stellar labs Flex36 60-8 User manual

Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Safety • Operation • Installation • Maintenance
OWNERS’ MANUAL
FLEX36 HOOKLIFT
Manual Part No. 35551
Last Revision: 01/14/10
Subject to Change without Notification.
© 2010 Stellar Industries, Inc.
Models
60-8
84-10
108-12
120-14

Flex36 Hooklift Manual Revisions
Date of Revision
August 27, 2007
May 14, 2008
January 14, 2010
Description of Revision
Updated Reservoir Assembly Drawing (PN 35883) to reflect
engineering changes.
Updatted Base Assembly Drawing Drawings to reflect
engineering changes.
Updated Controller Assembly to reflect engineering
changes.
Section Revised
Chapter 6 - Installation
Chapter 7 - Assembly
Drawings
Chapter 6: Installation

Table of Contents i
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Stellar Flex Hooklift Nomenclature . . . . . . .iv
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . .1
General Safety . . . . . . . . . . . . . . . . . . . . . . .1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . .1
Maintenance Safety . . . . . . . . . . . . . . . . . .1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Load Safety . . . . . . . . . . . . . . . . . . . . . . . . . .2
Environment . . . . . . . . . . . . . . . . . . . . . . . . . .2
Chapter 2 - Operation . . . . . . . . . . . . . . . . . . .3
Job-Site Set-Up . . . . . . . . . . . . . . . . . . . . . . .3
Operator Requirements . . . . . . . . . . . . . . . .3
Operator Conduct . . . . . . . . . . . . . . . . . . . .3
Hooklift Controls . . . . . . . . . . . . . . . . . . . . . .4
Operation Overview . . . . . . . . . . . . . . . . . . .4
Unloading Operation . . . . . . . . . . . . . . . . . .5
Loading Operation . . . . . . . . . . . . . . . . . . . .6
Dumping Operation . . . . . . . . . . . . . . . . . . .7
Chapter 3 - Maintenance . . . . . . . . . . . . . . . .9
Maintenance Procedures . . . . . . . . . . . . . .9
Periodic Inspection . . . . . . . . . . . . . . . . .9
Daily Inspection . . . . . . . . . . . . . . . . . . . .9
Monthly Inspection . . . . . . . . . . . . . . . . .9
General Service . . . . . . . . . . . . . . . . . . . .9
Choice Lubricants for DX Bearings . . . . . .10
Chapter 4 - Specifications . . . . . . . . . . . . . .11
Stellar Flex36 Model 60-8
Hydraulic Hooklift Specifications . . . . .12
Stellar Flex36 Model 84-10
Hydraulic Hooklift Specifications . . . . .13
Stellar Flex36 Model 108-12
Hydraulic Hooklift Specifications . . . . .14
Stellar Flex36 Model 120-14
Hydraulic Hooklift Specifications . . . . .15
Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . .17
Decals of Note . . . . . . . . . . . . . . . . . . . . . .17
Decal Kit Placement - PN 35559 . . . . . . . .18
Chapter 6 - Installation . . . . . . . . . . . . . . . . .19
Basic Installation Overview . . . . . . . . . . . .19
Installation Steps - Basic Guidelines . . . . .20
Mounting Kit (Model 60-8) - PN 33320 . . .22
Mounting Kit (Models 84-10, 108-12,
120-14) - PN 23700 . . . . . . . . . . . . . . . . .23
Rotary Valve
(All Models) - PN 37741 . . . . . . . . . . . . .24
Reservoir Assembly - PN 35883 . . . . . . . . .25
Setting System Relief Pressure . . . . . . . . .26
Installation Instructions for the
Power Beyond VDM8 Valve . . . . . . . . .28
Port Side Relief Installation . . . . . . . . . . . . .29
Controller Assembly . . . . . . . . . . . . . . . . . .30
Dump Light Kit Installation . . . . . . . . . . . . .31
Hydraulic Schematic
(Model 60-8) - PN 34616 . . . . . . . . . . . .32
Hydraulic Schematic
(Model 84-10)- PN 34617 . . . . . . . . . . . .33
Hydraulic Schematic
(Model 108-12) - PN 34618 . . . . . . . . . .34
Hydraulic Schematic
(Model 120-14)- PN 34619 . . . . . . . . . . .35
Subframe Model 60-8 . . . . . . . . . . . . . . . . .36
Subframe Model 84-10 . . . . . . . . . . . . . . . .37
Subframe Model 108-12 . . . . . . . . . . . . . . .38
Subframe Model 120-14 . . . . . . . . . . . . . . .39
Chapter 7 - Assembly Drawings . . . . . . . . . .41
Base Assembly (60-8) - PN 41828 . . . . . . .41
Base Assembly (84-10) - PN 41826 . . . . . .42
Base Assembly (108-12) - PN 41827 . . . . .43
Base Assembly (120-14) - PN 41773 . . . . .44
Dump Assembly (60-8) - PN 31824 . . . . . .45
Dump Assembly (84-10) - PN 33339 . . . . .46
Dump Assembly (108-12) - PN 34247 . . . .47
Dump Assembly (120-14) - PN 33417 . . . .48
Secondary Assembly
(60-8) - PN 33047 . . . . . . . . . . . . . . . . . .49
Secondary Assembly
(84-10) - PN 33341 . . . . . . . . . . . . . . . . .50
Secondary Assembly
(108-12) - PN 34249 . . . . . . . . . . . . . . . .51
Secondary Assembly
(120-14) - PN 33415 . . . . . . . . . . . . . . . .52
Tilt Assembly
(All Flex36 Models) - PN 33049 . . . . . . .53
Tilt Assembly
(Optional Tall Tilt) - PN 35032 . . . . . . . .54
Tilt Cylinder Assembly
(All Flex36 Models) - PN 23460 . . . . . . .55
Main Cylinder Assembly
(60-8) - PN 27116 . . . . . . . . . . . . . . . . . .56
Main Cylinder Assembly
(84-10)- PN 33404 . . . . . . . . . . . . . . . . . .57
Main Cylinder Assembly
(108-12, 120-14)- PN 33462 . . . . . . . . . .58
Chapter 8 - Replacement Parts . . . . . . . . . .59
Chapter 9 - Troubleshooting . . . . . . . . . . . . .61
Warranty Information . . . . . . . . . . . . . . . . . . .62

ii Flex36 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 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, 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! 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 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.

Introduction 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 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
Introduction
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.

iv Flex36 Owner’s Manual
Stellar Flex Hooklift Nomenclature
HOOKLIFT
BASE
DUMP
SECONDARY
TILT
The Stellar Flex is a hydraulic, body-loading device when mounted on a truck chassis.
When mounted, the Stellar Flex can handle a variety of bodies ranging from flatbeds to
recycling containers to dump bodies.
Two independently controlled cylinders operate all the functions of the Stellar Flex. By
varying the cylinder operation, the Stellar Flex can be used to dump or unload a body.
The Stellar Flex consists of four basic parts: The base, dump, secondary, and tilt sections.
Familiarize yourself with the various components of this hooklift and the names of those
components. Knowing the proper terminology is necessary to get full benefit from this
manual

Safety 1
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.
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 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.
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 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.
Chapter 1 - Safety
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
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,
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 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 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.

2Flex36 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.
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
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.
Know 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.
Keep 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.

Operation 3
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 clear-
ance 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 support for the body.
4. The parking brake must be removed to
allow the truck to roll under the body
while loading.
CAUTION
1. When loading and unloading
bodies, the tilt cylinder 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.
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. Know 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.

4Flex36 Owner’s Manual
Hooklift Controls
1. Be familiar with the sequence and oper-
ation 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 opera-
tion 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 condi-
tion.
• 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.
Operation Overview
Unloading Operation
1. Stop the truck at the location you wish to unload.
2. Put the truck in neutral and engage the PTO.
Run RPM as needed.
3. Locate the black control lever labeled tilt.
4. Pull the tilt lever until the cylinder is fully extend-
ed, 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.
Loading Operation
1. Position the truck in line with the body you intent
to pick up.
2. Engage the hook to the body by maneuvering
the hooklift with the red(lift) lever. Run RPM as
needed.
3. Push the red(lift) lever until the main cylinder is
fully retracted.
4. Push the black(tilt) lever until the tilt is fully
extended.
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.
Run RPM as needed.
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.
NOTE: The controller assembly pictured in this
chapter may differ from model to model.