Beruflich Dokumente
Kultur Dokumente
OWNERS MANUAL
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lifting a Front Load Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Placing a Front Load Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lifting a Rear Load Container. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Placing a Rear Load Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lifting a Large Rear Load Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation of Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Trunnion Bar Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Choice Lubricants for DX Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 4 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Basic Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Truck Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bumper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Container Carrier Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hoist-Up Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Tank, Valve and Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil Tank, Valve and Hose Installation Continued.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cable Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cable Control Installation Continued.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Air Controls - PN 47144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-Section Air Controls - PN 46152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Decal Placement Kit - PN 46288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic System Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hose Kit - PN 49534 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Base Assembly - PN 45029 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 5 - Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lift Frame Assembly - PN 45033. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fork Frame Assembly (Rotator) - PN 47487 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fork Frame Assembly (Non Rotator) - PN 45066 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Reservoir Assembly (Cable Controls) - PN 46285 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Reservoir Assembly (Air Controls) - PN 46074 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bumper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ii Container Carrier Owners Manual
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 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 manufacturers 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.
Introduction
Stellar Container carriers are designed to general and may or may not apply to your
provide safe and dependable service. With specific model.
proper use and maintenance, these
container carriers will operate at peak This manual is not binding. Stellar Industries,
performance for many years. Inc. reserves the right to change, at any
time, any or all of the items, components,
To promote this longevity, carefully study the and parts deemed necessary for product
information contained in this manual before improvement or commercial/production
putting the equipment into service. Though purposes. This right is kept with no
it is not intended to be a training manual for requirement or obligation for immediate
beginners, this manual should provide solid mandatory updating of this manual.
guidelines for the safe and proper usage of
the container carrier. In closing:
If more information is required or technical
Once you feel comfortable with the material assistance is needed, or if you feel that any
contained in this manual, strive to exercise part of this manual is unclear or incorrect,
your knowledge as you safely operate and please contact the Stellar Customer Service
maintain the container carrier. This process Department by phone at 800-321-3741 or
is vital to the proper use of the unit. email at service@stellarindustries.com.
Chassis
**84 Minimum 32 GVW Rating
Cab--to--Axle
Aft of Axle of 30,000 lbs.
(Recommended)
or more is
recommended
** 60 cab--to--axle minimum
is possible with reduced
capacity rating.
Clearance Height:
10 Minimum Fork Tip
186 Maximum Mast Top
Chapter 1 - Safety
Please Read the Following Carefully! shoes with steel toes, protective gloves, anti-
This portion of the manual contains noise headphones, protective glasses,
information regarding all Stellar breathing apparatus, and reflective jackets.
manufactured container carriers. Some Consult your employer regarding current
items contained within this chapter may not safety regulations and accident-prevention
apply to your specific equipment. equipment.
Safety should be the number one thought on Do not wear rings, wristwatch, jewelry, loose-
every operators mind. Three factors should fitting or hanging clothing such as ties, torn
exist for safe operation: a qualified operator, garments, scarves, unbuttoned jackets or
well-maintained equipment, and the proper unzipped overalls, which could get caught
use of this equipment. The following up in the moving parts of the container
information should be read and understood carrier.
completely by everyone working with or near
the container carrier before putting the unit Keep a first-aid box and a fire extinguisher
into operation. readily available on the truck. Regularly
check to make sure the fire extinguisher is
Please take note that Stellar Industries, Inc. is fully charged and the first-aid kit is stocked.
not liable for accidents incurred by the
container carrier because of non-fulfillment Do not use controls and hoses as handholds.
from the operators side of current rules, laws, These parts move and cannot provide stable
and regulations. support.
Personal Safety
Keep clear of all moving parts.
ATTENTION
Always wear the prescribed personal safety The Manual Hardcase, which holds
devices. the maunal and other useful
documents, must be installed
Always wear approved accident-prevention permanently to the truck chassis.
clothing such as: protective helmets, anti-slip
2 Container Carrier Owners Manual
Release system pressure before attempting maximum load rating to determine how
to make adjustments or repairs. much weight can be lifted.
Do not attempt service or repair when PTO is Keep everyone clear when loading,
engaged. unloading, and dumping.
Decals are considered safety equipment. Do not push on fixed objects or bodies with
They must be maintained, as would other the forks of the container carrier.
safety devices. Do not remove any decals.
Replace any decals that are missing, Do not permit loose objects on the container
damaged, or not carrier.
legible.
Use a qualified person to assist in loading
The safety instruction plates, notices, load when the load is not visible to the operator.
charts and any other sticker applied to the
container carrier must be kept legible and in Do not leave container carrier unattended
good condition. If necessary, replace them. with suspended load.
Keep all surfaces of the container carrier free Be aware of the cushioning effect of springs
of oil and grease to avoid slippery surfaces and tires when loading/unloading.
and aid in inspections.
Never use the drivetrain of the chassis to
Stability assist the hydraulics in loading
Know the container carrier components and
their capabilities and limitations. Environment
Do not operate the container carrier during
Do not move the truck while the fork frame electrical storms.
and container are raised. A raised load can
create a top heavy unstable load. In extreme cold, allow adequate time to
warm the truck before engaging the PTO. Do
Overloading the container carrier may result not rev the truck engine and over speed the
in serious damage of self, others, equipment hydraulic pumps as permanent damage to
or the surroundings. the pumps may occur. Follow the vehicle
owners manual regarding operating the
Never exceed manufacturers load ratings. vehicle in such adverse conditions.
These ratings are based on the machines
hydraulic, mechanical, and structural design In extreme cold, operate the controls slowly
rather than stability. to allow for viscosity changes.
Chapter 2 - Operation
Job-Site Set-Up Operator Requirements
Thoroughly plan the lift before positioning the Operation is limited to the following people:
vehicle. Consider the following: 1. Qualified individual.
1. The vehicle should be positioned in an area 2. Trainees under direct supervision of the quali-
free from overhead obstructions to eliminate fied individual.
the need for repositioning. 3. Test or maintenance individual.
2. Position the vehicle so that it is impossible for 4. Container carrier Inspector.
any portion of the equipment to come within
the minimum required safe distance of any Operators must:
power line. Maintain a clearance of at least 1. Demonstrate the ability to understand all
10 feet between any part of the container decals, the owners manual, and any other
carrier, or load, and any electrical line or information required for safe operation of the
apparatus carrying up to 50,000 volts. One container carrier.
foot additional clearance is required for every 2. Be able to demonstrate the ability to safely
additional 30,000 volts or less. Remember to control the container carrier.
allow for winds that cause power lines to 3. Know all safety regulations.
sway. It is recommended that a signal person 4. Be responsible for maintenance requirements.
be used when the vehicle is set-up near 5. Understand and be fully capable of imple-
power lines. menting all emergency procedures.
3. The vehicle should also be positioned on a 6. Understand the operating procedures as out-
firm and level surface that will provide ade- lined by this manual, ANSI Z245.6 and
quate support. Federal/State Laws.
1. If the forks are in the stored position, manually 2. Engage the pump and raise the mast up a mini-
rotate them to the extended position and lock in mum of 2 to disengage the automatic safety
place with the fork stop pin. latch.
CAUTION: Be sure that the area in which the container carrier is Note: Safety latch may be set so that it does not automatically
to be operated is clear of personnel and obstacles overhead, engage by raising the latch and inserting the pin to hold it up;.
and on the ground. When transporting a container, the pin should be removed so
that the safety latch will engage.
3 4
Back
Tilt
to Container
Forks
3. Tilt the forks so that they are aligned with the con- 4. Back the truck up to the container to be lifted
tainer pockets. and align the forks with the container pockets.
Continue backing until the forks extend through
the pockets and container is against fork frame.
5 6 Tilt
Forks
Tilt
Forks Lower
Mast
Raise
Mast
5. Raise the mast and tilt the forks up until the con- 6. To transport the container, lower the mast com-
tainer clears the ground. pletely down and tilt the forks all the way up, so
that full contact is made will all rest pads.
Operation 5
1 2
Tilt
Forks
Raise
Mast Raise
Mast
1. Back the truck up close to where the container 2. Tilt the forks and raise the mast until the bottom of
will be placed. From the transport position, the the container is higher than and parallel with the
mast must be raised up a minimum of 2, be- surface on which you want to set the container.
fore tilting the forks, to disengage the automatic
safety latch.
3 4 Lower
Mast
Back
3. Back the truck up until the container is centered 4. Slowly lower the mast and tilt the forks to keep
over the area where you want to set it. the container level, until the container bottom is in
full contact with the surface where it will sit.
5 6
Tilt Tilt
Forks Forks
Forward Lower
Mast
1 2
Rotate Forks
to Stored
Position Raise
Mast
1. If the forks are in the extended position, manu- 2. Engage the pump and raise the mast up a mini-
ally rotate them to the stored position and lock in mum of 2 to disengage the automatic safety
place with the fork stop pin. Make sure both trun- latch.
nion bar stops are in the unlocked position.
Note: Failure to lift forks before tilting mast will result in overload-
ing and possible damage to safety latch.
3 4
Tilt
Forks
Back Raise
to Container Mast
3. Back the truck up to the container to be lifted 4. Raise the mast until the trunnion bars are securely
and align the trunnion slots with the container located in the slots and tilt the forks up to make
trunnion bars. Continue backing until the slots the rubber bumpers contact the container. Put
are under the trunnion bars. both trunnion bar stops in the locked position.
5 6
Tilt
Forks Tilt
Forks
Raise
Mast
Lower
Mast
5. Raise the mast up and tilt the forks to lift the con- 6. To transport the container, lower the mast com-
tainer. pletely down and tilt the forks up so that full con-
tact is made with all rest pads. Disengage the
pump before driving away.
Operation 7
1 2 Raise
Mast Tilt
Raise Forks
Mast
Back
1. Back the truck up close to where the container 2. Tilt the forks and raise the mast until the bottom of
will be placed. Set both trunnion bar stops to the container is higher than and parallel with the
unlocked position. From the transport position, surface on which you want to set the container.
the mast must be raised up a minimum of 2, be-
fore tilting the forks, to disengage the automatic
safety latch.
Lower
3 4 Mast
Tilt
Forks
Back
3. Back the truck up until the container is centered 4. Slowly lower the mast and tilt the forks to keep
over the area where you want to set it. the container level until the container bottom is in
full contact with the surface where it will set.
5 6
Lower
Mast
Tilt
Forks
Lower
Forward Mast
5. Lower the mast to clear the container trunnion 6. After the last container has been placed, lower
bars and slowly pull the truck forward until clear the mast completely down and tilt the forks all the
of the container. way up so that full contact is made with the rest
pads and disengage the pump.
8 Container Carrier Owners Manual
1 2
Rotate Forks
to Stored
Position Raise
Mast
1. If the forks are in the extended position, manually 2. Engage the pump and raise the mast up a mini-
rotate them to the stored position and lock in place mum of 2, before tilting the forks, to disengage the
with the fork stop pin. Make sure both trunnion bar automatic safety latch.
stops are the unlocked position.
3 4 20
to
30
Back Raise
to Container Mast
3. Back up the truck to the container to be lifted 4. Raise the mast until the trunnion bars are securely
and align the trunnion slots with the container located into the slots are under the trunnion bars.
trunnion bars. Continue backing until the slots are
under the trunnion bars.
5 6
Tilt
Forks
Lower
Mast
5. Attach a chain from the top of the fork frame to 6. Put both trunnion bar stops in the locked position
the container. Run the chain through a pipe to pre- and tilt forks until the chain is tight. Tilt the forks all the
vent the container from tipping forward if the truck way up and lower the mast completely down until full
has to make a sudden stop. contact is made with all rest pads.
Operation 9
Trunnion Trunnion
Stop Stop
Unlocked Locked
Position Position
Trunnion
Bar
Operation of Rotator
Important Notes:
Do not lift a container heavier than 8,000 lbs. max
er
o n tain
C t
igh
We 0 lbs.
00
Directions < 8,
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
10 Container Carrier Owners Manual
Maintenance 11
Chapter 3 - Maintenance
Please read the following before performing any Daily Inspection
maintenance on the container carrier. Daily Inspection should occur each day before the
1. Only authorized service personnel are to perform container carrier is put into use. Each day, inspect
maintenance on the container carrier. the container carrier for all of the following:
2. Disengage the PTO before any service or repair is 1. Hydraulic oil level.
performed. 2. Loose parts or damage to structures or weld.
3. Do not disconnect hydraulic hoses while there is 3. Cylinder movement due to leakage.
still pressure in those components. 4. Hoses for evidence of oil leaks.
4. Before disconnecting hydraulic components, shut 5. Controls for malfunction or adjustment.
off the engine, release any air pressure on the 6. Parking brake operation.
hydraulic reservoir, and move control levers 7. All securing hardware such as cotter pins, snap
repeatedly through their operating positions to rings, hairpins, and pin keepers for proper installa-
relieve all pressures. tion.
5. Keep the container carrier clean and free from 8. All safety covers for proper installation.
grease build-up, oil and dirt to prevent slippery 9. Cylinder holding valves for proper operation.
conditions. 10. Equipment for missing, illegible, or defaced oper-
6. Perform all safety and maintenance checks ating decals and safety signs.
before each period of use.
7. Replace parts with Stellar Industries, Inc. Monthly Inspection
approved parts only. Monthly Inspection should occur at the beginning of
8. Immediately repair or have repaired any compo- every work month. Each month, inspect the contain-
nents found to be inadequate. er carrier for all of the following:
1. Frame bolt tightness - turn barrel nuts and mount-
Maintenance Procedures ing bolts during the first month of operation on
1. Position the container carrier where it will be out of new machines and then quarterly thereafter.
the way of other operations or vehicles in the 2. Cylinders and valves for leaks.
area. 3. Lubrication.
2. Place all controls in the off position and secure 4. Structural weldments for bends, cracks, or breaks.
operating features from inadvertent motion. 5. All pins and keepers for proper installation.
3. Relieve hydraulic oil pressure from all hydraulic cir- 6. All control, safety, and capacity placards for read-
cuits before loosening or removing hydraulic com- ability and secure attachment.
ponents. 7. Inspect all electrical wires and connections for
4. Label or tag parts when disassembling. worn, cut, or deteriorated insulation and bare
wire. Replace or repair wires as required.
Periodic Inspection 8. Lubrication of all points requiring lubrication.
Periodic Inspection should occur while the container
carrier is in use. For the duration of the usage, General Service
inspect the container carrier for all of the following: The following general suggestions should be helpful
1. Loose bolts and fasteners. in analyzing and servicing your container carrier.
2. All pins, bushings, shafts, and gears for wear, Using the following systematic approach should be
cracks, or distortion to include all pivot points, and helpful in finding and fixing problems:
bushings. 1. Determine the problem.
3. Hydraulic systems for proper operating pressure. 2. List and record possible causes.
4. Main frame mount bolts. 3. Devise checks.
5. Cylinders for: 4. Conduct checks in a logical order to determine
A. Damaged rods. the cause.
B. Dented barrels. 5. Consider the remaining service life of components
C. Drift from oil leaking internally. against the cost of parts and labor necessary to
D. Leaks at rod seals or holding valves. replace them.
6. PTO and hydraulic pump(s) for leaks. 6. Make the necessary repair.
7. Hydraulic hose and tubing for evidence of dam- 7. Recheck to ensure that nothing has been over-
age such as blistering, crushing, or abrasion. looked.
8. Presence of this owners manual. 8. Functionally test the new part in its system.
12 Container Carrier Owners Manual
Greases Recommended
Type of Grease Description
Premium Quality Stabilized, Anti-Oxidant Lithium Base
Multi-Purpose 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
Cleanliness
An important item in preserving the long life of the container carrier is keeping
dirt, grime, and corrosive material out of the working parts. Thoroughly wash and
grease the container carrier periodically.
Chapter 4 - Installation
Installation 13
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.)
Figure 1 84 Minimum
Cab-to-Axle 32
(Recommended) Aft of Axle
60 Cab-to-Axle mini-
mum is possible with re-
duced capacity rating.
Chassis
GVW Rating
of 30,000 lbs.
or more is
recommended.
Clearance Height:
10 Minimum Fork Tip
186 Maximum Mast Top
Rotator Frame: 27.75 Inside, 33.75 Outside Capacity: 2 through 10 cubic yard containers
Installation 15
Truck Preparation
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 on page 14.
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.
Bumper Installation
TYP 2
FRAME RAIL
TYP 2
PART # 51618
PULL PLATE PINTLE 30K W/ BUMPER
TYP 2
16 Container Carrier Owners Manual
2. Set the container carrier on the truck frame with the rear of the container carrier even with
the truck frame. See Figure 1. Center the container carrier on the truck frame at the front
and rear.
3. Locate the U-Bolts as shown on Figure 3. The rear U-Bolt may have to be moved to just in
front of the rear stop for the overload spring. The front U-Bolt must be located as shown.
4. Put the U-Bolt shims (PN 44915) under the U-Bolts as shown on Figure 3. Weld to the con-
tainer carrier support frame.
6. Weld retainer plates (PN 44916PC) to either inside or outside of container carrier frame so
they contact truck frame to prevent side movement. Do not weld to truck frame.
Figure 3
4
5
7
6
2
PN 45085
MTG KIT CONTAINER CARRIER
ITEM PART DESCRIPTION Q TY.
2 44916PC PLATE RETAINER KPCC 4
3 44914 FLAT U BOLT STRAP KPCC 6
4 44915 FLAT U BOLT SHIM KPCC 6
5 45086 U BOLT 0.75X3.50X18.00 ST 6
6 C0538 NUT 0.75-10 HHGR8 NYLOC 12
7 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 12
Installation 17
Figure 7
21
44
44
Clean all hydraulic components and keep all hoses, tubes, valves, and fittings capped until
they are to be installed.
Warning: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid
the hazard by relieving pressure before disconnecting hydraulic lines. Tighten all connections
before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high pressure flu-
ids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be sur-
gically removed within a few hours or gangrene may result.
2. The valve is mounted to the valve brack- D. Allow room for flexing where the cable is
et welded to the left side of the main attached to moving parts of the equip-
assembly. ment so that the cable is neither kinked
nor stretched.
3. Position the control cable bulkhead plate
on the top of the valve bracket welded 5. Choose a mounting location which is
to the left side of the main assembly. convenient and comfortable for the
Install the control cable bulkhead plate operator and provides adequate clear-
with 1/2 cap screws and nuts, or weld. If ance for the control lever movement.
necessary, temporarily assemble the Check the underside of the cab for rein-
threaded cable end to the bulkhead forcement members, air lines, wiring har-
plate for proper positioning with the valve nesses, and linkages before cutting into
handles. the floor. Be sure the location chosen
allows the cables to be led easily away
4. Mount the cable controllers to the con- from the control. Reversing control direc-
trol mount supplied. Other mounting tion usually is not necessary. In most
options are shown in the following illustra- cases, the direction of the lever move-
tion: ment for a given valve function can be
changed by switching the hydraulic lines
at the valve. If this is not an option, con-
Figure 9 trol operation can be changed simply by
turning the cable controller 180.
through.
MOUNTING MOUNTING TOGETHER
10. Install the control head end of the cable into the cable controller. Reinstall the
cable controller screw passing through the groove in the end of the cable housing.
11. Check the control for free movement and correct valve control.
12. To connect the cable to the valve handle, start by removing the mounting nut from
the cable assembly (Large nut in photo above).
13. Install the threaded portion of the cable assembly through the bulkhead weldment
and replace the mounting nut.
14. Install the clevis provided to the cable end. The cable end should be parallel to the
bulkhead weldment.
clevis.
CAB FLOOR
PN 47144
ITEM PART DESCRIPTION QTY.
1 52901 CONTROL TOWER ASM 2SECT AIR 1
2 0345 CAP SCR 0.38-16X1.50 HHGR5 4
3 0346 WASHER 0.38 USS FLAT ZINC 8
4 0347 NUT 0.38-16 HHGR5 NYLOC 4
5 45687 ELBOW ADAPTER MALE SWIVEL (NOT SHOWN) 4
24 Container Carrier Owners Manual
CAB FLOOR
PN 46152
ITEM PART DESCRIPTION QTY.
1 52902 CONTROL TOWER ASM 3SECT AIR 1
2 0345 CAP SCR 0.38-16X1.50 HHGR5 4
3 0346 WASHER 0.38 USS FLAT ZINC 8
4 0347 NUT 0.38-16 HHGR5 NYLOC 4
5 45687 ELBOW ADAPTER MALE SWIVEL (NOT SHOWN) 6
Installation 25
16
11 BOTH SIDES *
10
8
5 BOTH SIDES
1 BOTH SIDES
14 15
PN 46288
ITEM PART DESCRIPTION QTY.
1 25627 DECAL CRUSH POI NT 4
2 45697 DECAL CAUTION PTO SPEED (NOT SHOWN, PLACE IN CAB) 1
3 45726 DECAL WARNING HYDRAULIC SAFET74-276 1
4 45906 DECAL K-PAC HOIST UP (NOT SHOWN, PLACE IN CAB) 1
5 45971 DECAL DNGRSTAND CLEAR, KPCC 74-346 2
6 45972 DECAL CAUTION-LATCH KPAC (PLACE QTY1 IN CAB) 2
7 45973 DECAL CARRIER CNTRLS KPCC (NOT SHOWN, PLACE IN CAB) 1
8 45974 DECAL CAUTION-OPERATIN INSTR 74-345 1
9 45975 DECAL CAUTION-FORK CARRIAGE (PLACE QTY 1 IN CAB) 2
10 45976 DECAL DNGR WATCH ELEC LINES K74-347 1
11* 16094 DECAL STELLAR LOGO5.00X13.00REFLECT 2
12* 13002 DECAL HYD OIL SPECIFICATION (NOT SHOWN, PLACE ON RSRVR) 1
13 42971 DECAL OIL FILTER CHANGE (NOT SHOWN, PLACE ON RSRVR) 1
14 4214 DECAL CONTACT STELLAR 1
15 35234 DECAL STELLAR MADE IN THE USA 1
16 46655 PLATE SERIAL VALVE PLATE KPCC (NOT INCLUDED IN PN46288 DECAL KIT) 1
1. Grease the lift cylinder and fork cylinder 4. Check the overhead area for obstruc-
pivot points and the container carrier tions.
hinge pins.
5. Clear all equipment from under the rear
2. Fill the reservoir with 10 gallons of high of the container carrier.
quality of SAE 10 hydraulic oil i.e.: Arco
Duro 150, Harmony 32 AE by Gulf, or 6. Slowly extend the cylinders. Check for
Mobil DTE 25. binding.
Warning: Escaping fluid under pressure can 7. Raise and lower the fork frame and tilt
penetrate the skin can cause serious injury. the forks up and down.
Avoid the hazard by relieving pressure
before disconnecting hydraulic lines. 8. Extend the cylinders completely a third
Tighten all connections before applying time, and bleed off any entrapped air.
pressure. Search for leaks with a piece of
cardboard. Protect hands and body from 9. Check all connections and components
high pressure fluids. If an accident occurs, for leaks.
see a doctor immediately. Any fluid inject-
ed into the skin must be surgically removed 10. Retract the cylinders, pressurize the lines,
within a few hours or gangrene may result. and check for leaks.
Hose Kit
PN - PN 49534
49534
Installation 27
Hydraulic Schematic
TILT CYLINDERS
CONTROL
VALVE
7
4
LIFT CYLINDERS
8 ROTATOR MOTOR
Electrical Schematic
EXISTING TRUCK
WIRING HARNESS
BACK-UP LIGHT
TRUCK CAB (BLACK)
LH, TURN, BRAKE, LIGHT
HOIST UP
LIGHT (YELLOW)
WHITE GROUND TAIL, CLEARANCE, LIGHT
REMOTE (WHITE) (BROWN)
SWITCH
RH, TURN, BRAKE, LIGHT
COLORED (GREEN)
Note: The Hoist Up Light will only
be activated when the iginition is hot.
PTO GROUND
It is recommended to tap into the GROUND
PTO light power source when wiring.
LIGHT
TO FRAME
(WHITE)
PN 38056
CAPPED
(NOT USED) PN 12516
JUMPER TO MID-BODY
CLEARANCE LIGHTS
BACK-UP ALARM
(WHITE/BLACK)
Note:
Installed inside
TAG LIGHT of the frame rail.
(BROWN)
TAG LIGHT
(BROWN)
LH TURN/ LH TURN/ BACKUP
STOP STOP WHITE LIGHT
RED LIGHT RED LIGHT (WHITE/
REAR CLEARANCE RED CLEARANCE
(WHITE/ (WHITE/ BLACK) (BROWN/WHITE) (WHITE/BROWN)
BROWN/ BROWN/
RED CLEARANCE YELLOW) YELLOW)
(WHITE/BROWN) RH TURN/ RH TURN/
BACKUP STOP STOP
WHITE LIGHT RED LIGHT RED LIGHT
(WHITE/ (WHITE/ (WHITE/
BLACK) BROWN/ BROWN/
YELLOW) YELLOW)
Assembly Drawings 29
14 10
6
1
5
11
2
2
3
10
13
9
12
PN 45029
ITEM PART DESCRIPTION QTY.
1 0340 WASHER 0.25 USS FLAT ZINC 3
2 0347 NUT 0.38-16 HHGR5 NYLOC 9
3 0530 CAP SCR 0.38-16X2.75 HHGR5 6
4 1554 FTG ADAPT 8-F5OLO-S 4
5 1556 FTG ADAPT 8 C5OLO-S 4
6 3381 HOSE CLAMP BOLT ON 1210 CRANE 1
7 8621 CLAMP HOSE/TUBE AG-3 2
8 19369 HOSE CLAMP 4.13-7.00 5416K38 4
9 45012 BASE KPCC 1
10 45020 PIN 1.25X7.00 W/ HOLE 4
11 45031 PIN 1.25X9.44 W/ HOLE 2
12 45072 CYLINDER 4.00X32.00 2
13 45077 CYLINDER 4.00X29.00 2
14 45764 PLUG PLASTIC 6.00X6.00 SQ-6 2
30 Container Carrier Owners Manual
4
10
3 1
6
8
2
6
PN 45033
ITEM PART D ESCRIP TION Q TY.
1 44959 LIFT FRAME WLDMT KPCC 1
2 45023 PIN WLDMT 1.25X10.31 2
3 c1592 ZERK 1/8 NPT STRAIGHT 4
4 42660 COLLAR 0.53X0.75X1.00 UHMW 1
5 45106PC CATCH ARM WLDMT KPCC 1
6 0249 BUSHING BPC20DXR20 1.25X1.25 8
7 0530 CAP SCR 0.38-16X2.75 HHGR5 2
8 0347 NUT 0.38-16 HHGR5 NYLOC 2
9 20939 CAP SCR 0.50-13X6.50 HHGR5 1
10 C6106 NUT 0.50-13 HHGR5 NYLOC 1
Assembly Drawings 31
24
13 23 20 22 14 11 18
17
18
28
30
29
19
21
15 12
11
26 10 6 9 31
4
16
25
12
27
7
PN 47487
ITEM NO. PART DESCRIPTION QTY.
1 47488 FORK FRAME WLDMT CRANE GEAR KPCC 1
2 45024 PIN 1.25X6.06 W/ HOLE 2
3 45020 PIN 1.25X7.00 W/ HOLE 2
4 51303 CARRIAGE FRAME WLDMT ROTATOR EXT 1
5 D1034 CAP SCR 0.63-11X3.00 HHGR8 15
6 C1026 CAP SCR 0.63-11X2.50 HHGR8 15
7 45120 CAP SCR 1.25-7X4.50 HHGR8 2
8 0529 CAP SCR 0.38-16X2.50 HHGR5 5
9 C0936 CAP SCR 0.38-16X6.00 HHGR5 8
10 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 30
11 0346 WASHER 0.38 USS FLAT ZINC 16
12 44980 BUMPER CONTAINER CARRIER FORK 4
13 0343 WASHER 0.31 USS FLAT ZINC 4
14 0347 NUT 0.38-16 HHGR5 NYLOC 15
15 5223 NUT 1.25-7 HHGR5 NYLOC 2
16 45121 PIN 0.50X4.50 CLEVIS 2
17 45125 PIN HITCH 1.00 FORK KPCC 2
18 45216 PIN 0.31X2.75 WIRE LOCK 3
19 11458P MOTOR HYD ROSS MG100611AAAB 1
20 4032 BEARING SWING DRIVE 6000 1
21 D1295 CAP SCR 0.50-13X1.50 SH GR5 2
22 47489 PLATE SPACER FORK KPAC 1
23 0486 CAP SCR 0.31-18X1.50 HHGR5 4
24 45048PC LATCH STD CONTAINER CARRIER UNIQUE 1
25 45079PC PLATE 0.25 KPCC TRUNNION STOP 2
26 50003 BOLT CARRIAGE 0.38X4.00 2
27 47472 HAIR PIN CLIP 0.13X1.56 2
28 50481PC GUARD CONT CARRIER LZR 1
29 C2252 FTG ADAPT 8-10-F5OLO-S 2
30 C2376 FTG ADAPT 8-C6LO-S 2
31 51307 PLATE FORK CONTAINER CARRIER EXT 2
32 Container Carrier Owners Manual
2
16
19
5 15
14
13
10
9
5
8
7 4
17
18
10
20
6
3
19
11 12 6
7
PN 45066
ITEM PART DESCRIPTION QTY.
1 44962 FORK FRAME WLDMT KPCC 1
2 45020 PIN 1.25X7.00 W/ HOLE 2
3 45024 PIN 1.25X6.06 W/ HOLE 2
4 C0936 CAP SCR 0.38-16X6.00 HHGR5 4
5 0529 CAP SCR 0.38-16X2.50 HHGR5 5
6 0347 NUT 0.38-16 HHGR5 NYLOC 15
7 0346 WASHER 0.38 USS FLAT ZINC 16
8 44980 BUMPER CONTAINER CARRIER FORK 4
9 38106 PIN 0.38 SQUARED RETAINER SNAP 1
10 0530 CAP SCR 0.38-16X2.75 HHGR5 4
11 45120 CAP SCR 1.25-7X4.50 HHGR8 2
12 5223 NUT 1.25-7 HHGR5 NYLOC 2
13 45125 PIN HITCH 1.00 FORK KPCC 2
14 45216 PIN 0.31X2.75 WIRE LOCK 2
15 45121 PIN 0.50X4.50 CLEVIS 2
16 47472 HAIR PIN CLIP 0.13X1.56 2
17 45048PC LATCH STD CONTAINER CARRIER UNIQUE 1
18 45079PC PLATE 0.25 KPCC TRUNNION STOP 2
19 50003 BOLT CARRIAGE 0.38X4.00 2
20 51307 PLATE FORK CONTAINER CARRIER EXT 2
Assembly Drawings 33
24 20
25
23
25
6 26
4 21
29
2
9
18 7 28
19
30
17
8
22
12
3 14 27
15 27
2
1
5 15 10
16
11
12 13
PN 46285
ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY.
1 26455 RSRVR ASM 10GAL K MODEL 1 15 C1123 HOSE CLAMP 88 DB-20 2
2 c2242 ST EL 0.75 90 DEG BLK 2 16 C4747 NIPPLE O'RING 45 4603-20-16 1
3 3320 NIPPLE 0.75X12.00 PIPE 1 17 10094 GAUGE OIL LF 2.5" 0-500 BM 1
4 c6226 FILTER HEAD 1 18 16145 GAUGE PRES FILTER SERVICE CI20 1
5 C6229 FILTER LARGE AE-10L 1 19 30541 FTG ML O'RING/FM PIPE 6405-12-04 1
6 C6014 FTG ADAPT 8-12 FOLO-S 1 20 45087 PLATE 0.38X6.00X32.50 1
7 C5511 VALVE BALL 1.25 1 21 C0930 CAP SCR 0.31-18X3.00 HHGR5 3
8 C2282 FTG 1.25 NPT TO 1.25 BARB 1 22 0342 NUT 0.31-18 HHGR5 NYLOC 3
9 47150 VB V20 3-SECTION W/ LOCKOUT KPCC 1 23 12386 CAP SCR 0.50-13X7.50 HHGR5 4
10 46721 HOSE 0.50(381-JC-J9-8-8-8-84) 1 24 0352 WASHER 0.50 USS FLAT ZINC 16
11 31676 HOSE 0.50(471TC-JC-JC-8-8-8-120) 1 25 C6106 NUT 0.50-13 HHGR5 NYLOC 8
12 1554 FTG ADAPT 8-F5OLO-S 5 26 0500 CAP SCR 0.50-13X1.75 HHGR5 4
13 D0549 FTG ADAPT 16-8 F5OG5-S 1 27 C4227 FTG MF/MSTR 90 8-12 C5OLO-S 2
14 17767 HOSE SUCT 1.25 10FT 1 28 C4694 ST EL 1.25 90 DEG BLK 1
28 22
29
27
29 30
6
4 2 12
13
33
19
32
7 20
10 23
8 24
18
16 21
15
3
9
16
2 25
1 5 26 31
11
17
PN 46074
ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY.
1 26455 RSRVR ASM 10GAL K MODEL 1 15 17767 HOSE SUCT 1.25 10FT 1
2 c2242 ST EL 0.75 90 DEG BLK 2 16 C1123 HOSE CLAMP 88 DB-20 2
3 3320 NIPPLE 0.75X12.00 PIPE 1 17 C4747 NIPPLE O'RING 45 4603-20-16 1
4 c6226 FILTER HEAD 1 18 10094 GAUGE OIL LF 2.5" 0-500 BM 1
5 C6229 FILTER LARGE AE-10L 1 19 16145 GAUGE PRES FILTER SERVICE CI20 1
6 C6014 FTG ADAPT 8-12 FOLO-S 1 20 C2376 FTG ADAPT 8-C6LO-S 1
7 C5511 VALVE BALL 1.25 1 21 25630 FTG ADAPT 10-1/4 F5OG 1
8 C2282 FTG 1.25 NPT TO 1.25 BARB 1 22 45087 PLATE 0.38X6.00X32.50 1
9 46146 VB 2-SECT VDM8 AIR CYL SPOOLS 1 23 0483 CAP SCR 0.25-20X3.50 HHGR5 3
10 C2252 FTG ADAPT 8-10-F5OLO-S 5 24 052 1 WASHER 0.25 LOCK 3
11 46721 HOSE 0.50(381-JC-J9-8-8-8-84) 1 25 0340 WASHER 0.25 USS FLAT ZINC 3
12 31676 HOSE 0.50(471TC-JC-JC-8-8-8-120) 1 26 0333 NUT 0.25-20 HHGR5 NYLOC 3
13 1554 FTG ADAPT 8-F5OLO-S 1 27 12386 CAP SCR 0.50-13X7.50 HHGR5 4
14 D0549 FTG ADAPT 16-8 F5OG5-S 1 28 0352 WASHER 0.50 USS FLAT ZINC 16
Bumper Assembly
8
1
7
6
2
3
2
6
5 3
6 2
Warranty Information