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108-11-32

Shuttle Hooklift

Owner’s Manual

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Subject to Change without Notification.
© 2018 Stellar Industries, Inc.

Rev 1

PN 92397

Installation • Assembly Drawings • Parts

Summary of Contents for 108-11-32

Page 1: ... Stellar Industries Inc 190 State Street PO Box 169 Garner IA 50438 800 321 3741 Fax 641 923 2811 www stellarindustries com Subject to Change without Notification 2018 Stellar Industries Inc Rev 1 PN 92397 Installation Assembly Drawings Parts ...

Page 2: ...Page ii Stellar 108 11 32 Shuttle Owner s Manual Model 108 11 32 Manual Revisions Date of Revsion Section Revised Description of Revision ...

Page 3: ...trols PN 86463 9 Reservoir Assembly with Air Controls PN 86467 10 Valve Bank Parts Drawing 12 Step 8 Install PTO and pump 13 Face Seal O Ring Size Chart 14 Step 9 Route hydraulic hoses 14 Hose Kit PN 44338 15 Power Beyond VDM8 Valve 16 Step 10 Route Electrical Components 17 Step 11 Install cab and PTO controls 18 Cable Controls 18 Air Controls 19 Step 12 Install mud flaps and fenders 20 Poly Tande...

Page 4: ...eral Shuttle Hooklift Manual for details on these items This manual is not binding Stellar Industries Inc reserves the right to change at any time any or all of the items components and parts deemed necessary for product improve ment or commercial production purposes This right is kept with no requirement or obliga tion for immediate mandatory updating of this manual In closing If more information...

Page 5: ... handle a multitude of bodies ranging from flatbeds to recycling containers and dump bodies The Shuttle consists of four basic parts the base dump secondary and tilt sections Please take the time to familiarize yourself with the various components Knowing the proper ter minology is necessary to get the full benefit of this manual HOOKLIFT BASE DUMP SECONDARY TILT ...

Page 6: ...749 389 6 558 104 5 427 495 5 108 247 6 065 942 5 082 417 CANADIAN PATENTS 6 749 389 5 108 247 WARNING 25627 Rev B Moving parts can crush and cut Keep hands and arms clear when operating equipment Crush Hazard DANGER Electrocution Hazard Death or serious injury will result from inadequate clearance if hooklift load or vehicle becomes electrically charged Maintain safe clearance from high voltage p...

Page 7: ...sis Cab to Axle 108 to 120 274 3 to 304 8 cm J Max Height When Loading 145 369 cm K Longest Body to Dump 180 457 cm L Max Height when Dumping 196 498 cm Operating Pressure 4200 psi Hydraulic Flow Not to exceed 24 GPM Shipping Weight 3 160 lbs 1 434 kg Hook Height 61 75 156 85 cm Shipping Dimensions LxHxW 140 x 84 x 51 Minimum Truck GVWR 34 000 RBM 1 600 000 Load Angle w Shortest Body Length 36 Rec...

Page 8: ...Page 2 Stellar 108 11 32 Shuttle Owner s Manual Acceptable Subframe Dimensions Model 108 11 32 ...

Page 9: ...14 40 Hooklift Each installation is considered unique so certain portions of this chap ter may or may not apply to your direct application If a question should arise during the installation process please contact Stellar Customer Service at 800 321 3741 PTO and Pump installation instructions are provided by the corresponding manufacturers For more information on which PTO and Pump fit your applica...

Page 10: ...loads Always replace shear bolts with identical grade Fasteners should be replaced with the same or higher grade If higher grade fasteners are used these should only be tightened to the strength of the original Tighten plastic insert or crimped steel type lock nuts to approximately 110 percent of the dry torque values shown in the chart below applied to the nut not to the bolt head Tighten toothed...

Page 11: ...ing system Be sure to square the hooklift on the truck frame to allow for proper measurement The front of the hooklift needs to be at least 2 50 behind the cab or any equipment mount ed behind the cab Step 1 Set the hooklift onto the truck frame Every hooklift installation is unique However certain guidelines exist that apply to every model Listed below is a general set of chronlological steps tha...

Page 12: ...each of the rear tabs using the channels as a guide Bolt the channels to the tab using 5 8 bolts washers and nuts DETAIL A SCALE 1 10 1 25 TYP 4 25 TYP 2 DETAIL B SCALE 1 15 3 25 W 38 TYP 4 4 7 7 10 1 2 11 8 9 0 4 7 7 10 1 2 6 8 11 8 9 ITEM PART DESCRIPTION QTY 1 79246 TIE DOWN 40 000 PC BLACK 4 2 1440 TIE DOWN 40000 4 3 80043 PLATE 0 50X8 00X16 00 W HOLE 4 4 12169 CAP SCR 1 00 8X3 50 HHGR8 4 6 C1...

Page 13: ... plates should be approximately even with the bottom of the base tube 2 Weld all tie down channels and shear plates to the base of the hooklift 3 Using the channels as a guide drill four 4 1 1 16 holes and two 2 11 16 holes through the truck frame 4 Drill two 2 1 1 16 holes through each of the shear plates and the truck frame NOTE LOCATE AS CLOSE TO FRONT PIN POINT AS POSSIBLE MUST BE IN FRONT OF ...

Page 14: ...NNEL 2 6 8 9 10 7 7 5 3 4 7 10 5 7 WELD HERE 2 0 0 6 8 9 10 7 7 5 3 4 7 10 5 7 WELD HERE 1 2 PN 16898 See NHTSA National Highway Truck Saftey Administration Regulations for acceptable placement Modify the truck frame as necessary so that it ends 2 from the rear of the hooklift Step 5 Install bumper 2 00 See brand specific installation instructions Before drilling and bolting to the frame confirm a...

Page 15: ...0339 CAP SCR 0 25 20X2 50 HHGR5 3 8 60395 FTG 16 20 MFS MAORB 90 1 9 C2252 FTG 8 10 MFS MORB STRAIGHT 2 10 16152 FTG 10 10 MFS MORB STRAIGHT 2 11 27119 HOSE 0 75 78C 12 JC JC 12 12 12 120 1 12 10094 GAUGE OIL LF 2 5 0 5000 BM 1 13 c4819 HOSE CLAMP 2 00 2 14 17766 HOSE SUCT 2 00 10FT 1 15 25630 FTG 10 4 MORB FP STRAIGHT 1 16 d1435 FTG 12 10 MFS MORB STRAIGHT 1 17 c4903 FTG 12 12 MFS FFSS 90 1 18 83...

Page 16: ...LOCK 3 7 0339 CAP SCR 0 25 20X2 50 HHGR5 3 8 60395 FTG 16 20 MFS MAORB 90 1 9 C2252 FTG 8 10 MFS MORB STRAIGHT 2 10 27119 HOSE 0 75 78C 12 JC JC 12 12 12 120 1 11 10094 GAUGE OIL LF 2 5 0 5000 BM 1 12 c4819 HOSE CLAMP 2 00 2 13 17766 HOSE SUCT 2 00 10FT 1 14 25630 FTG 10 4 MORB FP STRAIGHT 1 15 d1435 FTG 12 10 MFS MORB STRAIGHT 1 16 c4903 FTG 12 12 MFS FFSS 90 1 17 16152 FTG 10 10 MFS MORB STRAIGH...

Page 17: ...ion Valve Bank w Cable Controls 2 Section Valve Bank w Air Controls NOTE INSTALL PORT RELIEF HERE WHEN PN S FROM THE FOLLOWING LIST ARE USED TILT ASM S 83048 USES PORT RELIEF 69172 85778 USES PORT RELIEF 26184 NOTE INSTALL PORT RELIEF HERE WHEN PN S FROM THE FOLLOWING LIST ARE USED DUMP ASM S 56861 47056 45730 55839 ...

Page 18: ...Owner s Manual Valve Bank Parts Drawing SPOOL SPRING KIT WITH COVER PN 43776 AIR ACTUATOR PN 26566 HANDLE ASM OUTSIDE CTRLS WITH HANDLE PN 30381 SPOOL RETAINER PN 61522 MAIN RELIEF VALVE PN 28510 HANDLE PN 26130 SPOOL SEAL KIT PN 29683 ...

Page 19: ...ified by looking from the front of the truck to the rear of the truck Use the brand specific PTO Pump installation instructions If the directions are not quite clear contact Stellar Customer Service or consult with a hydraulic specialty house or company prior to installation PTO DRIVEN EQUIPMENT PUMP DRIVEN EQUIPMENT PUMP TRANSMISSION TRANSMISSION From rear of truck PTO shaft rotates opposite engi...

Page 20: ...he Power Beyond feature for additional function see Power Beyond VDM8 Valve later in this chapter for further details Notes on hose line routing Protect these lines with hose wrap when necessary Keep these lines away from sharp edges Keep these lines away from the exhaust or other temperature extreme items Keep these lines away from the driveshaft or other moving items Step 9 Route hydraulic hoses...

Page 21: ...Stellar 108 11 32 Shuttle Owner s Manual Page 15 PRESSURE FROM PUMP RETURN TO TANK NOTE SYSTEM PRESSURE IS 4200 P S I Hose Kit PN 44338 ...

Page 22: ... portion of cavity to activate the power beyond fea ture Use thread sealer tape sealers not recommended 3 The Power Beyond feature is now activated and will divert oil to alternate system via the port shown Notes The return tank line must be connected to the top or the side port labeled T Using the return line to run auxillary equipment will directly result in a failure and will not in any circums...

Page 23: ...wer source when wiring BLOCK COLORED WHITE REARCLEARANCE BROWN WHITE BACK UPALARM WHITE BLACK REDCLEARANCE WHITE BROWN REDCLEARANCE WHITE BROWN TAGLIGHT BROWN TAGLIGHT BROWN TAGLIGHT BROWN LHTURN STOP REDLIGHT WHITE BROWN YELLOW RHTURN STOP REDLIGHT WHITE BROWN YELLOW RHTURN STOP REDLIGHT WHITE BROWN YELLOW BACKUP WHITELIGHT WHITE BLACK TAGLIGHT BROWN MID BODY CLEARANCE 2 AMBER RND LED MID BODY CL...

Page 24: ...VER RVC 1 2 37475 CTRL CNTR LOCK LEFT BEND 1 3 37476 CTRL CNTR LOCK NO BEND 1 4 37474 CTRL CNTR LOCK RIGHT BEND 1 5 37469 CABLE CONN KIT FOR VD8A VDM8 3 6 37471 CONTROL CABLE 96 IN WESCON 3 7 20057 CAP SCR 0 31 18X6 50 HHGR5 2 8 0343 WASHER 0 31 USS FLAT 12 9 0342 NUT 0 31 18 HHGR5 NYLOC 6 10 16948 GROMMET 2 50ODX0 125X0 25ID 1 11 0486 CAP SCR 0 31 18X1 50 HHGR5 4 PARTS NOT SHOWN 61233 LIGHT LED C...

Page 25: ... R V R ITEM PART DESCRIPTION QTY 1 41988 CTRL 2 BANK 4WAY AIR CNTR LOCK 1 2 45687 FTG 4 2 MP PTC 90 BRASS 1169X4S 7 3 D1711 CAP SCR 10 24X0 50 BTNHD SS 4 4 C6021 CAP SCR 0 25 20X0 75 BTNHD SS 4 5 0486 CAP SCR 0 31 18X1 50 HHGR5 4 6 0343 WASHER 0 31 USS FLAT 8 7 0342 NUT 0 31 18 HHGR5 NYLOC 4 8 16948 GROMMET 2 50ODX0 125X0 25ID 1 9 35211 PTO AIR REGULATOR 378414 1 10 45333 FTG 4 2 PC DOT MP STRAIGH...

Page 26: ... Shuttle Owner s Manual 1 2 ITEM PART DESCRIPTION QTY 1 64060 FENDER POLY MIN 900 FRONT REAR 4 2 64057 FENDER MNT KIT TANDEM POLY SET MIN 900 1 PN 58217 Step 12 Install mud flaps and fenders Poly Tandem Fender Assembly PN 58217 ...

Page 27: ...0 FLAT 0 13X1 50X24 50 HR W HOLE 2 7 47211 CAP 0 13X3 00X2 88 FENDER KP60 2 8 C0966 CAP SCR 0 63 11X5 00 HHGR5 3 9 C1038 WASHER 0 63 FLAT 3 10 C1026 CAP SCR 0 63 11X2 50 HHGR8 10 11 C5902 WASHER 0 63 SAE FLAT YELLOW GR8 20 12 24868 NUT 0 63 11 HHGR8 NYLOC 10 13 46120 TUBE REAR FENDER SUPPORT 1 14 46119 WLDMT TUBE FRONT FENDER 2 15 46117 TUBE FRONT FENDER SUPPORT 2 16 47208 PLATE 1 00X2 50X2 50 SPA...

Page 28: ...1 29409 TERML 12 10X 31 RING X 1 ITEM PART DESCRIPTION QTY 1 45907 SWITCH REMOTE KP60 1 2 30472 CAP SCR 10 24X1 25 BTNHD SS 3 3 D0178 WASHER 10 SAE FLAT 6 4 26034 NUT 10 24 HH NYLOC 3 NOTE BRACKET SHOWN AS REFERENCE ONLY 2 3 1 3 4 USE 29409 TO GROUND BLACK WIRE USE C0073 TO CONNECT RED WIRE TO THE CONTROLLER ASSEMBLY PEDESTALS BLUE DUMP UP LIGHT WIRE A DETAIL A SCALE 1 12 NOTE MOUNT SWITCH ON BRAC...

Page 29: ...an crush and cut Keep hands and arms clear when operating equipment Crush Hazard 26134 Rev A Operating hooklift when dump tabs are not properly fastened can result in death or serious injury Inspect tabs daily Immediately replace damaged tabs Misuse Hazard WARNING 26134 Rev A Operating hooklift when dump tabs are not properly fastened can result in death or serious injury Inspect tabs daily Immedi...

Page 30: ... oil level and add oil if needed When checking hydraulic oil level make certain that all system cylinders are fully retracted Calibrate dump light system Be sure to check all clearances Be sure that relief pressure is no higher than 4200 PSI Step 15 Fill reservoir and activate hydraulic flow Fill reservoir to site gauge within 3 from the top Roughly 10 Gallons Note ISO 32 hy draulic oil is recomme...

Page 31: ...nd release the jam nut using a 13 mm wrench 4 Adjust the system relief pressure using 4 mm allen wrench See chart on previous page Clockwise increases pressure counter clockwise decreases pressure 5 Once system pressure is set tighten the jam nut to lock system pressure Permanent thread lock should not be used 6 Release all functions and disengage the PTO Snap tamper cap into position over the jam...

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Page 33: ...0X1 25 2 4 0857CR PIN 2 50X12 38 SR D T 1 5 26048CR PIN 2 50X36 44 1 6 23930 COLLAR 2 51X3 50X1 00 2 7 0333 NUT 0 25 20 HHGR5 NYLOC 6 8 C0082 CLAMP 0 75 BLK VINYL 6 9 0636 SNAP RING 2 50 HD 2 10 1593 MACHY WASHER 2 50ID 10GA 2 11 32086 CAP SCR 0 38 16X4 25 HHGR5 2 12 0347 NUT 0 38 16 HHGR5 NYLOC 2 13 58052 SET SCREW 0 50 13X0 50 W RED PATCH 2 14 1547 THRUST WASHER 2 51DIA UHMW 12THK 4 PN 92287 Cha...

Page 34: ...CREW 0 50 13X0 50 W RED PATCH 1 7 C0954 CAP SCR 0 38 16X4 50 HHGR5 4 8 0506 CAP SCR 0 50 13X4 00 HHGR5 2 9 0332 CAP SCR 0 25 20X1 75 HHGR5 2 10 C6106 NUT 0 50 13 HHGR5 NYLOC 2 11 0333 NUT 0 25 20 HHGR5 NYLOC 2 12 1548 THRUST WASHER 3 01DIA UHMW 12 THK 6 13 c1592 ZERK 1 8 NPT STRAIGHT 4 14 26187 TAB LOADER BREAK AWAY 1 50 OFFSET W TAP PC BLACK 1 15 25582CR PIN 2 50X25 25 ZC 1 16 54866 TAB LOADER BR...

Page 35: ... 17315CR PIN 2 00X14 75 D T 1 4 0635 BUSHING 40DXR32 GARLOCK 6 5 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 8 6 12921 THRUST WASHER 0 64x3 50x0 125 2 7 12719 THRUST WASHER 0 64x3 00x0 125 2 8 8455 PIN CAP 0 69X3 50X0 19 YZ 2 9 8454 PIN CAP 0 69x3 00x0 19 YZ 2 10 75007 THRUST WASHER 0 63X1 13X0 09 MTI 10 4 11 12673 BOLT SHOULDER 0 63X0 50 0 50 13X0 75 4 12 19066 CYLINDER ASM 3028 1 13 c1592 ZERK 1 8 NP...

Page 36: ...LATCH CS 40000K 1 6 23160 CYLINDER ASM 4 00X12 00 1 7 c1592 ZERK 1 8 NPT STRAIGHT 2 8 8457 CAP SCR 0 50 13X1 00 SS 2 9 8818 PIN CAP 0 55X2 00X0 63 YZ 2 10 0427 MACHY WASHER 2 00ID 10GA 2 11 0108 SNAP RING 2 00 7200 200 2 12 58052 SET SCREW 0 50 13X0 50 W RED PATCH 2 13 12673 BOLT SHOULDER 0 63X0 50 0 50 13X0 75 2 14 12719 THRUST WASHER 0 64x3 00x0 125 2 15 75007 THRUST WASHER 0 63X1 13X0 09 MTI 10...

Page 37: ...BUSHING 32DXR32 2 00X2 00 GARLOCK 8 6 12719 THRUST WASHER 0 64x3 00x0 125 2 7 8454 PIN CAP 0 69x3 00x0 19 YZ 2 8 75007 THRUST WASHER 0 63X1 13X0 09 MTI 10 2 9 12673 BOLT SHOULDER 0 63X0 50 0 50 13X0 75 2 10 23160 CYLINDER ASM 4 00X12 00 1 11 92364 TILT 108 11 32K 54 1 12 58052 SET SCREW 0 50 13X0 50 W RED PATCH 2 13 0427 MACHY WASHER 2 00ID 10GA 2 14 0108 SNAP RING 2 00 7200 200 2 15 24610CR PIN 2...

Page 38: ...tellar 108 11 32 Shuttle Owner s Manual Main Cylinder PN 19066 7 0 3 57 6 5 37 21 47 1 5 0 1 2 60 8 7 36 78 60 86 1 5 5 2 7 0 6 025 675 7 7 0 6 025 675 7 26 03 03 3257 78 5 7 025 3 8 2 2 7 0 6 025 675 7 PN 19066 ...

Page 39: ... 32 Shuttle Owner s Manual Page 33 Tilt Cylinder PN 23160 2 2 1 3 ITEM NO QTY PART NO DESCRIPTION 1 1 14388 CYLINDER 4 00X12 00 2 3 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 3 2 D1290 FTG 8 6 MFS MORB STRAIGHT PN 23160 ...

Page 40: ... 3 D1638 O RING 1 12X1 38X0 12 568 216 1 4 3748 WASHER ROTARY VALVE 1 5 0480 CAP SCR 0 25 20X1 00 HHGR5 1 6 0353 CAP SCR 0 38 16X2 00 HHGR5 2 7 0347 NUT 0 38 16 HH NYLOC 3 8 0977 O RING 1 00X1 25X0 12 568 214 1 9 24236PC PLATE ROTARY VALVE ARM 1 10 0482 CAP SCR 0 25 20 X 3 00 HHGR5 2 11 0333 NUT 0 25 20 HHGR5 NYLOC 2 12 1554 FTG 8 8 MFS MORB STRAIGHT 4 13 0340 WASHER 0 25 USS FLAT ZINC 4 14 C0946 ...

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Page 42: ...Subject to Change without Notification 2018 Stellar Industries Inc ...

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