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108-12 Flex 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.
© 2021 Stellar Industries, Inc.

Rev 1

PN 34624

Installation • Assembly Drawings • Parts

Summary of Contents for 108-12 Flex

Page 1: ...llar 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 2021 Stellar Industries Inc Rev 1 PN 3462...

Page 2: ...if hooklift load or vehicle becomes electrically charged Maintain safe clearance from high voltage power sources Never approach vehicle or load if equipment is near a high voltage power source 55832 R...

Page 3: ...17 Reservoir Assembly Electric Controls PN 97093 18 Reservoir Subassembly PN 86117 19 Side Mount Reservoir Subassembly PN 88147 20 Valve Bank Parts Drawing 21 Step 8 Install PTO and pump 22 Face Seal...

Page 4: ...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 neces...

Page 5: ...dle 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 famil...

Page 6: ...Page vi Stellar 108 12 Flex Owner s Manual This page intentionally left blank...

Page 7: ...36 92 cm E Hooklift Height 41 5 106 cm G Hooklift Length 154 391 cm H Hooklift Center of Gravity 68 173 cm I Chassis Cab to Axle 108 to 120 2 743 to 3 048 cm J Max Height When Loading 135 343 cm K Lo...

Page 8: ...12 Flex Owner s Manual Acceptable Subframe Dimensions Model 108 12 Flex QTY 1 BASE END OF TILT CYL QTY 1 BASE END OF LIFT CYL QTY 2 QTY 1 QTY 2 QTY 2 QTY 2 Note Grease After Every 100 Cycles Flex36 Gr...

Page 9: ...ooklift Each installation is considered unique so certain portions of this chapter may or may not apply to your direct application If a question should arise during the in stallation process please co...

Page 10: ...s 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 or...

Page 11: ...any potential issues For example Clearance problem cross members extending too high insufficient room in front of the hooklift for tarpers exhaust manifolds etc or insufficient room in the rear to al...

Page 12: ...es are designed with multiple slots to offer more flexibility in mounting locations Additional holes may not be added Step 2A Non F550 RAM5500 Bolt tie down castings to mounting plates ITEM PART DESCR...

Page 13: ...nting holes into frame rail 11 16 11 16 Bolt each tie down angle to the truck frame both sides Step 4A Non F550 RAM5500 Bolt tie down castings to truck frame ITEM PART DESCRIPTION QTY 3 C1026 CAP SCR...

Page 14: ...00 Mounting Kit PN 23700 PN 23700 ITEM PART DESCRIPTION QTY 1 D0143 TIE DOWN CHANNEL 6 2 C1026 CAP SCR 0 63 11X2 50 HHGR8 12 3 C5902 WASHER 0 63 SAE FLAT YELLOW GR8 24 4 24868 NUT 0 63 11 HHGR8 NYLOCK...

Page 15: ...added Note Tack spacer PN 91312 to bottom of base Note Use 2 sets of hardware in order to attach spacer PN s 91311 91313 to the hooklift base Step 2B F550 Bolt tie down castings to mounting plates 4 5...

Page 16: ...CHASSIS 4 9 3 2 NOTE USE 2 SETS OF HARDWARE IN ORDER TO ATTACH SPACERS PN S 91311 91313 TO THE HOOKLIFT BASE 8 3 NOTE TRIM STUD BOLTS FLUSH WITH TRUCK FRAME IF THEY INTERFERER WITH MOUNT RECOMMENDED M...

Page 17: ...2 5 C5902 WASHER 0 63 SAE FLAT YELLOW GR8 36 6 24868 NUT 0 63 11 HHGR8 NYLOC 18 7 C1026 CAP SCR 0 63 11X2 50 HHGR8 18 8 D0143 TIE DOWN CHANNEL 2 9 97423 ANGLE FORMED FLEX BASE MNT SS 1 10 97424 ANGLE...

Page 18: ...added Note Tack spacer PN 96261 to bottom of base Note Use 2 sets of hardware in order to attach spacer PN s 96259 96260 to the hooklift base Step 2C RAM5500 Bolt tie down castings to mounting plates...

Page 19: ...l 11 16 mounting holes through the truck frame as shown Both Sides Step 3C RAM5500 Drill mounting holes into frame rail RECOMMENDED MOUNTING CONFIGURATION FOR RAM 5500 CHASSIS NOTE USE 2 SETS OF HARDW...

Page 20: ...OT SHOWN 62177 BRKT FUEL FILL X 1 ITEM PART DESCRIPTION QTY 1 96259 PLATE 0 19X5 00X14 00 SLOTS W PAINT 4 2 96260 PLATE 0 19X5 00X8 50 SLOTS W PAINT 2 3 96261 FLAT 0 19X2 00X10 00 CR W HOLE PAINT 2 4...

Page 21: ...placement Modify the truck frame as necessary so that it ends 3 50 from the rear of the hooklift Step 5 Install bumper 3 50 See brand specific installation instructions Before drilling and bolting to...

Page 22: ...0 25 20X2 50 HHGR5 7 D0549 1 FTG 16 8 MORB FORB STRAIGHT REDUCER 8 17767 1 HOSE SUCT 1 25 10FT 10 C4747 1 FTG 20 16 HB MAORB 45 9 C0075 2 HOSE CLAMP HC125 11 10094 1 GAUGE OIL LF 2 5 0 5000 BM ITEM P...

Page 23: ...20 14 1554 1 FTG 8 8 MFS MORB STRAIGHT 13 C2376 1 FTG 8 8 MFS FFSS 90 16 C2252 5 FTG 8 10 MFS MORB STRAIGHT 17 84341 1 MNT KIT RSRVR 10GAL 18 86117 1 RSRVR ASM 10GAL K MODEL W TANK TOP FILTER 19 C2142...

Page 24: ...UCT 1 25 10FT 1 13 C1025 CAP SCR 0 63 11X2 00 HHGR8 3 14 24868 NUT 0 63 11 HHGR8 NYLOC 3 15 C5902 WASHER 0 63 SAE FLAT YELLOW GR8 6 16 C0075 HOSE CLAMP HC125 2 17 C5552 FILTER STRAINER TFS 1220 0 1 18...

Page 25: ...002 DECAL HYD OIL SPECIFICATION MOBIL 1 5 86118 RSRVR 10GAL K MODEL W TANK TOP FILTER 1 6 86123 FILTER TANK TOP SFM 12 SAE 1 7 5591 WASHER 0 31 SAE FLAT YELLOW GR8 2 8 0420 CAP SCR 0 31 18X0 75 HHGR5...

Page 26: ...N 86123 ITEM PART DESCRIPTION QTY 1 73278 CAP FILL 1PSI ZINGA THREADED 1 2 C4841 PLUG 0 38 NPT SQ HD BLK 2 3 15463 THERMO SIGHT GAUGE ZINGA SG O5 A T N 1 4 13002 DECAL HYD OIL SPECIFICATION MOBIL 1 5...

Page 27: ...al Page 21 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 P...

Page 28: ...d 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 co...

Page 29: ...ower 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 thes...

Page 30: ...Page 24 Stellar 108 12 Flex Owner s Manual PRESSURE FROM PUMP RETURN TO TANK PRESSURE FROM PUMP RETURN TO TANK Hose Kit PN 72355...

Page 31: ...tion 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 sho...

Page 32: ...Page 26 Stellar 108 12 Flex Owner s Manual Step 10 Route Electrical Components...

Page 33: ...OL CABLES TO VALVE BANK 3 4 2 1 8 7 6 8 9 10 11 8 8 9 5 At Valve Installation ITEM PART DESCRIPTION QTY 1 38351 VALVE CTRL CONSOLE 3LEVER RVC 1 2 37475 CTRL CNTR LOCK LEFT BEND 1 3 37476 CTRL CNTR LOC...

Page 34: ...CT LOAD UNLOAD EXTEND RETRACT IN OUT EXTEND TILT LIFT PN 99376 1 92090 1 WLDMT CONTROL TOWER RAM MNT 2SEC FOR F550 2016 2017 4 C0930 4 CAP SCR 0 31 18X3 00 HHGR5 3 37475 1 CTRL CNTR LOCK LEFT BEND 2 3...

Page 35: ...ount Adjustment Instructions Ford F550 ADJUSTMENT SCREW ADJUSTMENT SCREW NOTE CONFIGURE PN 97465 AS SHOWN USING THE ADJUSTMENT SCREWS ALIGN HANDLES SO THE MIDDLE SEAT CONSOLE CAN BE FOLDED DOWN AND GL...

Page 36: ...T IN UNLOAD EXTEND TILT RETRACT LOAD PN 99377 1 91606 1 WLDMT CONTROL TOWER RAM MNT 2SEC FOR RAM5500 2017 4 C0930 4 CAP SCR 0 31 18X3 00 HHGR5 3 37475 1 CTRL CNTR LOCK LEFT BEND 2 37474 1 CTRL CNTR LO...

Page 37: ...ount Adjustment Instructions RAM 5500 ADJUSTMENT SCREW ADJUSTMENT SCREW NOTE CONFIGURE PN 97465 AS SHOWN USING THE ADJUSTMENT SCREWS ALIGN HANDLES SO THE MIDDLE SEAT CONSOLE CAN BE FOLDED DOWN AND GLO...

Page 38: ...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...

Page 39: ...Stellar 108 12 Flex Owner s Manual Page 33 Electric Controls PN 97617...

Page 40: ...7 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 MOUNT SWITCH ON BRACKET ON THE BASE ITEMS NOT SHOWN C0073 TERML 16 14 BUTT W...

Page 41: ...KIT OFFSET POLY FENDER FLEET 2 9 7633 FENDER MOUNT ASM KIT 2 PN 15681 Poly Fender Assembly PN 15681 Step 13 Install mud flaps and fenders 10 2 9 5 3 4 7 8 9 6 1 ITEM PART DESCRIPTION QTY 1 47991 FEND...

Page 42: ...4 00X11 50 06 55832 2 DECAL DANGER ELECTROCUTION HOOK 07 68024 1 DECAL WARNING UNTRAINED OPERATOR ITEM PART No QTY DESCRIPTION Rev Level O Date 08 16 21 Changes Separate chassis decals from hooklift a...

Page 43: ...N 10 91219 1 DECAL HITCH CAPACITY 30K 09 91220 1 DECAL HITCH CAPACITY 16K 11 68222 1 DECAL HITCH CAPACITY 90K 12 45697 1 ENGINE SPEED PTO CAUTION 13 69463 1 DECAL BACK UP ALARM VERIFY IN CAB CONTROL T...

Page 44: ...gns before operating or servicing this equipment Bleed the air out of the hydraulic system Check the hydraulic oil level and add oil if needed When checking hydraulic oil level make certain that all s...

Page 45: ...elease 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...

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Page 47: ...2 14 C6106 NUT 0 50 13 HHGR5 NYLOC 2 15 C0078 CLAMP 0 38 BLK VINYL 1 16 0479 CAP SCR 0 25 20X0 75 HHGR5 1 17 0333 NUT 0 25 20 HHGR5 NYLOC 1 18 0220 CAP SCR 0 25 20 X 1 50 HHGR5 4 19 0340 WASHER 0 25...

Page 48: ...50 HHGR5 2 5 0333 NUT 0 25 20 HHGR5 NYLOC 2 6 C6106 NUT 0 50 13 HHGR5 NYLOC 2 7 c1592 ZERK 1 8 NPT STRAIGHT 2 8 0481 CAP SCR 0 25 20X2 00 HHGR5 2 9 0352 WASHER 0 50 USS FLAT 1 10 65135 LEVER PLUNGER...

Page 49: ...IPTION QTY 1 34250 SECONDARY 108 12 FLEX 36 1 2 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 6 3 0068 BUSHING QSI 1618 24 6 4 3875 SNAP RING 1 00 INTERNAL 2 5 2257 SNAP RING INSIDE 2 00 2 6 33462 CYLINDER A...

Page 50: ...BUSHING QSI 1618 16 1 4 4912ZP PIN 1 00X3 25 SR 1 5 0110 SNAP RING 1 00 ID 7200 100 2 6 0068 BUSHING QSI 1618 24 4 7 33103ZP PIN WLDMT 1 00X9 81 2 8 d0419 THRUST WASHER 2 9 33104PC COLLAR 1 03X2 00X1...

Page 51: ...5 33103 PIN WLDMT 1 00X10 50 2 6 D0419 THRUST WASHER 2 7 33104 COLLAR 1 03X2 00X1 00 2 8 0339 CAP SCR 0 25 20X2 50 HHGR5 2 9 0333 NUT 0 25 20 HHGR5 NYLOC 2 10 c1592 ZERK 1 8 NPT STRAIGHT 4 11 35066 P...

Page 52: ...11A 5000 PSI 1 5 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 4 1 3 1 0 4 X 0 5 0 M S A E B U T 0 5 7 3 3 6 7 19369 HOSE CLAMP 4 13 7 00 5416K38 1 8 18701 CLAMP PORT TUBE ZR518 1 9 16256 TUBE ASM 0 50X6 75...

Page 53: ...R WLDMT FOR 30K PINTLE FLEX 1 4 0479 CAP SCR 0 25 20X0 75 HHGR5 2 5 0521 WASHER 0 25 LOCK 2 6 0340 WASHER 0 25 USS FLAT 2 7 82431 LIGHT STOP TURN TAIL REV 4 RND GROTE LED 4 8 82430 GROMMET 4 00 ROUND...

Page 54: ...PN 20057 WITH 3 SECTION CONTROL TOWER 3 9 6 1 3 8 4 7 5 NOTE WHEN USED WITH AIR CONTROL TOWERS BRACKET PN 26293 IS NOT USED B C COMPONENTS ARE TO BE INSTALLED IN TOWER ASSEMBLY NOTE WIRE HARNESS PN 26...

Page 55: ...Stellar 108 12 Flex Owner s Manual Page 49 Optional Tab Alarm Wire Harness PN 26291...

Page 56: ...Page 50 Stellar 108 12 Flex Owner s Manual Optional Proximity Switch Wire Harness PN 26416...

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Page 60: ...Subject to Change without Notification 2021 Stellar Industries Inc...

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