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96-10-24
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.
www.stellarindustries.com
© 2017 Stellar Industries, Inc.
Last Revision: 04/21/17
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- Page 1 96-10-24 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. www.stellarindustries.com © 2017 Stellar Industries, Inc. Last Revision: 04/21/17...
- Page 2 Model 96-10-24 Manual Revisions Date of Revsion Section Revised Description of Revision Page ii | Stellar 96-10-24 Shuttle Owner’s Manual ®...
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Page 3: Table Of Contents
Hooklift Nomenclature .......................... v Serial Tag Location ..........................vi Chapter 1 - Specifications ......................1 Model 96-10-24 Shuttle Specifications ....................1 Acceptable Subframe Dimensions - Model 96-10-24 ................ 2 Chapter 2 - Installation ........................ 3 General Installation ..........................3 Installer Notice ............................. 3 Torque Data Chart .......................... -
Page 4: Introduction
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 service@stellarindustries.com Order Parts parts@stellarindustries.com Warranty Information warranty@stellarindustries.com Page iv | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 5: Hooklift Nomenclature
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 Stellar 96-10-24 Shuttle Owner’s Manual | Page v ®... -
Page 6: Serial Tag Location
CANADIAN PATENTS 6,749,389 6,558,104 5,427,495 6,749,389 Proudly Designed ® 5,108,247 6,065,942 5,082,417 5,108,247 and Manufactured 4214 MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC. PN C5942 in the USA by 35234 Page vi | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 7: Chapter 1 - Specifications
14.5’ (4.42 m) * Assumes 3ft. overhang from center of rear roller pin. * Assumes 5ft. overhang from center of rear roller pin - May require bumper and latch options. Stellar 96-10-24 Shuttle Owner’s Manual | Page 1 ®... -
Page 8: Acceptable Subframe Dimensions - Model 96-10-24
Acceptable Subframe Dimensions - Model 96-10-24 PN 3123 Page 2 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 9: Chapter 2 - Installation
Shuttle ® 96-10-24 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 in- stallation process, please contact Stellar Customer Service at (800) 321 3741. -
Page 10: Torque Data Chart
“Dry” means plain or zinc plated without lubrication. Tighten lubricated bolts to approximately 80% of dry bolts. Page 4 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 11: Installation Note
2.50” behind the cab or any equipment mount- ed behind the cab. At Least 2.5” Back of Truck Cab or Mounted Truck Frame Equipment (Such as a Front of Tarper Tower) Hooklift Stellar 96-10-24 Shuttle Owner’s Manual | Page 5 ®... -
Page 12: Step 2: Bolt Tie-Down Castings To Mounting Plates
Additional holes may not be added. 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 Page 6 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 13: Step 3: Drill Mounting Holes Into Frame Rail
Bolt each tie-down angle to the truck frame (both sides): 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 Stellar 96-10-24 Shuttle Owner’s Manual | Page 7 ®... -
Page 14: Step 5: Install Bumper
• Before drilling and bolting to the frame, confirm adequate room for cable routing be- tween in-cab controls and the valve bank. Note: The top of the reservoir should not be above the truck frame. Refer to the Reservoir Assembly Drawings for details. Page 8 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 15: Reservoir Assembly (Cable Controls) - Pn 87078
Stellar 96-10-24 Shuttle Owner’s Manual | Page 9 ®... -
Page 16: Reservoir Assembly (Air Controls) - Pn 87081
Page 10 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 17: Valve Bank Parts Drawing
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 Stellar 96-10-24 Shuttle Owner’s Manual | Page 11 ®... -
Page 18: Step 8: Install Pto And Pump
• 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. Page 12 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 19: Face Seal/O-Ring Size Chart
• 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. Stellar 96-10-24 Shuttle Owner’s Manual | Page 13 ®... -
Page 20: Hose Kit - Pn 81916
Page 14 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 21: Power Beyond Vdm8 Valve
• A standard Stellar Hooklift will have 6 hydraulic lines attached to the valve. With Power ® Beyond activated, they will have 7 hydraulic lines attached to the valve. Stellar 96-10-24 Shuttle Owner’s Manual | Page 15 ®... -
Page 22: Step 10: Route Electrical Components
RH TURN/ (WHITE/BROWN) BLACK) BROWN/ BROWN/ (WHITE/BROWN) STOP STOP BACKUP YELLOW) YELLOW) RED LIGHT RED LIGHT WHITE LIGHT (WHITE/ (WHITE/ (WHITE/ BROWN/ BROWN/ BLACK) YELLOW) YELLOW) TAG LIGHT TAG LIGHT (BROWN) (BROWN) Page 16 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 23: Step 11: Install Cab And Pto Controls
37473 CONTROL CABLE 192 IN WESCON 20057 CAP SCR 0.31-18X6.50 HHGR5 (3-Section) 20057 CAP SCR 0.31-18X4.00 HHGR5 (2-Section) 0343 WASHER 0.31 USS FLAT ZINC 0342 NUT 0.31-18 HHGR5 NYLOC CONTROL CABLES TO VALVE BANK Stellar 96-10-24 Shuttle Owner’s Manual | Page 17 ®... -
Page 24: Air Controls
ONLY BE ACTIVATED WHEN THE BLOCK IGNITION IS HOT. IT IS RECOMMENDED TO TAP INTO THE PTO LIGHT POWERSOURCE WHEN WIRING. DUMP UP LIGHT BLUE BOTH LIGHTS PTO LIGHT DUMP UP LIGHT SWITCH Page 18 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 25: Optional - Controller Pedestal Reinforcement
NUT 0.38-16 HHGR5 NYLOC CLAMP CLAMP 2.00 BLK VINYL BRACKET BRKT 10GAX2.00X24.00 Note: The bracket can be bent, cut, trimmed, etc to allow fastening to the structure under the passenger seat. Stellar 96-10-24 Shuttle Owner’s Manual | Page 19 ®... -
Page 26: Step 12: Install Mud Flaps And Fenders
Page 20 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 27: Step 13: Install Hoist Up Alarm - Pn 83115
29409 - TERML 12-10X.31 RING X 1 USE 29409 TO GROUND BLACK WIRE USE C0073 TO CONNECT RED WIRE TO THE CONTROLLER ASSEMBLY PEDESTALS (BLUE) DUMP UP LIGHT WIRE NOTE: BRACKET SHOWN AS REFERENCE ONLY Stellar 96-10-24 Shuttle Owner’s Manual | Page 21 ®... -
Page 28: Step 14: Apply Decals
16*** 68221 DECAL HITCH CAPACITY TMAX2 17*** 68222 DECAL HITCH CAPACITY TMAX3 * Extra QTY 1 shipped loose. ** This item not included in decal kit. *** This decal not shown. Page 22 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 29: Step 15: Fill Reservoir And Activate Hydraulic Flow
• Calibrate dump light system. • Be sure to check all clearances. • Be sure that relief pressure is no higher than 4200 PSI. Stellar 96-10-24 Shuttle Owner’s Manual | Page 23 ®... -
Page 30: Set System Relief Pressure
6. Release all functions and disengage the PTO. Snap tamper cap into position over the jam nut. The break away clip will be destroyed if the cap is removed. Page 24 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 31: Chapter 3 - Assembly Drawings
LEVER PLUNGER VALVE FINGER VALVE PLUNGER VILLA HYD NORMALLY 53853 CLOSED 57735 FTG 8-8 MBSPP-MFS STRAIGHT 81972 TUBE ASM 0.50 96-10-24 TILT RETRACT YZ 81973 TUBE ASM 0.50 96-10-24 TILT EXTEND YZ 33741CR PIN 2.00X10.19 SR 1546 THRUST WASHER 2.01DIA UHMW .12THK Stellar 96-10-24 Shuttle Owner’s Manual | Page 25... -
Page 32: Dump Assembly - Pn 81873
NUT 0.31-18 HHGR5 NYLOC 0343 WASHER 0.31 USS FLAT C0929 CAP SCR 0.31-18X2.75 HHGR5 8622 CLAMP HOSE/TUBE AG-2 58052 SET SCREW 0.50-13X0.50 C4516 WASHER 0.56IDX1.50ODX0.13 THK NYLON 0352 WASHER 0.50 USS FLAT Page 26 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 33: Secondary Assembly - Pn 81869
21880 CYLINDER ASM 5.00X40.25 2257 SNAP RING INSIDE 2.00 0377 MACHY WASHER 2.00ID 14GA 0108 SNAP RING 2.00 7200-200 c1592 ZERK 1/8 NPT STRAIGHT 58052 SET SCREW 0.50-13X0.50 W/ RED PATCH Stellar 96-10-24 Shuttle Owner’s Manual | Page 27 ®... -
Page 34: Tilt Assembly 54" Hook Height - Pn 79418
24250CR PIN WLDMT 2.00X10.50 22764 COLLAR 2.01X3.00X1.00 W/HOLE c1592 ZERK 1/8 NPT STRAIGHT 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 23159 CYLINDER ASM 4.00X14.50 28766 LATCH CS 40000K 79419 TILT 138-18-20K GEN2 58052 SET SCREW 0.50-13X0.50 Page 28 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 35: Tilt Assembly 61.75" Hook Height - Pn 83048
CAP SCR 0.38-16X4.00 HHGR5 0347 NUT 0.38-16 HH NYLOC c1592 ZERK 1/8 NPT STRAIGHT 58052 SET SCREW 0.50-13X0.50 W/ RED PATCH NOTE: ITEMS NOT SHOWN 69172 - PORT RELIEF VDM8 3600 PSI X 1 Stellar 96-10-24 Shuttle Owner’s Manual | Page 29 ®... -
Page 36: Main Cylinder - Pn 25244
NOTE: BUSHINGS ARE SHOWN FOR REFERENCE. PN 25244 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 15822 MANIFOLD DOUBLE T11A 5000 PSI C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 19369 HOSE CLAMP 4.13-7.00 5416K38 15888 TUBE ASM 0.38X7.22 TM14160 Page 30 | Stellar 96-10-24 Shuttle Owner’s Manual ®... -
Page 37: Tilt Cylinder - Pn 23159
Tilt Cylinder - PN 23159 BUSHINGS SHOWN AS REFERENCE PN 23159 ITEM NO. QTY. PART NO. DESCRIPTION 1 0907 CYLINDER 4.00X14.50 3 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2 0279 FTG 6-6 MFS-MORB STRAIGHT Stellar 96-10-24 Shuttle Owner’s Manual | Page 31 ®... - Page 38 Subject to Change without Notification. © 2017 Stellar Industries, Inc.
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