.

Stellar Industries, Inc. is not liable

for accidents occurred during the

usage of the hooklift caused by non-

fulfillment from the operator’s side of

current rules, laws, and regulations.

AATTTTEENNTTIIOONN!!

2-1

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 hooklift, 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 adequate sup-

port for the body.

4. The parking brake must be removed to allow

the truck to roll under the body while loading.

Unloading Operation

1. Stop the truck at the location you wish to unload.

2. Put the truck in neutral and engage the PTO.

3. Locate the black control lever labeled tilt.

4. Pull this lever until full stroke is reached, thus

releasing tabs.

5. Locate the red lever labeled lift.

6. Pull lift lever until the body is on the ground and

can be detached. Return the hooklift to the stored

position and disengage the PTO.

Caution!

1. When loading and unloading, the tilt cylin-

der must be fully extended before operating

the lift cylinder to prevent damage to the

latch systems.

2. When the PTO is engaged do not run the

engine over 1400 RPM.

3. Do not hold the brakes while performing

operations.

Loading Operation

1. Perform the steps for unloading a container.

2. Engage the hook to the body by maneuvering

the loader with the red(lift) lever.

3.Push the red(lift) lever until the main cylinder is

fully retracted.

4. Push the black(tilt) lever until the tilt is fully

retracted.

5. Disengage the PTO.

Dumping Operation

1. Stop the truck at the location you wish to dump

the load.

2. Put the truck in neutral and engage the PTO.

3. Locate the red lever labeled lift.

4. Pull the lever to dump the body.

5.Wait until dumping is complete, then push the

red(lift) lever until the main cylinder fully retracts.

6. Disengage the PTO.

Operation Overview

Chapter 2 - Operation

2-2

1. Stop the truck at the location you wish to

unload.

2. Put the truck in neutral and engage the

PTO.

3. Locate the black control lever labeled tilt. 4. Pull tilt lever until full stroke is reached, thus

releasing tabs.

5. Locate the red lever labeled lift.

6. Pull lift lever until the body is on the ground

and can be detached. Return the hooklift to

the stored position and disengage the PTO.

Unloading Operation

Chapter 2 - Operation

2-3

Loading Operation

1. Perform the steps for unloading a container. 2. Engage the hook to the body by maneuver-

ing the loader with the red(lift) lever and the

black (tilt) lever..

3. Push the red(lift) lever until the main

cylinder is fully retracted.

4. Push the black(tilt) lever until the tilt is fully

retracted.

5. Disengage the PTO.

Chapter 2 - Operation

2-4

Dumping Operation

1. Stop the truck at the location you wish to

dump the load.

2. Put the truck in neutral and engage the

PTO.

3. Locate the red lever labeled lift. 4. Pull the lift lever to dump the body.

5. Wait until dumping is complete, then push

the red(lift) lever until the main cylinder fully

retracts.

6. Disengage the PTO.

Operator Requirements

Operation is limited to the following people:

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 operation of the

hooklift.

B. Be able to demonstrate the ability to

safely control the hooklift.

C. Know all safety regulations.

D. Be responsible for maintenance

requirements.

E. Understand and be fully capable of

implementing all emergency

procedures.

F. Understand the operating

procedures as outlined by this

manual, ANSI Z245 and

Federal/State Laws.

Operator Information

Operator Conduct

1. Operators will not engage in any operation that

would cause them to divert attention away from the

operation of the hooklift.

2. Operators are responsible for all operations

under their direct control.

3. Operators will not leave a suspended load unat-

tended.

4. Operators will be familiar with the equipment and

the maintenance required for proper care.

Handling the Load

1. Size of the load:

A. Do not load the hooklift beyond the

rated capacity.

B. It is the responsibility of the operator

to know the weight of the handled

load.

2. Moving the load:

A. Make certain that the hooklift is level

and properly blocked.

B. Ensure that the load is secure and

balanced before moving it.

C. Be sure that the hooklift is stable

before moving the load.

E. Avoid sudden starts and stops when

moving a load.

Chapter 2 - Operation

2-4

Chapter 3 - Maintenance

3-1

Chapter 3 - Maintenance

WARNING - Read the Following

before performing any mainte-

nance on the hooklift.

1. Only authorized 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 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 hooklift 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 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

removing hydraulic components.

4. Label or tag parts when disassembling.

Periodic Inspection

Periodic Inspection should occur while the

hooklift is in use. For the duration of the

usage, inspect the hooklift for all of the follow-

ing:

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 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

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.

Chapter 3 - Maintenance

3-2

Monthly 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

operation on new machines and then

quarterly thereafter.

2. Cylinders and valves for leaks.

3. Lubrication.

4. Tilt hook for cracks.

5. Structural weldments for bends, cracks, or

breaks.

6. All pins and keepers for proper

installation.

7. All control, safety, and capacity placards

for readability and secure attachment.

8. Inspect all electrical wires and connections

for worn, cut, or deteriorated insulation

and bare wire. Replace or repair wires as

required.

10. Lubrication of all points requiring

lubrication.

Service

The following general suggestions should

be helpful in analyzing and servicing your

hooklift. 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

components against the cost of parts and

labor necessary to replace them.

6. Make the necessary repair.

7. Recheck to ensure that nothing has been

overlooked.

8. Functionally test the new part in its

system.

Cleanliness

An important item in preserving

the long life of the hooklift is

keeping dirt, grime, and corrosive

material out of the working parts.

Thoroughly wash and grease the

hooklift periodically.

Chapter 3 - Maintenance

3-3

Choice Lubricants for DX Bearings

Type of Grease Description

Premium Quality

Multi-Purpose

Stabilized, Anti-Oxidant Lithium Base

Lithium Base with 3% Molybdenum Disulfide

High Drop Point

Multi-Purpose Calcium Based, for General Automotive and Industrial Use

Calcium Grease, Water Stabilized, High Drop Point

Anti-Friction Bearing Calcium Based with EP Additives

Lithium Based

Sodium Based

Extreme Pressure (EP) Lithium Based with EP Additives

Calcium 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

Inhibitors & Zinc Oxide Additives

Silicone Lithium Based with Silicone Oil Lubricant

Greases Recommended

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

Chapter 4 - Specificaitons

4-1

Chapter 4 - Specifications

•Standard in-cab manual controls which allow for precise metering of the

manual hydraulic valve. Solenoid-activated hydraulic control valve with

electric remote control pendant is optional.

•Ten (10) gallon capacity frame-mounted oil reservoir.

•Hydraulic flow shall not exceed 16-gallons per minute.

•Patented dump/load interface on double pivot models.

•Hydraulic locks to prevent cylinder movement in case of pressure loss.

•Grease zerks at all points to allow purging of contaminates.

•Mechanical rear body tie-down latches.

•Resettable dump/tilt tabs.

•Hydraulic rotary valve to prevent front tilt movement when the dump

frame is raised.

•DX pre-lubricated bushings used at pivot points.

•Greaseable load rollers.

Up to 9,000

54°

23.5”

91”

34”

39.5”

99.25”

43”

60”

104”

120”

141”

See table 1.1

1,275

35.63”

100” x 49” x 47”

38.5°

8’ to 9’

To 10’

Up to 16,000

53°

25”

115”

36”

41.5”

126”

58”

84” to 96”

118”

144”

162”

See table 1.1

1,360

35.63”

126” x 49” x 47”

35°

10’ to 12’

To13’

Up to 16,000

50°

28”

151”

36”

41.5”

161”

70”

120” to 130”

136”

192”

187”

See table 1.1

1,650

35.63”

161” x 49” x 47”

32°

13’ to 15’

To16

60-8 84-10 120-14

Up to 16,000

54°

27”

142”

36”

41.5”

154”

68”

108” to 120”

135”

180”

185”

See table 1.1

1,615

35.63”

154” x 49” x 47”

36°

12’ to 14’

To13’

108-12

Lifting/Dumping Capacity (pounds)

Dump Angle

Lowest Hook Height

Effective Length

Truck Frame Height

Hooklift Height

Hooklift Length

Hooklift Center of Gravity

Chassis Cab to Axle

Max. Height When Loading

Longest Body to Dump

Max. Height When Dumping

Operating pressure

Shipping Weight (pounds)

Hook Height (from bottom of hook bar)

Shipping Dimensions (LxHxW)

Load Angle w/ Shortest Body Length

Recommended Body Lengths*

Recommended Body Lengths**

Stellar Flex Model 60-8 Hydraulic Hooklift Specifications

Lifting Capacity: Check table 1.1 for variable lifting capabilities.

Container Length: 8-foot through 9-foot. Longer bodies up to 10-feet may be accommodated if full dump angle is not

required (may require special body-mounted or extendable truck-mounted bumper and additional latches

to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86

and Securing Hooklift Containers regulation 393.134). Body length does not include A-frame.

Maximum Dump Angle: 54°

Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.

Weight of Hooklift: Hooklift weight not to exceed 1,275 pounds.

Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body

10-inches below grade, when mounted on a 34” truck frame height.

Hydraulic Pump: Direct-coupled high-pressure gear pump.

Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.

Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all

hooklift functions.

Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle

and also to provide a wider stance for side to side stability.

Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated

counterbalance valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retract-

ed when in the transport mode to prevent exposure of cylinder rod to corrosive road salts.

Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section

while hooklift is in the dumping mode.

Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylin-

der movement in case of pressure loss.

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock

into a rigid full length 25” wide frame to provide support for the container while in the dump mode.

These sections form this frame without the use of mechanical latches which rely on gravity,springs, or

container/body mounted latches. The system must be protected from out of sequence operation.

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift

through all ranges of the dump mode. This must be accomplished without the use of steel springs

and/or hydraulic/air cylinders.

Rear Dump Hinge Pin: 2-inch diameter type 304 or 17-4 stainless steel minimum.

Pins: All pins to be type 304 or 17-4 stainless steel.

Bushings: All bushings to be of the DX pre-lubricated variety, used with grease fittings. Bronze bushings not

allowed due to survivability in heavy containment and corrosive environments.

Hoses & Hyd. Fittings: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized

wherever possible. Secured steel hydraulic tubing to be used whenever possible.

Electrical: All electrical wiring to be protected by full length steel conduit fastened into the hooklift framework.

Technical Documentation: All hooklifts shall come with documentation on operation, maintenance, safety and a parts manual.

Regulations: Hooklift shall be designed and manufactured to all local, state and federal regulations.

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

Chapter 4 - Specificaitons

4-2

Stellar Flex Model 84-10 Hydraulic Hooklift Specifications

Lifting Capacity: Check table 1.1 for variable lifting capabilities.

Container Length: 10-foot through 12-foot. Longer bodies up to 13-feet may be accommodated if full dump angle is not

required (may require special body-mounted or extendable truck-mounted bumper and additional latches

to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86

and Securing Hooklift Containers regulation 393.134). Body length does not include A-frame.

Maximum Dump Angle: 53°

Operating Pressure: See table 1.1 in Chapter 6: Installation for variable pressure settings.

Weight of Hooklift: Hooklift weight not to exceed 1,360 pounds.

Height of Hooklift: Hooklift height not to exceed 5.5" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body

10-inches below grade, when mounted on a 36” truck frame height.

Hydraulic Pump: Direct-coupled high-pressure gear pump.

Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir with power beyond capabilities.

Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all

hooklift functions.

Tilting Hook Assembly: Hooklift must have pivoting type front tilt section (jib) to provide a low degree loading/unloading angle

and also to provide a wider stance for side to side stability.

Tilt Cylinder: Cylinder must be double acting (4” Bore x 2” Rod x 17” Stroke) and include dual integral pilot-operated

counterbalance valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retract-

ed when in the transport mode to prevent exposure of cylinder rod to corrosive road salts.

Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section

while hooklift is in the dumping mode.

Lift/Dump Cylinder: Cylinder must be double acting and include dual pilot-operated counterbalance valves to prevent cylin-

der movement in case of pressure loss.

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock

into a rigid full length 25” wide frame to provide support for the container while in the dump mode.

These sections form this frame without the use of mechanical latches which rely on gravity, springs, or