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Related Manuals for stellar labs Shuttle 108-12-20/36
Summary of Contents for stellar labs Shuttle 108-12-20/36
- Page 1 108-12-20/36 Shuttle Hooklift Owner’s Manual Installation • Assembly Drawings • 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. Rev 1 www.stellarindustries.com © 2021 Stellar Industries, Inc. PN 26133...
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Page 2: Serial Tag Location
Serial Tag Location The serial tag should be located on the right side (passenger side) of the base assembly: ® D ATE PATENT INFORMATION http://www.stellarindustries.com/ip M OD EL NO . S E R IA L NO . MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC. PN C5942 DANGER WARNING... -
Page 3: Table Of Contents
Table of Contents Serial Tag Location ..............................ii Introduction ................................iv Hooklift Nomenclature ............................v Chapter 1 - Specifications ............................1 Model 108-12-20/36 Shuttle Specifications ......................1 Acceptable Subframe Dimensions - Model 108-12-20/36 ................. 2 Chapter 2 - Installation ............................... 3 General Installation ..............................3 Installer Notice .............................. -
Page 4: Introduction
Introduction A copy of this manual is provided with every hooklift and can be found in the hard plastic manual case that is installed on the chassis. A copy of this manual shall remain with the hooklift at all times. Throughout the manual, three signal words will be used to bring attention to important items: NOTICE... -
Page 5: Hooklift Nomenclature
Hooklift Nomenclature The Stellar Shuttle is a hydraulic, body-loading device when mounted on a truck chassis. It ® can 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. - Page 6 This page intentionally left blank. Page vi | Stellar 108-12-20/36 Shuttle Owner’s Manual ®...
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Page 7: Chapter 1 - Specifications
Chapter 1 - Specifications Model 108-12-20/36 Shuttle Specifications Model 108-12-20/36 Shuttle Lifting/Dumping Capacity 20,000 lbs (9,072 kg) A Dump Angle 53° B Lowest hook Height 30" (76 cm) C Effective Length 126" (320 cm) D Truck Frame Height 39" (99 cm) E Hooklift Height 47.38"... -
Page 8: Acceptable Subframe Dimensions - Model 108-12-20/36
Acceptable Subframe Dimensions - Model 108-12-20/36 Page 2 | Stellar 108-12-20/36 Shuttle Owner’s Manual ®... -
Page 9: Chapter 2 - Installation
Chapter 2 - Installation General Installation This chapter is designed to serve as a general guide for the installation of a Stellar Shuttle ® 108-12-20/36 Hooklift. 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 installation process, please contact Stellar Customer Service at (800) 321 3741. -
Page 10: Torque Data Chart
Torque Data Chart When using the torque data in the chart, the following rules should be GRADE 5 GRADE 8 GRADE 9 observed: • Bolt manufacturer’s particular specifications should be consulted Size Bolt DIA Plain Plated Plain Plated Plated when provided. (DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) 5/16-18... -
Page 11: Installation Note
Installation Note Every hooklift installation is unique. However, certain guidelines exist that apply to every model. Listed below is a general set of chronological steps that may be followed when installing a Stellar Hooklift. If any questions arise during the installation process, feel free to contact your local dealer or Stellar Customer Service at 800-321-3741. -
Page 12: Step 2: Bolt Tie-Down Castings To Mounting Plates
Step 2: Bolt tie-down castings to mounting plates. Bolt each tie-down casting to the underside of each mounting plate located on the out- side of the main rails of the base (both sides): Note: The mounting plates are designed with multiple slots to offer more flexibility in mount- ing locations. -
Page 13: Step 3: Drill Mounting Holes Into Frame Rail
Step 3: Drill mounting holes into frame rail. Using the holes in the tie-down castings as guides, drill 11/16” mounting holes through the truck frame as shown (both sides): 11/16" Step 4: Bolt tie-down castings to truck frame. Bolt each tie-down angle to the truck frame (both sides): ITEM PART DESCRIPTION... -
Page 14: Step 5: Install Bumper
Mounting Kit - PN 1022 PN 1022 ITEM PART DESCRIPTION QTY. 24868 NUT 0.63-11 HHGR8 NYLOCK ZY C5902 WASHER 0.63 SAE FLAT YELLOW GR8 C1026 CAP SCR 0.63-11X2.50 HHGR8 ZY D0143 TIE DOWN CHANNEL Step 5: Install bumper. • See NHTSA (National Highway Truck Safety Administration) Regulations for acceptable placement. -
Page 15: Reservoir Assembly (Cable Controls) - Pn 87078
Reservoir Assembly (Cable Controls) - PN 87078 PN 87078 ITEM PART DESCRIPTION QTY. 1115 FTG 20-20 MP-MP HEX NIPPLE STRAIGHT C5511 VALVE BALL 1.25 C2282 FTG 1.25 NPT TO 1.25 BARB 24611 VB 2-SECTION VDM8 0521 WASHER 0.25 LOCK 0339 CAP SCR 0.25-20X2.50 HHGR5 C1855 FTG 6-10 MFS-MORB STRAIGHT D0549 FTG 16-8 MORB-FORB STRAIGHT REDUCER 17767 HOSE SUCT 1.25 10FT... -
Page 16: Reservoir Assembly (Air Controls) - Pn 87081
Reservoir Assembly (Air Controls) - PN 87081 PN 87081 ITEM PART DESCRIPTION QTY. 1115 FTG 20-20 MP-MP HEX NIPPLE STRAIGHT C5511 VALVE BALL 1.25 C2282 FTG 1.25 NPT TO 1.25 BARB 25940 VB 2-SECTION VDM8 W/AIR ACTUATORS 0521 WASHER 0.25 LOCK 0339 CAP SCR 0.25-20X2.50 HHGR5 C1855 FTG 6-10 MFS-MORB STRAIGHT D0549 FTG 16-8 MORB-FORB STRAIGHT REDUCER... -
Page 17: Reservoir Subassembly - Pn 86117
Reservoir Subassembly - PN 86117 NOTE: FILTER GAUGE - PN 16145 COMES WITH FILTER - PN 86123 NOTE: REPLACEMENT OIL FILTER - PN 86124 NOTE: REPLACEMENT GASKET RG-14 - PN 98200 PN 86117 ITEM PART DESCRIPTION QTY. C2126 MAGNETIC PLUG DRAIN 3/4" 15463 THERMO SIGHT GAUGE ZINGA SG-O5-A-T-N 73278... -
Page 18: Valve Bank Parts Drawing
Valve Bank Parts Drawing HANDLE ASM - OUTSIDE CTRLS WITH HANDLE PN 30381 SPOOL SPRING KIT WITH COVER PN 43776 AIR ACTUATOR PN 26566 MAIN RELIEF VALVE PN 28510 SPOOL RETAINER PN 61522 HANDLE PN 26130 SPOOL SEAL KIT PN 29683 Page 12 | Stellar 108-12-20/36 Shuttle Owner’s Manual ®... -
Page 19: Step 8: Install Pto And Pump
Step 8: Install PTO and pump. • Before installing the pump to the PTO, always check the direction of the PTO output shaft to determine which direction the hydraulic pump needs to rotate to operate the equip- ment. If this is not determined prior to installing the hydraulic pump, the hydraulic pump may rotate in the incorrect direction and damage the front shaft seal. -
Page 20: Face Seal/O-Ring Size Chart
Face Seal/O-Ring Size Chart Hose Fitting Face Seal (A) O-ring Boss (B) Size Size Stellar Stellar ® ® 1/4” C2027 D1245 3/8” C2028 D1246 1/2” C2029 D1247 5/8” 32223 D1248 3/4” D1244 D1249 1” D1250 Step 9: Route hydraulic hoses. 1. -
Page 21: Hose Kit - Pn 81916
Stellar 108-12-20/36 Shuttle Owner’s Manual | Page 15 ®... -
Page 22: Power Beyond Vdm8 Valve
Power Beyond VDM8 Valve These instructions are intended for correct installation of power beyond on a Salami VDM8 valve bank. If any hydraulic component is integrated after this valve the power beyond must be installed correctly, or serious damage may incur to the hydraulic system. Plug PN 5597 Power Beyond... -
Page 23: Step 10: Route Electrical Components
Step 10: Route Electrical Components EXISTING TRUCK WIRING HARNESS BACK-UP LIGHT (BLACK) LH, TURN, BRAKE, LIGHT (YELLOW) TAIL, CLEARANCE, LIGHT GROUND (BROWN) (WHITE) RH, TURN, BRAKE, LIGHT (GREEN) GROUND (WHITE) NOTE: GROUND THE WHITE WIRES TO THE BUMPER. BACK-UP ALARM (WHITE/BLACK) PN 40310 MID-BODY CLEARANCE... -
Page 24: Step 11: Install Cab And Pto Controls
Step 11: Install cab and PTO controls. • Use PTO brand specific installation instructions. • For cab controls, see controller assembly drawing for details: Cable Controls 2 SECTION 3 SECTION 96 INCH PN 50835 PN 50836 144 INCH PN 53444 PN 53445 192 INCH PN 50837... -
Page 25: Air Controls
Air Controls ITEM PART DESCRIPTION QTY. 41988 CTRL 2 BANK 4WAY AIR CNTR LOCK 45687 FTG 4-2 MP-PTC 90 BRASS 1169X4S D1711 CAP SCR #10-24X0.50 BTNHD SS C6021 CAP SCR 0.25-20X0.75 BTNHD SS 0486 CAP SCR 0.31-18X1.50 HHGR5 0343 WASHER 0.31 USS FLAT 0342 NUT 0.31-18 HHGR5 NYLOC 16948... -
Page 26: Step 12: Install Hoist Up Alarm - Pn 83115
Step 12: Install Hoist Up Alarm - PN 83115 Install the hoist up alarm onto the base of the hooklift as shown: NOTE: MOUNT SWITCH ON BRACKET LOCATED ON THE BASE USE 29409 TO GROUND BLACK WIRE DETAIL A SCALE 1 : 8 ITEM PART DESCRIPTION... -
Page 27: Step 13: Install Mud Flaps And Fenders
Stellar 108-12-20/36 Shuttle Owner’s Manual | Page 21 ®... -
Page 28: Step 14A: Apply Hooklift Assembly Decals
Step 14A: Apply Hooklift Assembly Decals DANGER WARNING Electrocution Hazard Death or serious injury will result from Crush Hazard inadequate clearance if hooklift, load, Moving parts can crush or vehicle becomes electrically and cut. charged. • Maintain safe clearance from high Keep hands and arms voltage power sources. -
Page 29: Step 14B: Apply Chassis Decals
Step 14B: Apply Chassis Decals 3” AMBER REFLECTOR (0540) NOT INCLUDED WITH DECAL KIT 3” RED REFLECTOR (0541) NOT INCLUDED WITH DECAL KIT Last Revision CTRL ASMY Rev Level: RELEASE IN CAB Date: 08/16/21 Changes: Separate chassis decals from hooklift assembly decals. PN 121012 ITEM PART No. -
Page 30: Step 15: Fill Reservoir And Activate Hydraulic Flow
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 recommended. • When connections are secure, activate hydraulic flow by opening the ball valve on the bottom of the reservoir. -
Page 31: Chapter 3 - Assembly Drawings
Chapter 3 - Assembly Drawings Base Assembly - PN 81887 PN 81887 ITEM PART DESCRIPTION QTY. 81880 BASE 108-12-20/36K GEN2 0635 BUSHING 40DXR32 GARLOCK 1593 MACHY WASHER 2.50ID 10GA 25574 BUSHING 40DXR20 2.50X1.25 0636 SNAP RING 2.50 HD 23930 COLLAR 2.51X3.50X1.00 32086 CAP SCR 0.38-16X4.25 HHGR5 0347 NUT 0.38-16 HH NYLOC... -
Page 32: Dump Assembly - Pn 81886
Dump Assembly - PN 81886 PN 81886 ITEM PART DESCRIPTION QTY. 81883 DUMP 108-12-20/36K GEN2 0635 BUSHING 40DXR32 GARLOCK 23301 TAB LOADER BREAK AWAY 44508 COLLAR 2.51X3.50X2.56 23930 COLLAR 2.51X3.50X1.00 32086 CAP SCR 0.38-16X4.25 HHGR5 0347 NUT 0.38-16 HH NYLOC 22216 SNAP RING INSIDE 2.50 c1592... -
Page 33: Secondary Assembly - Pn 25729
Secondary Assembly - PN 25729 PN 25729 ITEM PART DESCRIPTION 25730 SECONDARY 108-12-20/36K 0635 BUSHING 40DXR32 GARLOCK 17320 BUSHING 40DXR40 GARLOCK 0067 BUSHING BPC-2426-24 1.50X1.50 0069 BUSHING QSI-1618-16 3875 SNAP RING 1.00 INTERNAL 22285ZP PIN 1.00X15.00 54317ZP PIN 2.50X15.75 D&T 22216 SNAP RING INSIDE 2.50 25734... -
Page 34: Tilt Assembly - Pn 84609
Tilt Assembly - PN 84609 10 9 PN 84609 ITEM PART DESCRIPTION 84610 TILT 108-12-20/36K MULTILIFT 4IN 23460 CYLINDER ASM 3.00X17.00 0295 LATCH 12,000# 24237 COLLAR 1.53X2.50X1.00 4912CR PIN 1.00X3.25 SR 0067 BUSHING BPC-2426-24 1.50X1.50 0069 BUSHING QSI-1618-16 0110 SNAP RING 1.00 ID 7200-100 14672 PIN CAP 0.44X1.50X0.63 9714... -
Page 35: Main Cylinder - Pn 25734
Main Cylinder - PN 25734 NOTE: BUSHINGS ARE SHOWN FOR REFERENCE. PN 25734 25735 CYLINDER 6.00X46.25 15995 MANIFOLD ASM DUAL T2A 5000PSI 26548 TUBE ASM 0.50 X 19.53 C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 0635 BUSHING 40DXR32 GARLOCK C2252 FTG ADAPT 8-10-F5OLO-S 1554 FTG ADAPT 8-F5OLO-S 19370 HOSE CLAMP 5.63-8.50 5416K39... -
Page 36: Tilt Cylinder - Pn 23460
Tilt Cylinder - PN 23460 PN 23460 ITEM PART No. DESCRIPTION QTY. 3767 CYLINDER 3.00X17.00 0279 FTG 6-6 MFS-MORB STRAIGHT Page 30 | Stellar 108-12-20/36 Shuttle Owner’s Manual ®... -
Page 37: Optional Tab Alarm Kit - Pn 43120
Optional Tab Alarm Kit - PN 43120 NOTE: USE PN 20057 WITH 3 SECTION CONTROL TOWER PN 43120 ITEM PART DESCRIPTION QTY. 26293 PLATE TAB ALARM MNT 0491 CAP SCR 0.31-18X4.00 HHGR5 0343 WASHER 0.31 USS FLAT ZINC 0342 NUT 0.31-18 HH NYLOC 26031 BACKUP ALARM PIEZO JAMECO 123537 D1711... -
Page 38: Optional Tab Alarm (Cont.) - Pn 43120
Optional Tab Alarm (cont.) - PN 43120 DUMP AND HARDWARE SHOWN AS REFERENCE TAB PN 33062 SHOWN AS REFERENCE ONLY DETAIL A SCALE 1 : 4 TO SET TAB ALARM ADJUST TO BE JUST FLUSH THEN UNSCREW 1/4 TURN AND TIGHTEN LOCK NUT. PN 43120 ITEM PART... -
Page 39: Optional Tab Alarm Wire Harness - Pn 26291
Optional Tab Alarm Wire Harness - PN 26291 Stellar 108-12-20/36 Shuttle Owner’s Manual | Page 33 ®... -
Page 40: Optional Proximity Switch Wire Harness - Pn 26416
Page 34 | Stellar 108-12-20/36 Shuttle Owner’s Manual ®... - Page 44 Subject to Change without Notification. © 2021 Stellar Industries, Inc.
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