SIꢀCable HoISt
ownerS’ꢀManual
SI-60 and SI-75 Models
Safetyꢀ•ꢀoperationꢀ•ꢀInstallationꢀ•ꢀParts
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
Subject to Change without Notification.
© 2012 Stellar Industries, Inc.
Last Revision: 05/25/12
Table of Contents
i
Table of Contents
ii
Stellar Cable Hoist 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 CABLE HOIST 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 cable hoist. Our goal in writing this manual was the safety of the operator and oth-
ers 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 cable
hoist. You shall make these available and known to all personnel working with and
around the equipment, so that all of you will take the necessary and required safety pre-
cautions.
FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
It is also your responsibility to operate and maintain your cable hoist with caution, skill,
and good judgment. Following the recognized safety procedures will help you avoid
accidents. Modification to any part of his cable hoist can create a safety hazard and
therefore shall not be made without the manufacturer’s written approval. Use only facto-
ry approved accessories, options, and parts on this equipment. The rebuilding or remount-
ing of this equipment requires the mounting procedures and retesting to be in accor-
dance with factory instructions. Safety covers and devices must remain installed and
maintained in proper working condition. Safety decals must be maintained, be com-
pletely 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!
is considered one of the manufacturers of
Attention!
the vehicle. As such a manufacturer, the
According to Federal Law (49 cfr part 571),
installer is responsible for compliance with all
each final-stage manufacturer shall com-
applicable federal and state regulations.
plete the vehicle in such a manner that it
They are required to certify that the vehicle
conforms to the standards in effect on the
is in compliance with the Federal Motor
date of manufacture of the incomplete
Vehicle Safety Standards and other regula-
vehicle, the date of final completion, or a
tions issued under the National Traffic and
date between those two dates. This require-
Motor Vehicle Safety Act.
ment shall, however, be superseded by any
Please reference the Code of Federal
conflicting provisions of a standard that
Regulations, title 49 - Transportation, Volume
applies by its terms to vehicles manufac-
5 (400-999), for further information, or visit
tured in two or more stages.
Therefore, the installer of Stellar cable hoists
the full text of Code of Federal Regulations.
Introduction
iii
Introduction
Stellar Cable hoists are designed to provide
safe and dependable service for a variety
of operations. With proper use and
maintenance, these cable hoists will
operate at peak performance for many
years.
manual contain information pertaining to
Stellar manufactured cable hoists 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
To promote this longevity, carefully study the time, any or all of the items, components,
information contained in this manual before
putting the equipment into service. Though
and parts deemed necessary for product
improvement or commercial/production
it is not intended to be a training manual for purposes. This right is kept with no
beginners, this manual should provide solid
guidelines for the safe and proper usage of
the cable hoist.
requirement or obligation for immediate
mandatory updating of this manual.
Once you feel comfortable with the
In closing:
material contained in this manual, strive to
exercise your knowledge as you safely
operate and maintain the cable hoist. This
process is vital to the proper use of the unit.
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 service@stellarindustries.com.
A few notes on this manual:
ATTENTION
A copy of this manual is provided with every
cable hoist and shall remain with the cable
hoist at all times. Information contained
within this manual does not cover all
maintenance, operating, or repair
Failure to adhere to the
instructions could result in
property damage or even serious
bodily injury to the operator or
others close to the cable hoist.
instructions pertinent to all possible situations.
Please be aware that some sections of this
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
Order Parts
Warranty Information
iv
Stellar Cable Hoist Owner’s Manual
Safety
1
Chapter 1 - Safety
Please Read the Following Carefully!
Always wear the prescribed personal safety
This portion of the manual contains informa- devices.
tion regarding all Stellar manufactured
Cable Hoists. Some items contained within
this chapter may not apply to your specific
equipment.
Always wear approved accident-preven-
tion 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.
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 fol-
lowing information should be read and
understood completely by everyone work-
Do not wear rings, wristwatch, jewelry,
loose-fitting or hanging clothing such as ties,
ing with or near the Cable Hoist prior to put- torn garments, scarves, unbuttoned jackets
ting the unit into operation.
or unzipped overalls, which could get
caught up in the moving parts of the Cable
Hoist.
Please take note that Stellar Industries, Inc.
is not liable for accidents incurred by the
Cable Hoist because of non-fulfillment from
the operator’s side of current rules, laws,
and regulations.
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.
General Safety
It is the responsibility of the owner to instruct Do not use controls and hoses as hand-
the operator in the safe operation of your
equipment and to provide the operator
with properly maintained equipment.
holds. These parts move and cannot pro-
vide stable support.
Do not allow unauthorized personnel or
Trainees or untrained persons shall be under equipment to enter within 10 feet of Cable
the direct supervision of qualified persons.
Hoist operating area.
Do not operate equipment under the
adverse influence of alcohol, drugs, or
medication.
Never allow anyone to ride the Cable Hoist
or load.
Operation Safety
Read all safety decals on the equipment
and understand their meaning.
Never operate the hoist unless the hydraulic
system, including the cylinders and lines, are
full of oil and free of air.
Personal Safety
Keep clear of all moving parts.
Check the area for power lines and over-
head obstructions.
Never allow anyone under any portion of
the hoist unless the hoist is firmly resting in
the hoist props.
Do not load, dump or unload a container
on uneven ground.
2
Stellar Cable Hoist Owner’s Manual
Do not move the truck while the hoist and Maintenance Safety
container are raised. A raised load creates Never modify or alter any of the equipment,
a top heavy unstable load.
whether mechanical, electrical, or
hydraulic, without Stellar Industries’
approval.
Do not use a chain between the reeving
cable and the container. A chain will not
withstand the force applied to the cable.
Be sure safety decals are clean and in
place.
Do not use any method to hold a valve
open which will not let the valve close auto- Check the reeving cable for wear and fray-
matically when released.
ing.
Always keep the cable centered on the
hoist frame. Do not allow the cable to rub
on any surface when loading or unloading
a container.
Do not perform any maintenance or repair
work on the Cable Hoist unless authorized
and trained to do so.
Release system pressure before attempting
to make adjustments or repairs.
Do not operate the reeving cylinders to
load or unload a container unless the front
of the hoist frame is above the top of the
truck cab.
Do not attempt service or repair when PTO
is engaged.
ATTENTION
Stellar Industries, Inc. is not liable for acci-
dents incurred by the Cable Hoist because
of the operator’s non-fulfillment of current
rules, laws and regulations.
Operation
3
Chapter 2 - Operation
Job-Site Set-Up
in place and in good operating condi-
tion.
Thoroughly plan the lift before positioning
the vehicle. Consider the following:
• 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 Cable
Hoist for physical damage.
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
• Check for fluid leaks.
come within the minimum required safe
distance of any power line. Maintain a
clearance of at least 10 feet between
any part of the Cable Hoist, load line, or
Operator Requirements
Operation is limited to the following people:
1. Qualified individual.
load, and any electrical line or apparatus 2. Trainees under direct supervision of the
carrying up to 50,000 volts. One foot qualified individual.
additional clearance is required for every 3. Test or maintenance individual.
additional 30,000 volts or less. Remember 4. Cable Hoist Inspector.
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.
Operators must:
1. Demonstrate the ability to understand all
decals, the owner’s manual, and any
other information required for safe opera-
tion of the Cable Hoist.
2. Be able to demonstrate the ability to
safely control the Cable Hoist.
3. Know all safety regulations.
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.
4. Be responsible for maintenance require-
ments.
Cable Hoist Controls
5. Understand and be fully capable of
implementing all emergency procedures.
6. Understand the operating procedures as
outlined by this manual, ANSI B30.5 and
Federal/State Laws.
1. Be familiar with the sequence and opera-
tion of the Cable Hoist controls.
2. Each individual Cable Hoist function
should have control function decals.
Replace them immediately if they are
missing or illegible.
Operator Conduct
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 Cable Hoist.
5. Be prepared before beginning operation
of the Cable Hoist:
1. Operators will not engage in any opera-
tion that would cause them to divert
attention away from the operation of the
Cable Hoist.
2. Operators are responsible for all opera-
tions under their direct control.
3. Operators will not leave a suspended
load unattended.
• 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
4. Operators will be familiar with the equip-
ment and the maintenance required for
proper care.
4
Stellar Cable Hoist Owner’s Manual
General Guidlines for Operation of the Cable Hoist
Loading a Container
3. Lower the hoist to the full-down position
and disengage the PTO.
1. Back the truck up to the container to be
loaded and align the hoist rails with the
container long sills. Caution: Be sure the
Unloading a Container (O.R. and I.O.)
area in which the hoist is to be operated 1. Back the truck up in front of where the
is clear of personnel and obstacles -
overhead and on the ground.
2. Engage the PTO and raise the hoist until
the rear roller is on the ground.
container is to be spotted. Allow room
for the container to roll off of the hoist.
2. Raise the hoist and retract the reeving
cylinders. Allow gravity to pull the con-
tainer to the ground.
3. Once the rear rollers are on the ground,
allow the truck to roll out from under the
container.
4. Once the container is on the ground,
lock the truck brakes and disconnect the
cable and secure it to the hoist.
5. Lower the hoist to the full down position.
Pull away from the container. Disengage
the PTO.
3. Set the parking brakes and retract the
reeving cylinders to connect the cable
to the container. Caution: Do not
attempt to load a container with faulty
equipment. Check the condition of the
cable, cable end, and container cable
connection. Never lift a container heav-
ier than the rated capacity of the hoist.
4. Relase the parking brake and allow the
truck to roll under the container. Extend
the reeving cylinders to pull the container
onto the hoist. The container long sills
must be kept on the hoist rollers.
5. Once the center of gravity of the con-
tainer is in front of the rear hinge, the
hoist can be lowered until the front is just
above the top of the truck cab.
6. Continue pulling the container forward
until it is securely locked into the front
stops. Caution: Rear hold-down devices
are required on the hoist and the con-
tainers.
Unloading a Container (Extendable Tail)
1. Back the truck up in front of where the
container is to be spotted. Allow room
for the container to roll-off of the hoist.
2. Raise the hoist and retract the reeving
cylinders. Allow gravity to pull the con-
tainer to the ground. Once the rear
rollers are on the ground, allow the truck
to roll out from under the container.
3. Alternate extending the cable and the
tail until the container is on the ground.
4. Lock the truck brakes and disconnect
the cable and secure it to the hoist.
5. Lower the hoist and retract the tail sec-
tion. Disengage the PTO before driving
away.
7. Lower the hoist to the full-down position
and disengage the PTO.
Dumping a Container
1. While the hoist is in the full-down position,
open the container door and secure it.
Caution: Be sure that the truck is on firm,
level ground before dumping. If one side
of the load breaks loose in this high cen-
ter of gravity position, a truck on unstable
footing may roll over on its side.
2. Engage the PTO and raise the hoist until
the load slides out of the container.
Caution: Do not pull forward until the
hoist is lowered to the full-down position.
Cable Hoist Check List
1. Check hydraulic oil level with all
cylinders retracted.
2. Grease all lubrication points.
3. All rollers and sheaves are free to
rotate.
4. Tires are properly inflated.
5. The container lock is free to move and
works properly.
Operation
5
Loading Operation
Back the truck up to the container
to be loaded and align the hoist rails
with the container long sills.
1
2
Engage the PTO and raise the hoist
until the rear roller is on the ground.
Set the parking brakes and retract
the reeving cylinders to connect the
cable to the container.
3
4
5
Release the parking brake and allow
the truck to roll under the container.
Extend the reeving cylinders to pull
the container onto the hoist. The
container long sills must be kept on
the hoist rollers.
Once the center of gravity of the
container is in front of the rear hinge,
the hoist can be lowered until the
front is just above the top of the
truck cab.
Continue pulling the container
forward until it is securely locked into
the front stops. Caution: Rear
hold-down devices are required
on the hoist and the containers.
6
7
Lower the hoist to the full-down
position and disengage the PTO.
6
Stellar Cable Hoist Owner’s Manual
Unloading Operation - O.R. and I.O. Models
Back the truck up in front of where the
container is to be spotted. Allow room
for the container to roll-off of the hoist.
1
2
Raise the hoist and retract the
reeving cylinders. Allow gravity to
pull the container to the ground.
3 Once the rear rollers are on the
ground, allow the truck to roll out
from under the container.
Once the container is on the ground,
lock the truck brakes and disconnect
the cable and secure it to the hoist.
4
5
Lower the hoist to the full down position.
Pull away from the container.
Disengage the PTO.
Operation
7
Unloading Operation - Extendable Tail Models
Back the truck up in front of where the
container is to be spotted. Allow room
for the container to roll-off of the hoist.
1
2
Raise the hoist and retract the
reeving cylinders. Allow gravity to
pull the container to the ground.
Once the rear rollers are on the
ground, allow the truck to roll out
from under the container.
Alternate extending the cable and
the tail until the container is on the
ground.
3
4
Lock the truck brakes and disconnect
the cable and secure it to the hoist.
5
Lower the hoist and retract the tail
section. Disengage the PTO before
driving away.
8
Stellar Cable Hoist Owner’s Manual
Correct Roll-Off Container Loads
Correct Container Position
Note: Removable front stops must
be used and rear hold downs must
match on container and roll-off
hoist.
Correct Position
For Short Container
Unsafe Roll-Off Container Loads
The Container is Too Long
Frame may crack or bend.
Load Center is Too Far to the Rear
Front Axle May Be Too Light
Frame may crack or bend.
Frame may crack or bend.
Front Axle May Be
Overloaded
Frame may crack or bend.
Frame may crack or bend.
Operation
9
Hoist Prop Operation
WARNING
BEFORE WORKING AROUND A
RAISED HOIST, THE HOIST
MUST BE SUPPORTED BY THE
HOIST PROP.
(SEE HOIST PROP OPERATING
INSTRUCTIONS)
FAILURE TO DO SO COULD RESULT IN
SERIOUS INJURY OR DEATH.
IF THE HOIST PROPS CANNOT BE
USED, CONSULT THE MAINTENANCE
SECTION OF THE OPERATION MANUAL
FOR THE PROPER PRECAUTIONS.
45553
10
Stellar Cable Hoist Owner’s Manual
Maintenance
11
Chapter 3 - Maintenance
Daily Inspection
Please read the following before performing any
maintenance on the Cable Hoist.
1. Only authorized service personnel are to perform
maintenance on the Cable Hoist.
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.
Daily Inspection should occur each day before the
Cable Hoist is put into use. Each day, inspect the
Cable Hoist 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 installa-
tion.
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.
5. Keep the Cable Hoist 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.
11. Inspect the wire rope for fraying or other wear.
7. Replace parts with Stellar Industries, Inc.
approved parts only.
8. Immediately repair or have repaired any com-
ponents found to be inadequate.
Monthly Inspection
Monthly Inspection should occur at the beginning
of every work month. Each month, inspect the
Cable Hoist for all of the following:
1. Frame bolt tightness - turn barrel nuts and mount-
ing bolts during the first month of operation on
new machines and then quarterly thereafter.
2. Cylinders and valves for leaks.
Maintenance Procedures
1. Position the Cable Hoist 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.
3. Lubrication.
4. Structural weldments for bends, cracks, or breaks.
5. All pins and keepers for proper installation.
6. All control, safety, and capacity placards for
readability and secure attachment.
7. Inspect all electrical wires and connections for
worn, cut, or deteriorated insulation and bare
wire. Replace or repair wires as required.
8. Lubrication of all points requiring lubrication.
4. Label or tag parts when disassembling.
Periodic Inspection
Periodic Inspection should occur while the Cable
Hoist is in use. For the duration of the usage,
inspect the Cable Hoist for all of the following:
1. Loose bolts and fasteners.
2. All pins, bushings, shafts, and gears for wear,
cracks, or distortion to include all pivot points,
and bushings.
3. Hydraulic systems for proper operating pressure.
4. Main frame mount bolts.
5. Cylinders for:
General Service
The following general suggestions should be helpful
in analyzing and servicing your Cable Hoist. Using
the following systematic approach should be help-
ful 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 compo-
nents against the cost of parts and labor neces-
sary to replace them.
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 dam-
age such as blistering, crushing, or abrasion.
8. Presence of this owner’s manual.
6. Make the necessary repair.
7. Recheck to ensure that nothing has been over-
looked.
8. Functionally test the new part in its system.
12
Stellar Cable Hoist Owner’s Manual
Inspection of Sheaves
Under normal conditions, machines should
receive periodic inspections, and their over-
all condition recorded. Such inspections
usually include the sheaves, and any other
parts that may come into contact with the
wire rope and subject it to wear. As an
additional precaution, rope related working
parts, particularly in the area described
below, should be re-inspected prior to the
installation of a new cable.
The very first item to be checked when
examining the sheaves is the condition of
the grooves. To check the size, contour and
amount of wear, a groove gage is used. As
shown in the illustration to the right of this
paragraph, the gage should contact the
groove for about 150º of arc.
Two types of groove gages are in general
use and it is important to note which of these
is being used. The two differ by their respec-
tive percentage over nominal.
Cross-sections illustrating three sheeve-groove conditions.
A is correct, B is too tight, and C is too loose.
For new or re-machine grooves, the groove
gage is nominal plus the full oversize per-
centage. The gage carried by most wire
rope representatives today is used for worn
grooves and is made nominal plus 1/2 the
oversize percentage.
The latter gage is intended to act as a sort
of “no-go” gage. Any sheave with a groove
smaller than this must be replaced or, in all
likelihood, the existing rope will be dam-
aged.
Experience has clearly demonstrated that
the service life of the wire rope will be mate-
rially increased by strict adherence to these
standards.
Cross-sections illustrating three sheeve-groove conditions.
A is correct, B is too tight, and C is too loose.
Maintenance
13
Cable Replacement
Important: Standard replacement cable must be 7/8” diameter 6 x 37 extra improved plow steel
with steel core (6 x 37 EXIWRC) with a 4.00” swaged button x 75’ (174” & 182” CT, or) 77 feet (194”
CT) in length.
1. Remove the cable clamps and discard the old cable.
2. Inspect all the sheaves (See Inspection of Sheaves on page 12).
3. Install cable end onto cable. Thread cable through sheaves and guides, etc. Loop cable
through cable anchor and install clamps following the diagram below. Torque all bolts evenly
to 225 ft. lbs.
CABLE CLAMP DETAIL
20.00
20.00
20.00
5.00
D
A
B
C
CLAMP INSTRUCTIONS
1. INSTALL CLAMP "A" TORQUE NUTS TO 225 FT-LBS.
2. INSTALL CLAMP "B" SNUG NUTS ON CABLE.
3. INSTALL CLAMPS "C" & "D" AS SHOWN SNUG NUTS.
4. APPLY TENSION TO CABLE.
5. TORQUE NUTS ON "B", "C" & "D" TO 225 FT-LBS.
6. CLAMP NUTS MUST FACE DOWN.
Cleanliness
An important item in preserving the long life of the cable hoist is keeping
dirt, grime, and corrosive material out of the working parts. Thoroughly
wash and grease the cable hoist periodically.
14
Stellar Cable Hoist Owner’s Manual
Choice Lubricants for DX Bearings
Greases Recommended
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
Calcium Based with EP Additives
Lithium Based
Anti-Friction Bearing
Sodium Based
Extreme Pressure (EP)
Lithium Based with EP Additives
Calcium Based with EP Additives
High Temperature
Transmission
Modified Sodium Based, High Drop Point
Semi-Fluid, Calcium Based
Molybdenum Filled
Graphite Filled
Block Grease
Lithium Based with 2% Molybdenum Disulfide
Sodium Based with 2% Graphite
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 Not Recommended
Description
Type of Grease
Cup Grease
Graphite Filled
Light Service Calcium or Sodium Based Grease
Greases with More than 10% Graphite
Greases with More than 10% Molybdenum Disulfide
Molybdenum Filled
Fluorocarbon
Low Molecular Weight Chlorofluoroethylene Polymer
with Inert Thickeners
White Grease
Calcium Based, Zinc Oxide Filled
Specifications
15
Chapter 4 - Specifications
Chassis C.T.:
See chart on next page.
Frame Width:
Minimum GVWR:
Frame Height:
Sub-Frame:
35-1/2”
18,000 lbs. Front, 44,000 lbs. Rear
43”
Full length 2 x 4 Tube
60,000 lbs., 75,000 lbs.
47º
Load Rating:
Dump Angle:
Operating Pressure:
Gear Pump:
1,850 PSI (60,000 lbs), 2,150 PSI (75,000 lbs)
35 GPM @ 1,500 RPM
Operation:
Inside Cab Cable Controls Standard
Weight:
6,400 lbs. - 7,400 lbs.
Twin Double Acting
Cylinders:
6 x 72
7 x 80
7 x 90
Lift
Model SI-60/75
Model SI-60/75
Model SI-60/75
Reeving
Reeving
Low Pressure Hydraulic System
Gear Driven Hydraulic Pump
Large 3” Rear Pivot Pin
Hold-down compatible with ANSI Z245.6 Type “U” Containers
16
Stellar Cable Hoist Owner’s Manual
Cable Hoist Dimensions
Specifications Chart
CT (Cab to Trunnion)
Models
A
B
C
D
w/o Autotarper w/ Autotarper
SI-60-174 OR/IO
SI-60-182 OR/IO
SI-60-194 OR/IO
281”
289”
301”
210”
218”
230”
174”
174”
186”
35.5”
35.5”
35.5”
174”
182”
194”
180”
188”
200”
CT (Cab to Trunnion)
Extended Tail Models
SI-60-174 ORX
SI-60-182 ORX
SI-60-194 ORX
SI-60-174 IOX
A
B
C
D
w/o Autotarper w/ Autotarper
237”
210”
218”
230”
210”
218”
230”
174”
174”
186”
174”
174”
186”
35.5”
35.5”
35.5”
35.5”
35.5”
35.5”
174”
182”
194”
174”
182”
194”
180”
188”
200”
180”
188”
200”
245”
257”
278.5”
286.5”
298.5”
SI-60-182 IOX
SI-60-194 IOX
*
*Autotarper installation requires 12” of unobstructed space behind the truck cab.
Specifications
17
Container Subframe
NOTE:
ALL DIMENSIONS ARE IN ACCORDANCE WITH
ANSI Z245.60 TYPE "U" CONTAINER REQUIREMENTS
FRONT VIEW
MAX. 41.00
GUIDE ROLLER
GROUND WHEEL
MIN. 3.38
MAX. 3.63
TYPICAL REAR
HOLDDOWN
2" X 6" STANDARD
STRUCTURAL TUBING
LEAD-IN-ROLLER
PICKUP HOOK
MIN. 6.00
MAX. 10.50
SIDE VIEW
MIN. 3.38
MAX. 3.63
MIN. 18.50
MAX. 24.00
MAX. 2.13
GROUND WHEEL
193.00 *SEE NOTE*
*LONG RAIL LENGTH*
*NOTE*
IF LONG RAIL LENGTH IS GREATER THAN OR EQUAL TO 12FT. AND LESS THAN
18FT, REAR HOLDDOWN DIMENSION IS 147.50 IN. PLUS 1 IN. MINUS 0 IN. FROM
FRONT OF LEAD-IN-ROLLER TO THE FRONT OF THE HOLDDOWN.
IF LONG RAIL LENGTH IS GREATER THAN OR EQUAL TO 18FT. AND LESS THAN
24FT, REAR HOLDDOWN DIMENSION IS 193.00 IN. PLUS 1 IN. MINUS 0 IN. FROM
FRONT OF LEAD-IN-ROLLER TO THE FRONT OF THE HOLDDOWN.
18
Stellar Cable Hoist Owner’s Manual
Decals
19
Chapter 5 - Decals
Decal Kit Placement
11
17
16
12
24
18
7
16
16
3
10
13
19
14
Item
1
2
3
4
PN
Description
Qty.
2
2
2
2
45702 TAPE CONSPICUITY YELLOW 9.00 IN a
45701 TAPE CONSPICUITY RED 9.00 IN b
16094 DECAL STELLAR LOGO5.00X13.00REFLECT
46657 DECAL TAIL
5
45981 DECAL WINCHc
2
6
46071 DECAL HOIST
2
7
45553 DECAL WARNING RAISED HOIST
45807 VALVE PLATEd
2
8
1
9
45691 DECAL HOIST INSTRUCTIONS
45692 DECAL WARNING CONTAINERe
45693 DECAL CAUTION OPERATION
45694 DECAL PROP INSTRUCTIONS
45695 DECAL WARNING UNEVEN GROUNDe
45696 DECAL DANGER POWER LINES HOIST e
45697 DECAL CAUTION PTO SPEEDc
25627 DECAL CRUSH POINT
45698 DECAL WARNING CABLE e
45557 DECAL DANGER STAND CLEAR
C5942 PLATE SERIAL # STELLAR TRUCKS
45699 DECAL ICC BUMPER REQUIREMENT c
45906 DECAL HOIST UPc
1
2
1
2
2
2
1
6
2
2
1
1
1
1
1
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
49546 TAPE CONSPICUITY RED/WHITE 38.00FT f
49547 TAPE CONSPICUITY WHITE 4.00FT f
35234 DECAL STELLAR MADE IN THE USA
d ON TOP OF HYD. RSRVR (NOT SHOWN)
e QTY 1 IN CAB (NOT SHOWN)
SEE PAGE 38 FOR PLACEMENT (NOT SHOWN)
a ON FRONT OF REAR FENDER (NOT SHOWN)
b ON BACK OF REAR FENDER (NOT SHOWN)
c IN CAB (NOT SHOWN)
f
Note: See page 41 for Reflective Tape Placement.
20
Stellar Cable Hoist Owner’s Manual
Safety Decals of Note
WARNING
WARNING
CRUSHING HAZARD
BEFORE WORKING AROUND A
RAISED HOIST, THE HOIST
MUST BE SUPPORTED BY THE
HOIST PROP.
(SEE HOIST PROP OPERATING
INSTRUCTIONS)
Moving parts can
crush and cut.
Keep hands and
arms clear.
FAILURE TO DO SO COULD RESULT IN
SERIOUS INJURY OR DEATH.
IF THE HOIST PROPS CANNOT BE
USED, CONSULT THE MAINTENANCE
SECTION OF THE OPERATION MANUAL
FOR THE PROPER PRECAUTIONS.
25627
45553
DANGER
WARNING
DO NOT ATTEMPT TO LOAD A CONTAINER
UNLESS THE HOIST AND CONTAINER ARE
CORRECTLY ALIGNED.
STAND CLEAR
KEEP THE CONTAINER RAILS SAFELY
ENGAGED WITH THE HOIST RAILS AND
ROLLERS.
WHEN THIS UNIT IS IN OPERATION!
FAILURE TO DO SO COULD RESULT IN
SERIOUS PERSONAL INJURY.
FAILURE TO DO SO COULD CAUSE THE
CONTAINER TO SLIDE OFF THE SIDE OF
THE HOIST OR JAM ON THE RAILS.
45557
45692
WARNING
CAUTION
DO NOT LOAD, UNLOAD OR
DUMP CONTAINER ON
UNEVEN GROUND.
DO NOT ATTEMPT TO OPERATE
THIS EQUIPMENT WITHOUT PROPER TRAINING.
A LOADED CONTAINER CREATES A TOP
HEAVY LOAD. USE CAUTION WHEN
DRIVING ON UNEVEN GROUND AND
TURNING CORNERS.
PERSONAL INJURY AND EQUIPMENT DAMAGE
CAN OCCUR IF THIS EQUIPMENT IS USED IMPROPERLY.
READ AND UNDERSTAND THE OPERATION MANUAL.
SERIOUS PERSONAL INJURY AND
EQUIPMENT DAMAGE COULD RESULT.
45695
45693
DANGER
BE AWARE OF POWER
LINES AND OVERHEAD
OBSTRUCTIONS.
CAUTION
DO NOT EXCEED 1600 ENGINE
CONTACT BY THE HOIST OR
CONTAINER COULD CAUSE
SERIOUS INJURY OR DEATH
TO THE OPERATOR AND
BYSTANDERS.
RPM WHEN OPERATING
POWER TAKE OFF!
45697
45696
WARNING
WARNING
RAISE HOIST ABOVE THE TOP
OF THE TRUCK CAB BEFORE
LOADING OR UNLOADING A
CONTAINER, UNLESS A CAB
GUARD IS INSTALLED.
Escaping fluid under pressure can penetrate the skin causing serious injury
or death. Relieve pressure before disconnecting hydraulic lines, tighten all
connections before applying pressure, and inspect all lines before
each use. See "Safety" section in operation manual for additional
information.
If an accident occurs, see a doctor immediately. Any fluid
CABLE FAILURE COULD RESULT
IN SERIOUS PERSONAL INJURY
AND EQUIPMENT DAMAGE.
injected into the skin must be surgically removed within a
few hours or gangrene may result.
45726
74-276
45698
Installation
21
Chapter 6 - Installation
General Install Guidelines
Cable Hoist Mounting and Assembly
teners are used, these should only be tight-
Study names and locations of the parts and ened to the strength of the original.
familiarize yourself with the Cable Hoist
before starting the assembly . Reading the
step-by-step instructions that follow will be
helpful.
Tighten plastic insert or crimped steel-type
lock nuts to approximately 110 percent of
the dry torque values shown in the chart
below, applied to the nut, not to the bolt
head. Tighten toothed or serrated-type
lock nuts to the full torque value.
Safety
Read all of the safety notations in the
assembly instructions for your protection.
Accidents can be prevented by recogniz-
ing the cause of an accident before it can
happen.
Note: “Lubricated” means coated with a
lubricant such as engine oil, or fasteners
with phosphate and oil coatings. “Dry”
means plain or zinc plated without lubrica-
tion. Tighten lubricated bolts to approxi-
mately 80% of dry bolts.
Assembly
Select an area for assembly that will be
large enough to accommodate the com-
pleted unit. The surface of the work area
should be as level as possible. Use the
proper hand tools to ensure proper bolt
tightness. Refer to the chart below for the
recommended torque values for different
sizes of bolts.
Grade 5
Grade 8
Grade 9
Size
(DIA-TPI)
Bolt DIA Plain Plated Plain Plated Plated
(Inches)
(Ft-Lb)
(Ft-Lb)
(Ft-Lb) (Ft-Lb)
(Ft-Lb)
5/16-18 0.3125
3/8-16 0.3750
7/16-14 0.4375
1/2-13 0.5000
9/16-12 0.5625
5/8-11 0.6250
3/4-10 0.7500
17
31
49
75
110
150
265
395
590
795
13
23
37
57
25
44
70
105
155
220
375
605
910
1290
18
33
52
22
39
63
96
139
192
340
549
823
1167
1646
2158
2865
80
Recommended Torque Values in Foot
Pounds
For SAE GRADE 2 and GRADE 5 coarse
thread cap screws and bolts shown are
suggested maximum for fasteners, carrying
only the residue oil of the manufacturer.
82
115
160
280
455
680
965
115
200
295
445
595
840
7/8-9
1-8
0.8750
1.000
1 1/8-7 1.1250
1 1/4-7 1.2500 1120
1 3/8-6 1.3750 1470 1100 2380 1780
1 1/2-6 1.500 1950 1460 3160 2370
1815 1360
Proper Bolt Use
Do not use these values if a different torque Model Number
value or tightening procedure is given for a Know the model number of the Stellar
specific application. Torque values listed Cable Hoist being mounted. Use this model
are for general use only. Check tightness of number whenever referring to the assembly
fasteners periodically.
or parts listing pages. The number is
stamped on the name plate which is locat-
ed on the front frame member.
Sheer bolts are designed to fail under pre-
determined loads. Always replace shear
bolts with identical grade.
Right and Left sides can be established by
standing behind the truck frame and look-
ing towards the front, or the direction of
travel.
Fasteners should be replaced with the
same or higher grade. If higher grade fas-
22
Stellar Cable Hoist Owner’s Manual
Truck Chassis Specifications
See the illustrations on pages 15-17 at the front of this manual for specific details.
Front: 18,000 lbs.
Minimum Axle Rating:
Rear: 44,000 lbs. with walking beam type suspension
Total RBM per frame rail = 2,400,000 in-lbs. (both channels)
Frame Strength:
Section Modulus (minimum) = 32 in3 for 36,000 PSI steel
Section Modulus (minimum) = 24 in3 for 55,000 PSI steel
Important: If your truck chassis height exceeds the 45” dimension, or tire dimension is
greater than 102”, the O.R.X. or I.O.X. hoist should be considered.
1. Thoroughly check the truck requirements to ensure proper clearance and frame
strength before mounting the hoist. Note: The rear cab boundary is the rearmost
unremovable protrusion behind the cab and above the chassis frame.
2. The CT, from the rear of the cab boundary to the center of the walking beam suspen-
sion, is shown in the table below:
Cab to Trunnion
Model
Relocate the rear axles as required.
w/o Tarper
SI60-174 174 Inches
SI60-182 182 Inches
SI60-194 194 Inches
With Tarper
180 Inches
188 Inches
200 Inches
Stellar Autotarper must have 10”
to 12” unobstructed space behind
cab for installation.
Step 1: Truck Frame Cut-Off
Measure and mark the truck frame as shown below. Use the dimensional drawings on
the following pages to determine where to mark the first vertical cut on the frame rail.
Measure assembled hoist to be sure that adequate room is available behind truck cab;
between bumper and tires; and between fender and tires. This verifies that a measure-
ment error has not been made either in the CT (Cab to Trunnion) or cut-off dimension.
After double checking your measurements, step-cut the truck frame as shown below.
Cab Boundary
Refer to dimensional drawings on the following pages
for placement of step cut in relation to cab boundary.
6-9/16
FRAME RAIL
11-3/4
Installation
23
Dimensions: 174 Models
Dimensions To Chassis Frame Rail
Forward Mount
9 - 9/16
2 - 1/4
11
281 - 1/4
8 - 9/16
24
86 - 1/2
87 - 7/16
9
26 - 5/8
25 - 13/16
21 - 3/4
43
Chassis Frame Height
14
Rearmost Axle
To First Cut
55
174
C.T.
206 - 15/16
Dimensions To Chassis Frame Rail
Reverse Mount
11
2 - 1/4
9 - 9/16
281 - 1/4
26 - 5/8
9
176 - 3/4
68 - 7/8
107 - 7/8
8 - 9/16
25 - 13/16
43
Chassis Frame Height
14
Rearmost Axle
To First Cut
21 - 3/4
55
174
C.T.
206 - 15/16
Dimensions to Chassis Frame Rail
11
9 - 9/16
2 - 9/16
Telescopic Mount
281 - 1/4
2 - 3/4
55 - 1/4
139 - 15/16
8 - 9/16
25 - 13/16
21 - 3/4
43
Chassis Frame Height
14
Rearmost Axle
to First Cut
9
55
174
C.T.
206 - 15/16
24
Stellar Cable Hoist Owner’s Manual
Dimensions: 182 Models
Dimensions to Chassis Frame Rail
9 - 9/16
2 - 1/4
11
Forward Mount
289 - 1/4
8 - 9/16
32
86 - 1/2
87 - 1/2
26 - 5/8
9
25 - 13/16
21 - 3/4
43
Chassis Frame Height
14
Rearmost Axle
to First Cut
55
182
C.T.
214 - 15/16
Dimensions to Chassis Frame Rail
2.22
11.00
Reverse Mount
9.56
289 - 1/4
26 - 5/8
176 - 3/4
107 - 7/8
8 - 9/16
9
86 - 1/2
25 - 13/16
43
Chassis Frame Height
14
Rearmost Axle
to First Cut
21 - 3/4
55
182
C.T.
214 - 15/16
Dimensions to Chassis Frame Rail
11
9 - 9/16
2 - 9/16
Telescopic Mount
289 - 3/8
6 - 7/16
2 - 7/8
26 - 5/8
147 - 15/16
9
21 - 3/4
25 - 13/16
43
Chassis Frame Height
14
Rearmost Axle
to First Cut
55 - 1/4
55
180
C.T.
215 - 1/16
Installation
25
Dimensions: 194 Models
Dimensions to Chassis Frame Rail
Forward Mount
9 - 9/16
2 - 1/4
11
301 - 1/4
8 - 9/16
44
86 - 1/2
9
87 - 7/16
25 - 13/16
21 - 3/4
43
Chassis Frame Height
14
Rearmost Axle
to First Cut
55
194
C.T.
226 - 15/16
Dimensions to Chassis Frame Rail
9 - 9/16
11
2 - 1/4
Reverse Mount
301 - 1/4
176 - 3/4
26 - 5/8
8 - 9/16
23 - 9/16
9
86 - 1/2
21 - 3/4
25 - 13/16
43
Chassis Frame Height
14
Rearmost Axle
to First Cut
55
194
C.T.
226 - 15/16
Dimensions to Chassis Frame Rail
Telescopic Mount
9 - 9/16
2 - 9/16
11
301 - 1/4
8 - 9/16
52 - 1/8
26 - 5/8
9
148 - 3/16
21 - 3/4
43
25 - 13/16
Chassis Frame Height
14
Rearmost Axle
to First Cut
55
55
194
C.T.
226 - 15/16
26
Stellar Cable Hoist Owner’s Manual
Step 2: Mount Hoist
Note: Refer to the illustration on the previous pages.
A. Position the hoist sub-frame onto truck frame, aligning and squaring up with truck
frame, clamp and then heavily tack in place.
B. Continue to fully weld the hoist rear apron to the truck frame. Weld 100% 3/8” weld
both sides of truck frame to hoist sub-frame:
A
.38
W=.38
TYP. (2)
DETAIL A
SCALE 1 : 8
(.25)
.38
TYP. (2)
.38
TYP. (2)
.38
.38
6
.38
TYP. (2)
TYP. (2)
.38
C. Weld the gussets onto the hoist apron:
.19
TYP. (2)
.19
ITEM PART
45129
DESCRIPTION
PLATE SIDE
QTY.
1
1
1
TYP. (2)
.19
3
TYP. (2)
.19
3
Installation
27
Step 3: Mount Lift Cylinders
A. Check frame for bolts, rivets, etc. and clearance required (Refer to the previous
pages) before placing the Lift Cylinder Weldment into place under the hoist sub-frame.
B. Install the cylinder weldment cross tube.
C. Install the Lift Cylinders and extend each cylinder rod 1/4”. Check the shaft to cylinder
dimension on both sides. Standard Lift Cylinders dimension should be 88 1/4” plus or
minus1/8”. Telescopic Cylinder dimension should be 61-1/4” plus or minus 1/8”. Be sure
to install proper cylinder shaft hardware so that Lift Cylinders do not interfere with truck
frame or bolts. The lift cylinders will precisely locate the lift cylinder weldments.
88.25 .13
DIMENSION WHEN INSTALLING.
Figure A
ACTUAL RETRACTED DIMENSION IS 88"
D. Clamp the Lift Cylinder Weldment in place and drill ten (10) 11/16” diameter holes as
per Figure B.
Figure B
TYPICAL BOLT HOLE PATTERN
11/16" DIAMETER DRILL
MOUNTING KIT - BOLTED ON
TRUCK FRAME
TRUCK FRAME
PN 24868
NUT 0.63-11
HHGR8 NYLOC
PN C5902
WASHER 0.63 SAE
FLAT YELLOW GR8
TYP 4
TYP 2
0.25
PN C1026
CAP SCR 0.63-11X2.50
HHGR8
0.25
TYP 2
0.25
TYP. 4
TYP. 4
0.25
0.19
1.00
28
Stellar Cable Hoist Owner’s Manual
Mount Lift Cylinders Continued...
E. Bolt the Lift Cylinder Weldment to the truck frame using the supplied hardware.
F. (FORWARD MOUNT ONLY) Weld the Lift
FRONT
Cylinder Weldment to the sub-frame as
shown in Figure C. Remove any gap
between the weldment and sub-frame
before welding.
TYP 2
0.38
4-7.63
G. Make sure the cylinder cross tube is cen-
tered. Weld the cylinder cross tube. (See
Figure B)
NOTE: Do not weld to truck frame. Welding
anywhere on the truck frame in front
of the rear spring shackle will likely void the
truck manufacturers warranty.
Figure C
H. Install the outside washers, collars, etc. to
secure Lift Cylinders at rod and butt end.
Refer to page 68 for mounting kit assembly
drawing.
Step 4: Hydraulic Reservoir Installation
Note: See Chassis Mounted Parts and Reservoir Tank Assembly Drawings for details
.
1. Assemble valve, hoses, etc. to tank before mounting tank. Label hoses per illustration.
2. Position and clamp the Tank Mounting Bracket approximately 22” behind the rear of
the cab boundary per illustration. Note: It may be necessary to relocate air tanks, fuel
tanks, battery cases or any other accessories mounted in the area. Check both sides
for clearance on hydraulic tank and toolbox mounting.
3. Drill six (6) 1/2” diameter holes as shown in illustration. Use six (6) 1/2 NC x 2-1/2”GD8
Cap Screws torqued to 80 ft. lbs. and six (6) 1/2 NC GD8 locknuts.
4. Install the Close Nipple, Ball Valve, and Hose Barb onto the Tank Assembly.
5. Remove the Tank Assembly and drill 3/8” diameter holes on the marks.
6. Re-Install the tank and tighten the set screws into the drilled holes. Tighten the jam nuts.
7. Note: Petro-Canada Hydrex 32 (ISO 32) hydraulic oil is recommended.
Installation
29
Step 5: Sub-Frame Front Clamp Installation
Before proceeding any further, it
5/8”NC x 2-1/2”
GD5 Cap Screw
is necessary to raise the hoist
and set it down on the hoist
props.
1. Position the L-shaped clamp
between the sub-frame and
truck frame as shown below.
2. Assemble the lower clamp
and two (2) shims with a
Hoist
Sub-Frame
5/8” STD.
Flat Washer
Weld
Weld
Sub-Frame
Clamp
5/8NC x 2-1/2” GD. 5 Cap
Screw, two (2) Flat Washers
and Self Locking Nuts. Trim the
lower clamp as required to
clear the frame channel.
Note: Stair-step the shims so fil-
let welds can be applied.
3. Tighten the bolts to the speci-
fied torque and weld the
plates and shims in position.
4. Do not weld to truck frame.
Sub-Frame
Shim
Truck
Frame
Sub-Frame
Clamp
5/8” STD.
Flat Washer
5/8” NC
Lock Nut
POSITION CLAMP HERE
FOR REVERSE MOUNT MODELS
FRAME RAIL
POSITION CLAMP HERE
FOR FORWARD MOUNT MODELS
Step 6: Hydraulic Plumbing Installation
Clean all hydraulic components and keep all hoses, tubes, valves, and fittings capped
until they are installed. Use pipe sealant on pipe thread joints only. (Do not use teflon
tape).
1. Install fittings and hoses as shown in parts illustration.
2. Note single stage Lift Cylinder plumbing and Telescopic Cylinder plumbing are different.
See hydraulics schematic/drawing for details.
30
Stellar Cable Hoist Owner’s Manual
Step 7: Hydraulic Relief Pressure Setting
1. Locate the pressure gauge facing front of truck.
2. Loosen Jam Nut.
3. Using allen wrench, adjust to proper pressure. See
Chapter 4: Specifications for pressure specifica-
tions.
4. Tighten Jam Nut, holding adjustment screw in posi-
tion.
5. Test unit for proper operation, readjust to correct
pressure if needed.
6. Retest unit checking leaks and proper operation.
Step 8: Cable Control Installation
The standard cable controls supplied with Stellar equipment are high-quality assembly
which seal out moisture, are corrosion protected, and engineered to minimize backlash
(lost motion). After the hoist and hydraulic tank are mounted to the truck chassis, the
remote cable controls may be installed.
Cable Control Mounting:
1. On the hydraulic control valve, remove the screws holding the spool cover plate.
Position the handle assembly on the valve face and install the screws provided with the
handle kit. Install the clevis pin and cotter pin.
2. Mount the valve to the underside of the mounting plate located on the top of the
hydraulic tank assembly with the handles sticking up through the rectangular cutout.
3. Position the control cable bulkhead plate on the top of the hydraulic tank assembly.
Install the control cable bulkhead plate with 1/2” cap screws and nuts, or weld. If nec-
essary, temporarily assemble the threaded cable end to the bulkhead plate for proper
positioning with the valve handles.
4. Mount the cable controllers to the
Flush
Mounting
Side
Mounting
Banked
Together
control mount supplied. Other
mounting options are shown in the
following illustration (parts not sup-
plied).
Important:
a. A good cable path is essential
for a properly operating sys-
tem. Keep bends in the cable
path to a minimum and as
generous as possible. Under no circumstances should any bend be tighter than
an 8” radius.
b. Protect the cable from heat above 225ºF and avoid hot areas such as the
exhaust system, etc.
c. Protect the cable from physical damage such as pinching or crushing and do
not use cable supports which may crush or deform the cable.
d. Allow room for flexing where the cable is attached to moving parts of the equip-
ment so that the cable is neither kinked nor stretched.
Installation
31
Cable Control Installation Continued...
5. Choose a mounting location which is convenient and comfortable for the operator
and provides adequate clearance for the control lever movement. Check the under-
side of the cab for reinforcement members, air lines, wiring harnesses, and linkages
before cutting into the floor. Be sure the location chosen allows the cable to be led
easily away from the control. Reversing control direction usually is not necessary. In
most cases, the direction of the lever movement for a given valve function can be
changed by switching the hydraulic lines at the valve. If this is not an option, control
operation can be changed simply by turning the cable controller 180º.
6. Cut a hole for the control cables to pass through.
7. If using the control mount provided, mark and drill four (4) 3/8” diameter holes for the
3/8” x 1-1/2” cap screws provided.
Cable Connections:
1. Remove the screw from
the cable controller
where the cable end
will install. Do not
remove the other
screws passing through
the cable control hous-
ing.
2. Screw the hex thread-
ed cable end into the
cable controller end.
3. 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.
4. Check the control for free movement and correct valve control.
5. To connect the cable to the valve handle, start be removing the mounting nut from the
cable assembly. (Large nut in the photo above).
6. Install the threaded portion of the cable assembly through the bulkhead weldment and
replace the mounting nut.
7. Install the clevis provided to the cable
end. The cable end should be parallel
to the bulkhead weldment.
8. Located the clevis on the control valve
handle. If a hole is not provided in the
control valve handle for the clevis, drill a
.375” diameter hole through the valve
handle as illustrated. Install pin and
keeper included with clevis.
Control Cable
Bulkhead Plate
Drill .375 DIA
hole through
handle if
hole is not
present.
1-1/2”
Valve
9. Do a final check of the controls for free
movement and correct valve control.
32
Stellar Cable Hoist Owner’s Manual
Step 9: Pneumatic Control Installation
The pneumatic controller provided with the Stellar Cable Hoist are dual three-way regulat-
ing valves. Output of the controllers is proportional to the control lever position and is bal-
anced against the force of an internal spring.
Pneumatic Actuator Installation:
The pneumatic actuator has been partially assembled and pre-lubricated for ease of
installation. The actuator does not have to be disassembled for installation.
1. Remove the valve from the hydraulic tank if previously installed.
2. Find a suitable area free of dust and dirt to attach the pneumatic actuators.
3. Set the hydraulic valve on its mounting base.
4. Determine which spools are to be pneumatically controlled.
5. From the valve assembly:
a. Remove and discard the 1/4” retainer screws
Hex. Slot
and the valve spring cover.
b. Retain the handle end of the spool. Using a
5/16” hex Allen wrench, remove and discard
the 3/8” shoulder bolt and washer from the
end of the valve spool exposed by the
removal of the valve spring cover. Note: It
may be necessary to give the hex Allen
wrench a sharp rap to break the socket head
screw loose.
c. Remove and discard the original centering spring. Keep the two original centering
cups and the sleeve for reuse.
d. Ensure the original seal retainer on the valve spool is properly seated.
6. Assemble the new centering spring (item 2)
Spool
Centering Cups
supplied with the pneumatic actuator using
the original centering cups and sleeve as
shown.
7. Apply a small bead of removable thread lock
to the threads of the spool adapter (item 2).
Holding the spool on the opposing end, hand
Seal Retainer
tighten (torque 45-50 in-lbs) in the centering
spring assembly by inserting 1/4” hex wrench
through the rear fitting port into the end of the
Tighten the assembly by hand using
a 1/4” Hex. Wrench Max. Torque 45-50 in-lbs
Do not use an air gun.
piston (Item 13). Do not use an air gun. Make
certain that the spring assembly does not bind
on the centering cups.
8. Make certain the o-ring (item 15) is in place.
Secure the pneumatic actuator assembly to
the valve body using the four socket head
screws and lock washers (Items 4 & 5). Test for
proper alignment by turning the valve spool.
The spool should rotate freely.
9. Assemble the valve to the mounting plate on
Apply Removable
Threadlock Here.
the hydraulic tank. Test spool for free move-
ment.
Installation
33
Pneumatic Control Installation Continued...
Pre-Assembled Pneumatic Control Tower Installation
1. Determine a suitable location which is in a comfortable location for the driver and not
in the way of the transmission lever.
2. Position the lower bolt holes so that the bolts will miss any cable, wires or structural mem-
bers in or under the cab floor.
3. Mark and drill the four (4) 3/8” diameter holes for the 3/8” x 1-1/2” cap screws supplied
for the tower.
4. Determine a location in the area between the mounting holes to run the air lines.
5. Drill a 2” to 3” diameter hole through the floor of the truck. Remove all burrs and sharp
edges. Line the hole with the grommet material supplied.
6. Using the washers on the underside of the floor, attach the tower to the floor with the
3/8” screws and lock nuts.
After the control tower has been mounted, the air lines can be routed. The air line tubing
is color coded as follows:
Blue
Winch/Cable In
Winch/Cable Out
Hoist Raise/On
Green
Orange
Yellow
Red
Hoist Down/Off
PTO
Black
Silver
Silver
Exhaust
Supply
Aux In
White
Aux Out
To remove an air line from a fitting, push the line in, hold the internal sleeve of the fitting,
then pull the air line out.
1. Press the air lines through the hole lined with grommet material in the floor.
2. Route the exhaust air line outside of the truck cab.
3. Determine a suitable route for the air lines to the control valve. Avoid sharp bends,
sharp edges, and heat sources.
4. Install supplied elbow fittings into pneumatic actuators on the valve bank.
5. Connect the air lines to the elbow fittings in the pneumatic actuators.
6. Bundle the air lines together and secure out of harms way.
A decal with an assortment of .94” diameter labels are provided with the owner’s manual.
These decal labels can be applied to the underside of the clear plastic caps to identify
the function of each pneumatic control handle. After the decals have been applied,
snap the clear covers into the handles.
Start-Up Procedure
1. Charge the air system of the truck. Check all lines for leakage.
2. Operate the controllers and check for correct hydraulic valve movement. Note: The
controllers pressurize the port toward which the handle is moved. If the function is to be
reversed, exchange the air lines at the controller or actuator.
3. After the correct connections have been made and the hoist has been completely
installed, engage the PTO to check the operation of the hoist.
34
Stellar Cable Hoist Owner’s Manual
Step 10: Bumper Installation
LIGHTED BUMPER
INSTALLATION
Lighted Bumper Installation
1. Align the holes in the lighted bumper with
the holes in the hoist sub-frame apron.
2. Install six (6) 5/8NC x 1-3/4” GD.8 Cap
Screws, twelve (12) Flat Washers, and six (6)
Hex Nuts. Torque to specifications.
3. Install wiring harness P/N 38056 through the
access hole.
4. Install the bumper lights as shown on parts
pages 59-60.
5/8" GRADE 8
FLAT WASHERS
5. Connect the female end of wiring harness
P/N 38056 to the male end of wiring harness
P/N 40310 as shown on page 42.
6. Check all light functions. Important: The
back-up alarm should sound when the
back-up lights are on.
5/8"NC SELF
LOCKING NUTS
5/8" GRADE 8
5/8"NC X 1-3/4" GRADE 8
HEX HEAD CAP SCREWS
FLAT WASHERS
PINTLE BUMPER
INSTALLATION
PN 46818
PINTLE BUMPER ASSEMBLY
PN 46822 GUSSET
SLIDE UNDER HOIST APRON
ON OUTSIDE OF FRAME RAILS
AND WELD SOLID
HOIST APRON
13
4- ”
32
FRAME RAIL
1/4" FILLET WELD
1/4” FILLET WELD
1/4" FILLET WELD
Pintle Bumper Installation
1. Position the bumper weldment over the hoist apron and center.
2. Make sure bumper is level and tack weld into position.
3. Match drill all fender and pintle mounting holes through the hoist apron.
4. Weld bumper to apron per weld call-out shown.
5. Position and weld the reinforcement gussets as shown.
6. Check all light functions. Important: The back-up alarm should sound when the back-up lights
are on.
Installation
35
Bumper Installation Continued...
I.C.C. Bumper Installation
1. Connect the bumper weldment to the hoist with two (2) 3/4NC x 4-1/2” Cap Screws, Spacers,
Flat Washers and Self-Locking Nuts. It may be necessary to use Flat Washers between the
bumper uprights and the hoist frame.
2. Connect the lower links between the pivot on the lighted bumper and the ICC bumper. Use a
3/4NC x 2-1/2” GD.5 Cap Screw, Spacer, Flat Washer and Self Locking Nut to attach each link to
the lighted bumper. Use a 3/4NC x 4-1/2” GD.5 Cap Screw, Spacer, Flat Washer, and Self
Locking Nut to connect each link to the ICC bumper.
3. Torque nuts to specifications.
4. The ICC Bumper should fold up against or near the tail of the hoist as the unit is raised to the full-
up position. If the ICC Bumper does not fold correctly, it will be necessary to add flat washers
between the lighted bumper and the sub-frame apron. To tuck the ICC Bumper closer to the
hoist frame, the flat washers must be installed on the upper lighted bumper mounting bolts. If
the ICC contacts the hoist before the unit is completely raised, the flat washers should be
installed on the lower lighted bumper mounting bolts.
ICC Bumper Installation (I.O.X.)
1. This ICC bumper is mounted in the same manner as the OR or IO ICC Bumper.
Pintle ICC Bumper Installation (See Illustration on Next Page)
1. Modify PN 46818 Pintle Bumper by welding PN 51629 collars to ICC bumper brackets.
2. Match drill holes in ICC bumper brackets to holes in PN 51629 collars 1.06 DIA.
3. Drill one side of PN 45813 Flat Link to 1.06” DIA.
4. Bolt PN 45814 Standard ICC bumper to existing brackets on the sides of the hoist frame.
5. Swing up ICC Bumper and locate where PN 48159 Bushings will be welded. Weld bushing to the
under side of hoist frame on both sides. Make sure cross-drilled holes in bushings are on the out-
side of the hoist frame.
6. Swing bumper down and weld PN 51628 Stop to the top of the ICC Pivot Tube. (See Illustration)
7. Lock ICC Bumper in the down position using PN 45311 Pin and PN 45216 Lock Pin.
8. Bumper must be pinned down except when pulling a pup trailer. Pin bumper up when pup trail-
er is attached to eliminate any possible damage to bumper or trailer tongue.
Heavy Duty ICC Bumper Installation
WELD 0.31" FILLET AROUND
TO BOTTOM OF HOIST
23.50
24.00
LARGE BLOCK TO THE REAR
HEAVY DUTY ICC BUMPER
36
Stellar Cable Hoist Owner’s Manual
Step 11: Hoist Up Light Installation
Locate bracket on hoist base.
Tighten Dump Up Light Kit to the bracket.
Installed
PN 31806
DUMP UP LIGHT KIT BUYERS SK10
BRACKET SHOWN
AS REFERENCE
Note: See Electrical Schematic in the Hydraulic-Electrical Chapter for wiring diagram.
Installation
37
Step 12a: Fender Installation - Steel Tandem/Tri-Axle
Steel Tandem/Tri-Axle
Position fender to allow
for max air bag travel
and spring compression.
Position fender to allow
for max walking beam
travel.
Position fender to allow adequate
clearance between fender & hydraulic
cylinder in upright extended position.
0.25” Weld Around
(6 Places)
5/8NC Self Locking Nut
Gusset
Rear Fender
Tube Weldment
Spacer
1” x 2.5” x 2.5”
Front
Fender
Tube Weldment
Fender
Weldment
1/2NC x 2” Square
Head cone Point
Set Screw
1/2NC Hex Nut
Front Fender
Tube Weldment
End Cap
Fender
Weldment
End
Cap
5/8” Std. Flat Washer
5/8NC x 5” GRD5
Fender
Cap Screw
Connector:
Weld into place with five (5) 1” welds after
fenders and bumpers have been installed.
38
Stellar Cable Hoist Owner’s Manual
Step 12b: Fender Installation - Plastic Tandem/Tri-Axle
Match drill fenders and attach
Plastic Tandem/Tri-Axle
3/8” bolt, flat washers and locknut.
Weld front braces to
cylinder mounting plate.
Weld rear fender
mounts to bumper.
Weld on end caps.
(8)
Weld center support to sub-frame.
After fender has been located properly,
locate and weld fender support.
Notch out if needed.
Position fender to allow
for max walking beam travel.
Position fender to allow
adequate clearance between
fender and hydraulic cylinder
in upright extended position.
Step 13: Mid-Body Light Installation
Right Front
Fender Brace
Wire Harnerss (2)
2” Rubber Grommet (2)
2” Beehive Sealed Light (2)
Drill 1/2” hole for wire
harness - both sides.
Left Front
Fender Brace
1/2” diameter hole -
Both mounting weldments.
Installation
39
Step 14a: Removable Stop Installation
40
Stellar Cable Hoist Owner’s Manual
Step 14b: Intermediate Stop Installation
47272
I.O. Fold Down Stop
.38 Fillet Weld
(Weld Both Sides,
Do not Weld Ends)
Outside Face
of Hoist Frame
PN 45621
O.R. Fold Down Stop
.38 Fillet Weld
Around
Outside Face
of Hoist Frame
Installation
41
Step 15: Reflective Tape Installation
REF. ANSI Standard
Z245.1-1999
Z.2.16 Vehicle Conspicuity
PN 63907
(Both Sides - No Tarper)
54”
18”
24”
6”
PN 63907
(Both Sides - With Tarper)
36”
12”
6”
36”
12”
18”
6”
24”
Back
(All models)
NOTE:
Reflective tape locations and lengths
are for reference. Your reflective tape
location may differ due to equipment
60”
options. Reflective tape to cover truck
chassis or hoist frame per ANSI Standard
Z245-1-1999
Install full width
ICC Bumper as shown.
42
Stellar Cable Hoist Owner’s Manual
Hydraulics - Electrical
43
Chapter 7 - Hydraulics - Electrical
Hydraulic Schematic
Auxilary
Cylinder
F1
E1
Extender
Cylinder
F
E
Reeving
Cylinder
Control Valve
C
D
E1
F1
Auxilary
Reeving
Cylinder
E
F
Ext. Tale
C
A
D
B
Reeving
Lift
Cylinder
Lift
A
B
Lift
Cylinder
44
Stellar Cable Hoist Owner’s Manual
Hydraulic Routing - Standard Lift Cylinder
Standard Cylinder Mount
Hydraulics - Electrical
45
Hydraulic Routing - Telescopic Lift Cylinder
Telescopic Cylinder Mount
45585
46
Stellar Cable Hoist Owner’s Manual
Hydraulic Routing - Reverse Mount Lift Cylinder
Reverse Cylinder Mount
Hydraulics - Electrical
47
Reverse Mount Lift Cylinder Mounting Kit - PN 56094
Part 1
NOTE: PN:45143 ALWAYS
WELDED ON STREET SIDE
.75
6.19
.19
.19
4.00
TYP. 2
TYP. 2
1.50
TYP. 2
.19
48
Stellar Cable Hoist Owner’s Manual
Reverse Mount Lift Cylinder Mounting Kit - PN 56094
Part 2
NOTE: CABLE HOIST
SHOWN AS REFERENCE
10
PN 56094
ITEM PART
DESCRIPTION
FTG TEE JIC 12 JTX-S
QTY.
2
1
45585
HOSE 0.75(471TC-06-39-12-12-12-
60)
HOSE 0.75(471TC-06-39-12-12-12-
70)
2
64064
2
2
3
64065
2
4
5
45948
45143PC
3381PC
0343
U BOLT 0.31X1.50X2.25 RD
4
1
4
3
PLATE 0.25X3.00X5.75
HOSE CLAMP BOLT ON 1210
CRANE
WASHER 0.31 USS FLAT ZINC
CAP SCR 0.31-18X2.25 HHGR5
NUT 0.31-18 HHGR5 NYLOC
HOSE 0.75x39 JIC F KPAC
6
2
3
5
7
1
7
10
2
8
C0927
0342
9
2
10
46111
2
9
8
6
7
Hydraulics - Electrical
49
Hydraulic Routing - Reeving Cylinder
Reeving Cylinder
50
Stellar Cable Hoist Owner’s Manual
Hydraulic Routing - Tail Extension IOX Cylinder Mount
Tail Extension IOX Cylinder Mount
Hydraulics - Electrical
51
Hydraulic Routing - Tail Extension ORX Cylinder Mount
Tail Extension ORX Cylinder Mount
52
Stellar Cable Hoist Owner’s Manual
Electrical Schematics
EXISTING TRUCK
WIRING HARNESS
BACK-UP LIGHT
(BLACK)
TRUCK CAB
LH, TURN, BRAKE, LIGHT
(YELLOW)
HOIST UP
LIGHT
WHITE
TAIL, CLEARANCE, LIGHT
(BROWN)
GROUND
(WHITE)
REMOTE
SWITCH
RH, TURN, BRAKE, LIGHT
(GREEN)
COLORED
Note: The Hoist Up Light will only
be activated when the iginition is hot.
It is recommended to tap into the
PTO light power source when wiring.
GROUND
(WHITE)
PTO
LIGHT
GROUND
TO FRAME
FUSE
BLOCK
NOTE: GROUND THE
WHITE WIRES TO THE
BUMPER.
PTO
GROUND
BACK-UP ALARM
(WHITE/BLACK)
PN 40310
PN 38056
MID-BODY CLEARANCE
2” AMBER RND LED
MID-BODY CLEARANCE
2” AMBER RND LED
PN 12516
JUMPER TO MID-BODY
CLEARANCE LIGHTS
BACK-UP ALARM
(WHITE/BLACK)
TAG LIGHT
(BROWN)
BACK-UP ALARM
(WHITE/BLACK)
TAG LIGHT
(BROWN)
RED CLEARANCE
(WHITE/BROWN)
LH TURN/
STOP
RED LIGHT
(WHITE/
BROWN/
YELLOW)
LH TURN/
STOP
RED LIGHT
(WHITE/
BROWN/
YELLOW)
BACKUP
WHITE LIGHT
(WHITE/
REAR CLEARANCE
(BROWN/WHITE)
BACK-UP ALARM
(WHITE/BLACK)
RED CLEARANCE
(WHITE/BROWN)
RH TURN/
STOP
WHITE LIGHT RED LIGHT
RH TURN/
STOP
RED LIGHT
(WHITE/
BROWN/
YELLOW)
BLACK)
BACKUP
(WHITE/
BLACK)
(WHITE/
BROWN/
YELLOW)
TAG LIGHT
(BROWN)
TAG LIGHT
(BROWN)
Assembly Drawings 53
Chapter 8 - Assembly Drawings
Cable Controls
Qty.
Qty.
2
3
2
3
Item
PN
Description
SPOOL SPOOL
Item
PN
Description
HANDLE HYDRAULIC KIT KPAC
VALVE HANDLE
SPOOL
SPOOL
1
2
3
46734 CONTROLLER STR NO LOCK WESCON KP60
45050 CONTROL MOUNT 2 SPOOL CONTROL
46658 CONTROL CABLE 108 IN WESCON KPAC
46713 CONTROL CABLE 156 IN WESCON KPAC
47284 CONTROL CABLE 252 IN WESCON KP60
46656 PLATE BULKHEAD CONTROL CABLE KP60
46291 CABLE CONN. KIT FOR V20 KPAC
CLEVIS (WITH 3/8” HOLE)
2
2
2
2
2
1
2
2
2
2
3
2
3
3
3
1
3
3
3
3
45798
2
2
2
6
2
2
2
4
3
3
3
3
9
3
3
3
6
8
9
LINK
10
11
12
13
14
15
COTTER PIN
LINK PLATE
4
PIN
HANDLE BRACKET
1/4NCX5/8” HEX SOCKET SCREW
CAP SCR 0.25-20X4.00 HHGR5
5
6
7
PIN
0439
COTTER PIN
C0916 CAP SCR 0.25-20X6.00 HHGR5
3
3
3
16
17
0333
NUT 0.25-20 HHGR5 NYLOC
3
3
46733
SCREW 0.38X1.50 THREAD CUTTING
54
Stellar Cable Hoist Owner’s Manual
Air Controllers Assembly 1
Item
PN
Description
Qty.
Item
16
PN
Description
WASHER 0.38 LOCK
Qty.
1
2
3
C1002
C6106
CAP SCR 0.50-13X6.00 HHGR5
NUT 0.50-13 HHGR5 NYLOC
3
1
1
1
1
0523
4
4
1
1
4
17
0535
NUT 0.38-16 HHGR5
2-Spool Valve Assembly Gresen Shown
3-Spool Valve Assembly Gresen
AIR ACTUATOR (V42) 1/8-NPT KPAC
18
42399
*47471
JOYSTICK DELL D45-1226-99-32
PNEUMATIC CONTROLLER
19
4
45159
20
#10NC x 1/2” Cross Recess Pan
Head Machine Screw
21
22
23
24
25
26
PTO CAP INDICATOR LIGHT
AIR VALVE
1
1
4
4
4
1
48161
47986
0478
0521
0533
TOWER ASM AIR CONTROL
CONTROL TOWER ASM
CAP SCR 0.25-20X0.50 HHGR5
WASHER 0.25 LOCK
NUT 0.25-20 HH
1
1
6
7
#10 Flat Washer
12
12
12
1
#10 External Tooth Lock Washer
#10 Hex Nut
8
9
1/8 NPT Male - 1/4” Tube 90º Com
pression Fitting
-
10
11
Cover
45040
CAP AIR CONTROL TOWER KPCC
(USED WHEN NOT EQUIPPED WITH ITEM 19)
1
27
28
46301
TEE ADAPTER 0.25 AIR QUICK LOCK
1
1
3/8 NPT Male - 1/4” Tube Straight
Compression Fitting
12
13
14
15
47467
47090
46733
0346
MOUNT PLATE AIR CONTROL KP60
SCREW SELF TAP 0.25X0.75 HWHH
SCREW 0.38X1.50 THREAD CUTTING
WASHER 0.38 USS FLAT ZINC
1
4
4
4
29
30
31
PRESSURE PROTECTION VALVE
1/4NPT Hex Nipple
1
1
1
Compression FItting 1/8NPT Male
- 1/4” Tube Straight
* USED WITH 3-SPOOL VALVE ASSEMBLY ONLY.
Assembly Drawings 55
Air Controllers Assembly 2
2 Section Air
PN 45833
ITEM
PART
45307
0345
0346
0523
0535
DESCRIPTION
CONTROL TOWER ASM 2SECT AIR K-PAC
CAP SCR 0.38-16X1.50 HHGR5
WASHER 0.38 USS FLAT ZINC
WASHER 0.38 LOCK
QTY.
1
2
3
4
5
1
4
4
4
4
1
NUT 0.38-16 HHGR5
2
6
7
45687
45159
ELBOW ADAPTER MALE SWIVEL (NOT SHOWN)
4
2
AIR ACTUATOR (V42) 1/8-NPT KPAC (NOT SHOWN)
3
CAB FLOOR
4
5
3 Section Air
PN 46638
DESCRIPTION
CONTROL TOWER ASM 3SECT AIR K-PAC
CAP SCR 0.38-16X1.50 HHGR5
WASHER 0.38 LOCK
1
ITEM
PART
QTY.
1
2
3
4
5
45244
0345
0523
0346
0535
1
4
4
4
4
WASHER 0.38 USS FLAT ZINC
NUT 0.38-16 HHGR5
2
6
7
45159
45687
AIR ACTUATOR (V42) 1/8-NPT KPAC (NOT SHOWN)
ELBOW ADAPTER MALE SWIVEL (NOT SHOWN)
3
6
4
CAB FLOOR
3
5
56
Stellar Cable Hoist Owner’s Manual
Main Hoist Assembly
2
45
29
16
27
3
49
44
39
7
34
28
6
4
37
41
37
7
34
24
24
22
31
21
42
6
4
33
41
24
25
12
48
NOTE:
30
30
- DECALS MUST BE BELOW TOP OF ROLLERS
- ALL ROLLERS AND SHEAVES MUST MOVE FREELY
5
4
18
20
36
35
21
48
34
38
48
31
32
9
1
46
11
47
32
30
26
10
32
23
15
31
32
4
19
17
32
43
13
40
14
4
ITEM
1
2
3
4
5
6
7
8
PART
DESCRIPTION
QTY. ITEM
PART
45556
45564
45583
45596
45623
46631
DESCRIPTION
QTY.
1
1
2
1
4
1
15
27
1
6
1
1
3
10
1
2
2
1
0335
0345
0346
0347
0351
0352
0359
0427
0505
0512
0532
0523
1589
CAP SCR 0.38-16X1.25 HHGR5
CAP SCR 0.38-16X1.50 HHGR5
WASHER 0.38 USS FLAT ZINC
NUT 0.38-16 HHGR5 NYLOC
CAP SCR 0.38-16X1.00 HHGR5
WASHER 0.50 USS FLAT ZINC
CAP SCR 0.50-13X1.50 HHGR5
MACHY WASHER 2.00ID 10GA
CAP SCR 0.50-13X3.50 HHGR5
CAP SCR 0.63-11X4.50 HHGR5
CAP SCR 0.38-16X3.75 HHGR5
WASHER 0.38 LOCK
2
4
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
CABLE ASM 0.88X71 FT 6X37 EXIWRC
REAR ROLLER ASSEMBLY KP60
STRAP WLDMT CYLINDER REEVING KP60
HANDLE WLDMT LOCK STRAP KP60
CAP SCR 0.75-10X4.50 HHGR5
DUMP KP60 174 IO
12
37
1
4
4
C0949 CAP SCR 0.38-16X3.00 HHGR5
c1592 ZERK 1/8 NPT STRAIGHT
C4659 HOSE CLAMP #16 SS
C6106 NUT 0.50-13 HHGR5 NYLOC
45096PC PROP WLDMNT
45579PC FLAT CROSS MEMBER PROP KP60
45139
45372PC COLLAR RETAINING 3.00X2.03X.75
45584PC PLATE COVER FRONT KP60
0578
45481ZP VERTICAL SHEAVE SHAFT KPAC
45138ZP PIN SHEAVE AND CABLE SHAFT KPAC
45560ZP PIN WLDMT REAR HINGE KP60
45411
60219
45593
45592
10
2
2
10
1
4
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
MACHY WASHER 3.00ID 14GA
SHEAVE 10IN X .88 CABLE ASM KP60
26168PC COLLAR RETAINING 3.01X4.00X1.00
2826
2828
2
2
4
8
NUT 0.63-11 HHGR5 NYLOC
NUT 0.75-10 HHGR5 NYLOC
CLAMP HOSE/TUBE AG-3
SPRING FLAT K PAC
CAP SCR 0.38-16X5.00 HHGR5
8621
42393
45177
45304
45373
45523
45535
45552
1
1
8
10
4
BASE CABLE HOIST SI60
2
1
1
1
1
8
ROLLER 6.00 KP60 INSIDE
ROLLER 4.00 OUTSIDE KP60
WIRE ROPE CLIP, 1 In. (G-450), CROSBY,
PIN 2.00X27.25 KP60 ROLLER SHAFT
ROLL PIN 0.38X3.50
CABLE END 0.88IN CABLE
CYLINDER ASM CABLE HOIST (174/182)
TUBE ASM 0.75X176.00 JIC KP6024-462 YZ
TUBE ASM 0.75X179.00 JIC KP6024-463 YZ
1010239
1
3
45358ZP PIN INSIDE ROLLER W/ZERK KP60
45556
45500
CABLE ASM 0.88X71 FT 6X37 EXIWRC (174-182 Models)
1
CABLE ASM 0.88X81 FT 6X37 EXIWRC (194 Models)
1
Assembly Drawings 57
Reeving Cylinder Assembly - PN 60219
174 and 182 Models
7
8
PN 60219
1
10
ITEM
1
2
3
4
5
6
7
8
PART
45243
45114
8621
0346
0347
45551
19371
18701
45585
DESCRIPTION
QTY.
2
2
12
6
6
6
4
4
2
4
1
1
1
1
2
2
2
CYLINDER 7.00X80.00 KPAC
REEVING SHEAVE WLDMT KP60
CLAMP HOSE/TUBE AG-3
WASHER 0.38 USS FLAT ZINC
NUT 0.38-16 HHGR5 NYLOC
BOLT CARRIAGE 0.38-16X3.00
HOSE CLAMP 7.13-10.00 5416K43
CLAMP PORT TUBE ZR518
FTG TEE JIC 12 JTX-S
17
18
12
2
9
16
10
11
12
13
14
15
16
17
18
C4498 FTG ORB/JIC STRT CONNT 12-F5OX-S
58391
58392
58389
58390
45590
2828
TUBE ASM 0.75X96.82 JIC YZ
TUBE ASM 0.75X94.94 JIC YZ
TUBE ASM 0.75X11.50 JIC YZ
TUBE ASM 0.75X14.06 JIC YZ
TUBE ASM 0.75X93.00 JIC 24-429 YZ
NUT 0.75-10 HH NYLOC
9
11
10
14
15
10
45623
c1592
CAP SCR 0.75-10X4.50 HHGR5
ZERK 1/8 NPT STRAIGHT
2
13
6
9
3
3
4
15
5
Reeving Cylinder Assembly - PN 60221
194 Models
7
8
PN 60221
ITEM
1
2
3
4
5
6
7
8
PART
45349
45114
8621
0346
0347
45551
19371
18701
45585
DESCRIPTION
QTY.
2
2
12
6
6
6
4
4
2
CYLINDER 7.00X80.00 KPAC
REEVING SHEAVE WLDMT KP60
CLAMP HOSE/TUBE AG-3
WASHER 0.38 USS FLAT ZINC
NUT 0.38-16 HHGR5 NYLOC
BOLT CARRIAGE 0.38-16X3.00
HOSE CLAMP 7.13-10.00 5416K43
CLAMP PORT TUBE ZR518
FTG TEE JIC 12 JTX-S
1
10
18
15
16
9
2
10
11
12
13
14
15
16
17
18
C4498 FTG ORB/JIC STRT CONNT 12-F5OX-S
4
1
1
2
2
2
2
1
58389
58390
45590
2828
TUBE ASM 0.75X11.50 JIC YZ
TUBE ASM 0.75X14.06 JIC YZ
TUBE ASM 0.75X93.00 JIC 24-429 YZ
NUT 0.75-10 HH NYLOC
14
45623
c1592
60324
60323
CAP SCR 0.75-10X4.50 HHGR5
ZERK 1/8 NPT STRAIGHT
TUBE ASM 0.75X106.81 JIC YZ
TUBE ASM 0.75X104.94 JIC YZ
9
17
10
1
12
13
10
11
6
9
3
3
4
13
5
58
Stellar Cable Hoist Owner’s Manual
Chassis Mounted Parts
Assembly Drawings 59
Chassis Mounted Parts
Item
1
PN
Description
Qty.
1
45054 SUB-FRAME FRONT WELDMENT
45059 SUB-FRAME FRONT WELDMENT
46134 PLATE SUBFRAME EXTENDER CLAMP
46062 MOUNTING BRACKET RSRVR SI60
46063 TUBE RSRVR MOUNTING SI60
45600 MOUNT BRKT TRUCK FRAME LUG SI60
47089 NUT 0.63-18 HHGR5 NYLOC
C1038 WASHER 0.63 USS FLAT ZINC
45762 PLATE SUBFRAME CLAMP BTTM SI60
45761 PLATE SUBRAME SHIM SI60
45760 PLATE SUBFRAME CLAMP SI60
47088 CAP SCR 0.63-18X2.50 HHGR5
47531 PIN PIVOT
2
1
3
2
4
2
5
2
6
2
7
2
8
2
9
2
10
11
12
13
14
15
16
17
18
19
20
21
4
2
2
1
45144 PIN 2.50 KP60 DROP SHAFT
45758 FLAT 0.50X4.00X0.75
1
4
45757 TUBE 3.00X3.00X.19WX3.50
47852 WASHER FLAT 2.56IDX3.25ODX0.25 THCK
45756 COLLAR 2.51X3.25X1.50 W/HOLE
0507 CAP SCR 0.50-13X4.50 HHGR5
C6106 NUT 0.50-13 HHGR5 NYLOC
45597 HANDLE PROP SI60
2
8
4
4
4
2
60
Stellar Cable Hoist Owner’s Manual
Mounting Kit (Forward Mount) - PN 55261
9
8
11
6
7
4
10
NOTE: USE REAR HOLE
TO BOLT CYLINDER
PIN WLDMT
1
PN 55261
ITEM
1
2
3
4
5
6
7
8
PART
49997
49995ZP
0500
C6106
0352
55262
45756PC
1593
0507
52889PC
52892PC
31680
DESCRIPTION
TUBE 5.00X3.00X0.38WX56.00
PIN WLDMT CYL MNT CABLE75
CAP SCR 0.50-13X1.75 HHGR5
NUT 0.50-13 HHGR5 NYLOC
QTY.
1
2
2
4
2
2
2
4
2
1
1
2
12
WASHER 0.50 USS FLAT ZINC
CYLINDER ASM 6.00X72.00 LIFT CABLE75 MNT
COLLAR 2.51X3.50X1.50 W/HOLE
MACHY WASHER 2.50ID 10GA
CAP SCR 0.50-13X4.50 HHGR5
CYL MNT WLDMT SS SI75 HP OFFSET
CYL MNT WLDMT SS SI75 HP
2
4
3
5
9
10
11
12
FTG ST RUN TEE 12-R6X
TYP. 4
0.25
TYP. 2
0.25
TYP. 4
0.25
0.19
TYP. 2
0.25
TYP. 4
1.00
Assembly Drawings 61
Mounting Kit (Reverse Mount) - PN 56094
8
9
11
6
7
4
10
NOTE: USE REAR HOLE
TO BOLT CYLINDER
PIN WLDMT
1
PN 56094
ITEM
1
2
3
4
5
6
7
8
PART
49997
49995ZP
0500
C6106
0352
55262
45756PC
1593
0507
52889PC
52892PC
31680
DESCRIPTION
TUBE 5.00X3.00X0.38WX56.00
PIN WLDMT CYL MNT CABLE75
CAP SCR 0.50-13X1.75 HHGR5
NUT 0.50-13 HHGR5 NYLOC
QTY.
1
2
2
4
2
2
2
4
2
1
1
2
12
2
WASHER 0.50 USS FLAT ZINC
CYLINDER ASM 6.00X72.00 LIFT CABLE75 MNT
COLLAR 2.51X3.50X1.50 W/HOLE
MACHY WASHER 2.50ID 10GA
CAP SCR 0.50-13X4.50 HHGR5
CYL MNT WLDMT SS SI75 HP OFFSET
CYL MNT WLDMT SS SI75 HP
4
3
5
9
10
11
12
FTG ST RUN TEE 12-R6X
TYP. 4
0.25
TYP. 2
0.25
TYP. 4
TYP. 4
0.25
0.19
TYP. 2
0.25
1.00
62
Stellar Cable Hoist Owner’s Manual
Mounting Kit (Telescopic) - PN 55265
11
9
8
10
6
7
4
12
1
13
2
4
3
5
PN 55265
PART
49997
49995ZP
0500
C6106
0352
51078
45756PC
1593
DESCRIPTION
QTY.
1
2
2
4
2
2
2
8
2
1
1
1
ITEM
1
2
3
4
5
6
7
8
TUBE 5.00X3.00X0.38WX56.00
PIN WLDMT CYL MNT CABLE75
CAP SCR 0.50-13X1.75 HHGR5
NUT 0.50-13 HHGR5 NYLOC
WASHER 0.50 USS FLAT ZINC
CYLINDER ASM 5.50X185.75 TELO KPAC
COLLAR 2.51X3.50X1.50 W/HOLE
MACHY WASHER 2.50ID 10GA
CAP SCR 0.50-13X4.50 HHGR5
CYL MNT WLDMT SS SI75 HP OFFSET
CYL MNT WLDMT SS SI75 HP
FTG ST RUN TEE 12-R6X
9
0507
10
11
12
13
52889PC
52892PC
31680
55320
FTG ST RUN TEE 16-R6X
1
Assembly Drawings 63
Cab Guard - PN 47263
1
4
2
6
3
7
4
5
Adjust position on truck frame to protect window & back of cab. Square cab guard with
truck frame, clamp to truck frame using shims if needed. Drill three (3) 5/8" holes through
cab guard and truck frame approx. 3" apart (both sides). Bolt cab guard to truck frame.
FRAME RAIL
PN 47263
ITEM PART
DESCRIPTION
QTY.
1
2
3
4
5
6
7
47262
47265
47264
2826
CAB GUARD WLDMT KP60
FLAT 0.25X2.00X10.50
CLAMP BAR CAB GUARD KP60
NUT 0.63-11 HHGR5 NYLOC
CAP SCR 0.63-11X4.00 HHGR5
CAP SCR 0.63-11X3.50 HHGR5
WASHER 0.63 USS FLAT ZINC
1
2
2
8
2
6
6
2827
C0964
C1038
64
Stellar Cable Hoist Owner’s Manual
Under Body Tool Box - PN 46579
1
8
9
10
3
5
4
6
12
4
2
7
2
7
13
PN 46579
ITEM
1
2
3
4
5
6
7
8
PART
46580
DESCRIPTION
QTY.
UBTB WLDMT OH 20X48X15
46578PC UBTB MNT WLDMT 15.00D-KPAC
1
2
1
8
4
4
2
2
2
1
1
1
2
46577
0352
0359
DOOR OH 16.19X40.06 VECTOR SPT-KPAC
WASHER 0.50 USS FLAT ZINC
CAP SCR 0.50-13X1.50 HHGR5
C6106 NUT 0.50-13 HHGR5 NYLOC
46590
22045
4110
23763
4183
CAP SCR 0.50X1.50 SQ HD CP SS
BRKT ROLLER MOUNT OH DOOR
ROLLER OH DOOR UHMW
9
10
11
12
13
LATCH ASM VECTOR SGL PT
ANGLE UHMW RH 1.50X1.50X0.25X1.25
ANGLE UHMW LH 1.50X1.50X0.25X1.25
NUT 0.50-13 HH JAM NYLOC
4167
16333
Assembly Drawings 65
Reservoir Assembly - PN 46133
5
4
RETURN PORT FACING THIS SIDE
3
10
9
6
1
2
7
8
PN 46133
ITEM
1
2
3
4
5
6
7
8
PART
46130
15463
45075
DESCRIPTION
QTY.
RSRVR WLDMT 60GAL KP60
THERMO SIGHT GAUGE
FILTER K-PAC TANK TOP
1
1
1
4
4
1
1
1
1
1
C6353 WASHER 0.38 SAE FLAT YELLOW GR8
0335
15464
CAP SCR 0.38-16X1.25 HHGR5
TANK COVER
C4845 PLUG 0.75 NPT SQ HD BLK
C6327 FILTER STRAINER 35GAL TF-2030
9
10
57739
58396
CAP FILL ASM W/3” NECK 1PSI
GASKET RG-11 TANK TOP FILTER
66
Stellar Cable Hoist Owner’s Manual
2 Section Valve Bank Reservoir - PN 45710
24
5
16
7
11
12
25
21
6
1
10
23
24
26
2
17
27
3
4
8
23
18
13
15
19
12
13
15
14
24
PN 45710
DESCRIPTION
ITEM
1
PART
46133
QTY
RSRVR ASM 60GAL KP60
1
1
1
1
1
1
1
1
1
3
7
4
1
4
1
1
1
1
2
1
2
6
6
2
1
1
2
3
4
5
6
7
8
D1306 FTG ADAPT MSTR/FSTR 16-12 F5OG5
30541
9758
FTG ADAPT 12-1/4 F5OG
FTG ST TH-F PIPE EL 90 6805-20-20
C2282 FTG 1.25 NPT TO 1.25 BARB
D0652 ST EL 2.00 90 DEG STL
45831
C4750 VALVE BALL 2.00
59841 VB 2-SECT VA20 KIT
C0954 CAP SCR 0.38-16X4.50 HHGR5
HOSE 1.25X19.00 KP60
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
0346
0347
WASHER 0.38 USS FLAT ZINC
NUT 0.38-16 HHGR5 NYLOC
45802
FTG ADAPT MJIC/MORING 16-16 45 DEG
C4498 FTG ORB/JIC STRT CONNT 12-F5OX-S
8617 FTG HOSE BARB 1.25 90 DEG MNPT
C0953 CAP SCR 0.38-16X4.00 HHGR5
C6353 WASHER 0.38 SAE FLAT YELLOW GR8
6397
46063PC TUBE RSRVR MOUNTING KP60
7285 NIPPLE 2.00X3.00 BLK
C1123 HOSE CLAMP 88 DB-20
GAUGE OIL LF 2.5 0-5000 CBM
16333
46590
c4819
17766
NUT 0.50-13 HH JAM NYLOC
CAP SCR 0.50X1.50 SQ HD CP SS
HOSE CLAMP 2.00
HOSE SUCT 2.00 10FT
C4730 FTG HOSE BARB 2.00
Assembly Drawings 67
3 Section Valve Bank Reservoir - PN 46642
22
14
3
9
5
11
12
21
27
23
7
25
24
4
1
18
28
26
2
25
8
6
10
24
20
19
17
12
13
15
16
PN 46642
ITEM
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
PART
46133
9758
DESCRIPTION
RSRVR ASM 60GAL KP60
FTG ST TH-F PIPE EL 90 6805-20-20
QTY
1
1
1
1
1
1
1
1
1
3
7
4
1
1
2
4
1
1
1
2
2
1
6
6
1
2
1
C2282 FTG 1.25 NPT TO 1.25 BARB
D0652 ST EL 2.00 90 DEG STL
HOSE 1.25X19.00 KP60
C4750 VALVE BALL 2.00
45831
D1306 FTG ADAPT MSTR/FSTR 16-12 F5OG5
30541
59843
FTG ADAPT 12-1/4 F5OG
VB 3-SECT VA20 KIT
C0954 CAP SCR 0.38-16X4.50 HHGR5
0346
0347
8617
45802
WASHER 0.38 USS FLAT ZINC
NUT 0.38-16 HHGR5 NYLOC
FTG HOSE BARB 1.25 90 DEG MNPT
FTG ADAPT MJIC/MORING 16-16 45 DEG
D1189 FTG ST TH CONNECT JIC 8-12 F5OX
C4498 FTG ORB/JIC STRT CONNT 12-F5OX-S
C0953 CAP SCR 0.38-16X4.00 HHGR5
C6353 WASHER 0.38 SAE FLAT YELLOW GR8
6397
GAUGE OIL LF 2.5 0-5000 CBM
46063PC TUBE RSRVR MOUNTING KP60
C1123 HOSE CLAMP 88 DB-20
7285
46590
16333
NIPPLE 2.00X3.00 BLK
CAP SCR 0.50X1.50 SQ HD CP SS
NUT 0.50-13 HH JAM NYLOC
C4730 FTG HOSE BARB 2.00
c4819
17766
HOSE CLAMP 2.00
HOSE SUCT 2.00 10FT
68
Stellar Cable Hoist Owner’s Manual
Reservoir Mounting Bracket for PN 45710
3
5
4
1
For Reservior
PN 45710
2
ITEM
PART
DESCRIPTION
QTY
2
2
12
12
24
1
2
3
4
5
46062PC MOUNTING BRACKET RSRVR KP60
46063
10662
5468
TUBE RSRVR MOUNTING KP60
CAP SCR 0.50-13X2.50 HHGR8
NUT 0.50-13 HHGR8 NYLOC
D0790 WASHER 0.50 SAE FLAT YELLOW GR8
3
5
4
1
2
For Reservior
PN 46642
ITEM
PART
DESCRIPTION
QTY
2
2
14
14
28
1
2
3
4
5
46062PC MOUNTING BRACKET RSRVR KP60
46063
10662
5468
TUBE RSRVR MOUNTING KP60
CAP SCR 0.50-13X2.50 HHGR8
NUT 0.50-13 HHGR8 NYLOC
D0790 WASHER 0.50 SAE FLAT YELLOW GR8
Assembly Drawings 69
Standard Lighted Bumper - PN 45887
17
14
20
19
19
9
12
12
11
11
15
10
18
9
16
8
4
3
6
13
5
2
7
19
12
3
1
PN 45887
ITEM
1
2
3
4
5
6
7
8
PART
0335
0340
0346
0347
0480
0533
0654
2320
DESCRIPTION
CAP SCR 0.38-16X1.25 HHGR5
WASHER 0.25 FLAT
QTY.
8
8
16
8
4
4
4
1
WASHER 0.38 FLAT
NUT 0.38-16 HH NYLOC
CAP SCR 0.25-20X1.00 HHGR5
NUT 0.25-20 HH
NUT 0.25-20 WING
LICENSE PLATE LIGHT ROUND 430 W
9
10334 GROMMET 4.00 ROUND LAMP (PETERSON)
7
10
11
12
13
14
15
11693
13143
13145
18742
24868
27626
CAP SCR 0.63-11X1.75 HHGR8
LIGHT STOP/TURN/TAIL 4 RND LED
LIGHT CLEARANCE RED RND 2 LED
BACKUP ALARM ACORN 97 DECIBAL
NUT 0.63-11 HHGR8 NYLOCK ZY
LIGHT BACKUP LED 62391
6
4
7
1
6
2
16 45039PC PLATE MUD FLAP BACKING 43"FENDER KP
2
17
18
19
20
45812
C0073
C4862
C5902
BUMPER WLDMT STANDARD KP60
TERML 16-14 BLUE BUTT WATER TIGHT
GROMMET FOR 2 CLEARANCE 30700
WASHER 0.63 SAE FLAT YELLOW GR8
1
2
7
12
70
Stellar Cable Hoist Owner’s Manual
Pintle Bumper - PN 46818
18
7
3
7
8
3
8
16
6
2
11
8
9
8
6
5
17
4
15
13
12
7
15
14
3
9
10
PN 46818
ITEM
PART
62293
45039PC PLATE MUD FLAP BACKING 43"FENDER KP
DESCRIPTION
BUMPER WLDMT 90K PINTLE TARPER
QTY.
1
2
3
4
5
6
7
1
2
7
1
2
4
7
13145
2320
27626
13143
LIGHT CLEARANCE RED RND 2 LED
LICENSE PLATE LIGHT ROUND 430 W
LIGHT BACKUP LED 62391
LIGHT STOP/TURN/TAIL 4 RND LED
C4862 GROMMET FOR 2 CLEARANCE 30700
GROMMET 4.00 ROUND LAMP
8
10334
7
(PETERSON)
9
0346
0335
0347
0480
0533
0654
0340
WASHER 0.38 FLAT
16
8
8
4
4
4
8
2
1
2
10
11
12
13
14
15
16
17
18
CAP SCR 0.38-16X1.25 HHGR5
NUT 0.38-16 HH NYLOC
CAP SCR 0.25-20X1.00 HHGR5
NUT 0.25-20 HH
NUT 0.25-20 WING
WASHER 0.25 FLAT
C0073 TERML 16-14 BLUE BUTT WATER TIGHT
18742
46822
BACKUP ALARM ACORN 97 DECIBAL
GUSSET 11.50X10.00X.75 PINTLE BUMPER
Assembly Drawings 71
ICC Wide Bumper - PN 53397
5
4
7
4
4
7
2
3
6
1
PN 53397
ITEM
PART
DESCRIPTION
QTY.
1
2
3
4
5
6
7
53398
BUMPER WLDMT ICC WIDE
1
2
4
16
6
2
45813PC PLATE LINK ICC BUMPER
45815 SPACER 1.25ODX0.75IDX2.16
C6219 WASHER 0.75 SAE FLAT YELLOW GR8
C0538 NUT 0.75-10 HHGR8 NYLOC
58681
5841
CAP SCR 0.75-10X2.50 HHGR8
CAP SCR 0.75-10X4.50 HHGR8
4
72
Stellar Cable Hoist Owner’s Manual
ICC Heavy Duty Bumper - PN 46809
3
2
5
4
1
PN 46809
ITEM
PART
46804
46877PC
5223
46810
46811
DESCRIPTION
QTY.
1
2
3
4
5
BUMPER WLDMT ICC HEAVY DUTY KPAC
PIVOT BLOCK WLDMT ICC KP60
NUT 1.25-7 HHGR5 NYLOC
1
2
2
2
2
PIN SNAP LOCK 1.00 KPAC 60-406
CAP SCR 1.25-7X5.50 HHGR5
TYP. 4
.31
W=.47
TYP. 4
(.31)
21.51
22.00
Assembly Drawings 73
ICC Bumper Weldment - PN 45574
4
3
TYP(2)
.19
.25
TYP (2)
1
2
19.00
16.00
TYP(2)
.25
15.44
35.50
66.38
PN 45574
ITEM
PART
45572
43138
45573
21447
DESCRIPTION
TUBE 3.00X2.00X0.25WX66.00
PLATE 0.19X2.63X1.63
TUBE 3.00X2.00X0.25WX22.63
TUBE 3.00X2.00X0.25WX14.00
QTY.
1
2
3
4
1
2
2
2
W=.47
TYP. 4
(.31)
TYP. 4
22.00
THREE SIDES
.25
OF TUBE
74
Stellar Cable Hoist Owner’s Manual
ICC Standard Narrow Bumper - PN 48848
6
20
3
13
14
8
19
7
18
9
15 16
17
12
5
4
9
3
6
2
3
10
11
PN 48846
ITEM
1
PART DESCRIPTION
QTY.
BUMPER WLDMT STANDARD KP60 NRW
48849
1
ICC
2
3
4
27626 LIGHT BACKUP LED 62391
2
7
4
13145 LIGHT CLEARANCE RED RND 2 LED
13143 LIGHT STOP/TURN/TAIL 4 RND LED
5
6
7
8
10334 GROMMET 4.00 ROUND LAMP (PETERSON)
C4862 GROMMET FOR 2 CLEARANCE 30700
18742 BACKUP ALARM ACORN 97 DECIBAL
2320 LICENSE PLATE LIGHT ROUND 430 W
45039PC PLATE MUD FLAP BACKING 43"FENDER KP
0346 WASHER 0.38 FLAT
7
7
1
1
2
16
8
8
12
6
6
4
4
4
8
2
9
10
11
12
13
14
15
16
17
18
19
20
0335 CAP SCR 0.38-16X1.25 HHGR5
0347 NUT 0.38-16 HH NYLOC
C5902 WASHER 0.63 SAE FLAT YELLOW GR8
24868 NUT 0.63-11 HHGR8 NYLOCK ZY
11693 CAP SCR 0.63-11X1.75 HHGR8
0480 CAP SCR 0.25-20X1.00 HHGR5
0533 NUT 0.25-20 HH
0654 NUT 0.25-20 WING
0340 WASHER 0.25 FLAT
C0073 TERML 16-14 BLUE BUTT WATER TIGHT
Assembly Drawings 75
ICC Narrow Bumper - PN 48846
1
4
5
5
3
4
5
5
6
2
3
7
5
6
6
5
5
PN 48846
ITEM
PART
48847
DESCRIPTION
BUMPER WLDMT ICC NARROW KPAC
QTY.
1
2
4
4
18
6
2
1
2
3
4
5
6
7
45813PC PLATE LINK ICC BUMPER
45815
5841
C6219 WASHER 0.75 SAE FLAT YELLOW GR8
C0538 NUT 0.75-10 HHGR8 NYLOC
58681
SPACER 1.25ODX0.75IDX2.16
CAP SCR 0.75-10X4.50 HHGR8
CAP SCR 0.75-10X2.50 HHGR8
76
Stellar Cable Hoist Owner’s Manual
ICC Extendable Bumper - PN 62663
4
5
7
3
6
1
2
PN 62663
ITEM
PART
62664PC
45813PC
45815
45623
C0538
58681
DESCRIPTION
BUMPER WLDMT ICC STANDARD EXT
PLATE LINK ICC BUMPER
SPACER 1.25ODX0.75IDX2.16
CAP SCR 0.75-10X4.50 HHGR5
NUT 0.75-10 HHGR8 NYLOC
CAP SCR 0.75-10X2.50 HHGR8
WASHER 0.75 SAE FLAT YELLOW GR8
QTY.
1
2
4
4
6
2
18
1
2
3
4
5
6
7
C6219
Assembly Drawings 77
Tri-Axle Fenders - PN 46299
NOTE: Includes PN 46122 Tandem Fenders
1
6
7
3
4
2
8
5
PN 46299
ITEM
1
PART
46626
DESCRIPTION
STD FEND WELDMENT-48"
QTY.
2
2
45039PC PLATE MUD FLAP BACKING 43"FENDER KP
2
3
4
46627PC
0347
FENDER SUPPORT WELDMENT
NUT 0.38-16 HH NYLOC
4
8
5
6
0351
0537
CAP SCR 0.38-16X1.00 HHGR5
NUT 0.50-13 HH
8
4
7
8
46590
C4821
CAP SCR 0.50X1.50 SQ HD CP SS
MUD FLAP 24.00X24.00 STELLAR
4
2
NOTE: MUD FLAPS ARE ONLY INCLUDED WITH A FACTORY INSTALLATION
78
Stellar Cable Hoist Owner’s Manual
Tandem Fenders - PN 46122
14
9
4
3
15
16
16
17
8
6
2
13
12
5
7
1
11
10
PN 46122
ITEM
1
2
3
4
PART
46121
DESCRIPTION
WLDMT FENDER STEEL TANDEM KP60
QTY.
2
1
2
2
46120PC TUBE REAR FENDER SUPPORT
46119PC WLDMT TUBE FRONT FENDER
46117PC TUBE FRONT FENDER SUPPORT
5
6
7
0537
2826
46590
NUT 0.50-13 HH
NUT 0.63-11 HH NYLOC
CAP SCR 0.50X1.50 SQ HD CP SS
4
3
4
8
47208PC PLATE 1.00X2.50X2.50 SPACER KP60
3
9
47209
47210
47211
BRKT FENDER KP60
FLAT 0.13X1.50X24.50 HR
CAP 0.13X3.00X2.88 FENDER KP60
2
2
2
3
10
11
12
13
C0966 CAP SCR 0.63-11X5.00 HHGR5
C1038 WASHER 0.63 FLAT
3
14
15
16
17
46906PC BRKT GANTRY MNT KPAC
2
C1026 CAP SCR 0.63-11X2.50 HHGR8
C5902 WASHER 0.63 SAE FLAT YELLOW GR8
10
20
10
24868
NUT 0.63-11 HHGR8 NYLOC
Assembly Drawings 79
Tandem Fenders - PN 46122 Continued...
TYP. 4
TYP. 2
.25
.25
TYP. 2
.19
TYP. 2
.19
TYP. 8
TYP. 4
.25
.25
80
Stellar Cable Hoist Owner’s Manual
Tandem Poly Fenders - PN 45795
3
9
5
6
10
2
1
7
4
11
1
2
1
8
ITEM
PART
0346
0347
DESCRIPTION
WASHER 0.38 FLAT
NUT 0.38-16 HH NYLOC
QTY.
36
30
1
2
3
10682
CAP SCR 0.38-16X1.50 BTNHD SOCKT SS
BRKT FENDER MNT CNTR KPAC TAND
24
4
5
45565PC
45566PC
2
2
POLY
BRKT FENDER MNT REAR KPAC TAND
POLY
6
7
8
9
10
11
45567
45568
FENDER TANDEM HALF KPAC POLY
4
4
1
1
2
6
FLAT 0.13X1.50X4.63
45569PC BRKT FENDER MNT FRRH KPAC TAND POLY
45570PC BRKT FENDER MNT FRLH KPAC TAND POLY
45571PC TUBE 2.00X2.00X0.25WX29.88
C0949 CAP SCR 0.38-16X3.00 HHGR5
Assembly Drawings 81
Tri-Axle Poly Fenders - PN 45893
5
4
2
1
3
4
2
3
5
PN 45893
ITEM
PART
45891
45890
59596
DESCRIPTION
QTY.
1
2
3
FENDER TRI-AXLE MIDDLE POLY KPAC
FENDER TRI-AXLE FRNT/REAR POLY KPAC
FENDER TRI-AXLE TRIM PLATES POLY
1
2
4
PLATE FORMED BRKT CNTR TRI POLY FENDER KPAC
(QTY 4 INCLUDED IN KIT 45892)
4
5
45892
45892
4
4
PLATE FORMED BRKT TAPERED POLY FENDER KPAC
(QTY 4 INCLUDED IN KIT 45892)
82
Stellar Cable Hoist Owner’s Manual
Standard Lift Cylinder - PN 55262
1
PN 55262
ITEM
PART
DESCRIPTION
QTY.
1
2
60132
CYLINDER 6.00X72.00 LIFT HOLLOW ROD
1
2
C4498 FTG ORB/JIC STRT CONNT 12-F5OX-S
2
Telescopic Lift Cylinder - PN 51078
3
NOTE: SEAL KIT P/N 48967
2
1
51078
ITEM
PART
45737
46113
46114
DESCRIPTION
QTY.
1
2
3
CYLINDER 5.50X185.75 TELO KPAC
FTG 90DEG MSTR/MJIC 16-20C50X
FTG MJIC/MSTR 90 12-16 C5OX
1
1
1
Assembly Drawings 83
Standard Reeving Cylinder - PN 51080
174 and 182 Models
NOTE: SEAL KIT P/N 45306
1
2
51080
2
ITEM
PART
DESCRIPTION
QTY.
1
2
45243
CYLINDER 7.00X80.00 KPAC
1
2
C4498 FTG ORB/JIC STRT CONNT 12-F5OX-S
Long Reeving Cylinder - PN 51201
194 Models
2
NOTE: SEAL KIT P/N 45306
1
51201
2
ITEM
PART
DESCRIPTION
QTY.
1
2
45349
CYLINDER 7.00X80.00 KPAC
1
2
C4498 FTG ORB/JIC STRT CONNT 12-F5OX-S
84
Stellar Cable Hoist Owner’s Manual
Tail Extension Cylinder - PN 51202
IOX Models
NOTE: SEAL KIT P/N 51070
2
2
1
51202
CYLINDER ASM 3.50X40.00 KP60 IOX
ITEM
1
2
PART
46153
46680
DESCRIPTION
CYLINDER 3.50X40.00 KP60 IOX
FTG MJIC/MSTR 90 8 C5OX
QTY.
1
2
Tail Extension Cylinder - PN 51203
ORX Models
3
NOTE: SEAL KIT P/N 51071
1
51203
CYLINDER ASM 3.50X80.00 KP60 ORX
ITEM
PART
45611
4594
DESCRIPTION
QTY.
1
2
3
CYLINDER 3.50X80.00 KP60 ORX
FTG ADAPT MSTR/MJIC 8 F5OX-S
FTG MJIC/MSTR 90 8 C5OX
1
1
1
46680
2
Assembly Drawings 85
Ratchet Strap Kit - PN 63150
NOTE: RATCHET TIE DOWN
SHOWN AS REFERENCE.
6
1
5
4
2
4
3
PN 63150
ITEM
PART
DESCRIPTION
QTY.
1
2
3
4
5
6
45496
STRAP 3X36 W/LOOP KPAC
1
1
1
2
1
1
45497PC STRAP HOOK (HOLD-DOWN) KPAC
C6106 NUT 0.50-13 HHGR5 NYLOC
0352
C1001 CAP SCR 0.50-13X5.50 HHGR5
45895 WINCH BAR STANDARD
WASHER 0.50 USS FLAT ZINC
86
Stellar Cable Hoist Owner’s Manual
Bolted Hold Down (Optional) - PN 42918
1
4
3
2
5
PN 42918
ITEM
PART
42917PC
0356
DESCRIPTION
QTY.
2
10
10
1
2
3
HOLD DOWN WELDMENT
CAP SCR 0.63-11X1.50 HHGR8
WASHER 0.63 LOCK
0526
4
5
C5902
45859
WASHER 0.63 SAE FLAT YELLOW GR8 10
FLAT TAP HOLD DOWN KP60
2
.25
.25
2-5.5
2-5.5
TYP. (2)
.25
.25
1
1
TYP. (2)
LENGTH/MODEL
DIM. A
35.75"
43.75"
DIM. B
174
182/194
IO
5.50"
8.00"
OR
DIM. B
DIM. A
Replacement Parts
87
Chapter 9 - Replacement Parts
Chassis Mounted Components
Hydraulic Components
Part number
15463
45074
15464
C6327
45332
45503
45343
45749
45737
48967
45243
45306
45349
46153
51070
45611
51071
Description
Part number
45600
Description
Mount Brkt - Truck frame lug SI60
Pin - Pivot
Pin - 2.50" drop shaft SI60
Collar 2.51x3.25x1.50 w/hole
Thermo Sight gauge
47531
Breather cap - Fill neck
45144
45756PC
Controller & Electrical Components
Tank cover - Clean out
Filter strainer
Filter element
Part number
46734
42399
47471
49580
45159
45798
D1810
45907
45908
46658
46713
47284
46291
Description
Relief valve
Controller - Straight No Lock
Controller - Joystick
Controller - Pnuematic
Controller - 2 section Pnuematic
Air Actuator (V42)
Cylinder 6.00" x 72.00" Lift
Cylinder seal kit (45343) 6.00 x 72.00
Cylinder - Telescopic 5.50" x 185.75" Lift
Cylinder seal kit (45737) 5.50" x 185.75"
Cylinder - Standard Reeving model 174 & 182 SI60 7.00" X 80.00"
Cylinder seal kit (45243 & 45349) 7.00" x 80.00" 174, 182, & 194
Cylinder - Long Reeving model 194 SI60 7.00" X 80.00" Long
Cylinder - Tail Extension SI60 IOX model hoists 3.50" x 40.00"
Cylinder seal kit (46153) 3.50" x 40.00"
Cylinder - Tail Extension SI60 ORX model hoists 3.50" x 80.00"
Cylinder seal kit (45611) 3.50" x 80.00"
Handle kit - 2 section VB
Air Line for air controllers
Switch - Remote SI60
Light - Dump up
Control Cable 108"
Control Cable 156"
Control Cable 252"
Cable Hoist Components
Cable connection kit (V20)
Part number
45372PC
0427
Description
Rear Bumper Components
Collar retaining 2.75x2.03x0.75
Machine Washer 2.00ID 10ga.
Machine Washer 3.00ID 14ga.
Grease Zerk 1/8 NPT straight
Roller 4.00" outside SI60
Part number
13143
Description
Light - Stop/Turn/Tail 4" Round LED
Light - Back up LED
Light - Clearance (Red) 2" Round LED
Light - Clearance (Amber) 2" Round LED
Light - License plate
Back up Alarm
Flat link - ICC Bumper
Spacer 1.25"OD x 0.75"ID x 2.16"
Pin snap lock - 1.00" ICC Heavy duty bumper
1589
27626
C1592
45373
45564
45304
45481
45523
46905
45556
45500
45410
45411
46604
42393
45114
46712
45138
45139
45583
49565
47277
47276
47272
45621
13145
13144
Roller - Rear Assembly SI60
Roller 6.00" SI60 Inside
2320
18742
Shaft - Vertical sheave
45813PC
45815PC
46810
U-Bolt Clamp 0.88" SI60
U-Bolt Clamp 1.00" SI75
Cable asm - Reeving cylinders 0.88" x 71 ft
Cable asm - Reeving cylinders 0.88" x 81 ft
Cable end casting SI60
Under Body Tool Box Components
Part number
23759
23764
33914
4410
Description
Latch - Door
Cable end - 0.88"
Latch Gasket - Door
Door roller asm for 1 side Includes 4110, 22045, 4166, 4659
Roller OH door
Cable end - 1.00"
Spring
Reeving Sheave weldment SI60
Reeving Sheave weldment SI75
Pin sheave and cable shaft
Sheave 10" - cable asm SI60
Strap weldment cylinder reeving SI60
U-Bolt 0.50" x 6.75"w x 7.88"
Removable stop - OR model Cable hoists
Removable stop - OR model Cable hoists
Intermediate stop - IO Fold down stop
Intermediate stop - OR Fold down stop
22045
4166
Bracket - Roller OH door
Cap Screw - Shoulder 0.38"
Nut - Center lock 0.38"
Angle - UHMW RH
4659
4183
4167
Angle - UHMW LH
Fender Components
Part number
46626
Description
Fender Weldment - Standard 48"
Fender Weldment - Steel Tandem SI60
Fender - Tandem Poly SI60 Half
Fender - Tri-Axle Middle section Poly
Fender - Tri-Axle Front & Rear sections Poly
Mud Flap 24.00" x 24.00" Stellar
46121
45567
45891
45890
C4821
88
Stellar Cable Hoist Owner’s Manual
Limited Warranty Statement
Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under
proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. This warranty
shall cover the following:
Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, and Stellar X-Tra-Lift Systems:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date
of manufacture,
Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of
manufacture, and
Thirty-six (36) month warranty on all Stellar Manufactured structural parts from the date recorded by Stellar as the in-service date, not to extend beyond
forty-eight (48) months from date of manufacture.
Stellar Tarper Systems:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date
of manufacture and
Three (3) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond fifteen (15) month from date of
manufacture.
The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, the
factory ship date will be used.
Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option)
of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-
applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24-hours of notification by
the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.
Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service
personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party
prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged parts
must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of
the warranty claim.
Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type
of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence
of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any
field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service
provider.
All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides
other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellar-manufactured
product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any
way not approved, in writing, by Stellar.
The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the
ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the
product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in
question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear,
accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and maintenance
duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such
duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.
The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above.
In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of delay, or for any
special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use,
wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.
All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not
participate in, or obligate itself to, any such warranty.
Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products
theretofore manufactured.
This warranty will apply to all Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, Stellar X-Tra-Lift
Systems, and Stellar Tarper Systems shipped from Stellar’s factory after January 1st, 2010. The warranty is for the use of the original owner only and is not
transferable without prior written permission from Stellar.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR
INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Revision Date: February 2010
Document Number: 37040
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