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stellar labs 108-12 Flex Owner's Manual

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108-12 Flex 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 34624

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  • Page 1 108-12 Flex 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 34624...

  • Page 2: Serial Tag Location

    M O D EL NO . SERIA L NO . 800-321-3741 Proudly Designed and Manufactured 4214 MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC. in the USA by 35234 PN C5942 Page ii | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 3: Table Of Contents

    Introduction iv Hooklift Nomenclature ....................................v Chapter 1 - Specifications ....................................1 Model 108-12 Flex Specifications ................................1 Acceptable Subframe Dimensions - Model 108-12 Flex ........................2 Flex36 Grease Zerk Locations ................................... 2 Chapter 2 - Installation ....................................3 General Installation ....................................3 Installer Notice .......................................

  • 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 108-12 Flex 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 108-12 Flex Owner’s Manual | Page v ®...
  • Page 6 This page intentionally left blank. Page vi | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 7: Chapter 1 - Specifications

    Hydraulic Flow Not to exceed 16 GPM Shipping Weight 1,615 lbs (733 kg) Hook Height 35.63" (90.5 cm) Shipping Dimensions (LxHxW) 154" x 49" x 47" Minimum Truck GVWR 16,000 510,000 Stellar 108-12 Flex Owner’s Manual | Page 1 ®...

  • Page 8: Acceptable Subframe Dimensions - Model 108-12 Flex

    Acceptable Subframe Dimensions - Model 108-12 Flex Flex36 Grease Zerk Locations QTY. 1 BASE END OF LIFT CYL QTY. 1 BASE END OF TILT CYL QTY. 2 QTY. 1 QTY. 2 Note: Grease After Every 100 Cycles. QTY. 2 QTY. 2 Page 2 | Stellar 108-12 Flex Owner’s Manual...

  • Page 9: Chapter 2 - Installation

    Vehicle Safety Act. Please reference the Code of Federal Regulations, title 49 - Transportation, Volume 5 (400-999), for further information, or visit http://www.gpoaccess.gov/nara/index.html for the full text of Code of Federal Regulations. Stellar 108-12 Flex Owner’s Manual | Page 3 ®...

  • 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 108-12 Flex Owner’s Manual ®...

  • Page 11: Installation Note

    • 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. 2.50 1.32 23.41 Stellar 108-12 Flex Owner’s Manual | Page 5 ®...

  • Page 12: Step 2A (Non-F550/Ram5500): Bolt Tie-Down Castings To Mounting Plates

    D0143 TIE DOWN CHANNEL 24868 NUT 0.63-11 HHGR8 NYLOCK ZY Note: The mounting plates are designed with multiple slots to offer more flexibility in mounting locations. Additional holes may not be added. Page 6 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 13: Step 3A (Non-F550/Ram5500): Drill Mounting Holes Into Frame Rail

    QTY. C1026 CAP SCR 0.63-11X2.50 HHGR8 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 24868 NUT 0.63-11 HHGR8 NYLOCK ZY Note: See torque chart at beginning of chapter for proper bolt tightness. Stellar 108-12 Flex Owner’s Manual | Page 7 ®...
  • Page 14 Non-F550/RAM5500 Mounting Kit - PN 23700 PN 23700 ITEM PART DESCRIPTION QTY. D0143 TIE DOWN CHANNEL C1026 CAP SCR 0.63-11X2.50 HHGR8 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 24868 NUT 0.63-11 HHGR8 NYLOCK ZY Page 8 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 15: Step 2B (F550): Bolt Tie-Down Castings To Mounting Plates

    NOTE: TACK SPACER (PN 91312) TO BOTTOM OF BASE 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 Stellar 108-12 Flex Owner’s Manual | Page 9 ®...

  • Page 16: Step 3B (F550): Drill Mounting Holes Into Frame Rail

    QTY. C1026 CAP SCR 0.63-11X2.50 HHGR8 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 24868 NUT 0.63-11 HHGR8 NYLOCK ZY Note: See torque chart at beginning of chapter for proper bolt tightness. Page 10 | Stellar 108-12 Flex Owner’s Manual ®...
  • Page 17 62177 BRKT FUEL FILL 13576 CAP SCR 0.38-16X1.25 HHGR8 NOTE: (PN 97701) IS NOT USED WITH GAS ENGINE OPTION C6353 WASHER 0.38 SAE FLAT YELLOW GR8 56673 NUT 0.38-16 HHGR8 NYLOC Stellar 108-12 Flex Owner’s Manual | Page 11 ®...

  • Page 18: Step 2C (Ram5500): Bolt Tie-Down Castings To Mounting Plates

    NOTE: TACK SPACER (PN 96261) TO BOTTOM OF BASE 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 Page 12 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 19: Step 3C (Ram5500): Drill Mounting Holes Into Frame Rail

    QTY. C1026 CAP SCR 0.63-11X2.50 HHGR8 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 24868 NUT 0.63-11 HHGR8 NYLOCK ZY Note: See torque chart at beginning of chapter for proper bolt tightness. Stellar 108-12 Flex Owner’s Manual | Page 13 ®...
  • Page 20 TIE DOWN CHANNEL C1026 CAP SCR 0.63-11X2.50 HHGR8 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 24868 NUT 0.63-11 HHGR8 NYLOC NOTE ITEMS NOT SHOWN: 62177 - BRKT FUEL FILL X 1 Page 14 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 21: 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. Stellar 108-12 Flex Owner’s Manual | Page 15 ®...

  • Page 22: Reservoir Assembly (Cable Controls) - Pn 87080

    C0075 HOSE CLAMP HC125 C5968 FTG 12-12 MFS-MAORB 90 C4747 FTG 20-16 HB-MAORB 45 87077 HOSE 0.75(300PSI)-12FFSS SHORT-12FFSS 90 SHORT-7.50CL 10094 GAUGE OIL LF 2.5" 0-5000 BM C5552 FILTER STRAINER TFS-1220-0 Page 16 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 23: Reservoir Assembly (Air Controls) - Pn 87083

    C0075 HOSE CLAMP HC125 C5968 FTG 12-12 MFS-MAORB 90 C4747 FTG 20-16 HB-MAORB 45 87077 HOSE 0.75(300PSI)-12FFSS SHORT-12FFSS 90 SHORT-7.50CL 10094 GAUGE OIL LF 2.5" 0-5000 BM C5552 FILTER STRAINER TFS-1220-0 Stellar 108-12 Flex Owner’s Manual | Page 17 ®...

  • Page 24: Reservoir Assembly (Electric Controls) - Pn 97093

    NOTE: ITEMS NOT SHOWN 25941 - DECAL LOADER VB VDM8 HOSE LOCATION X 1 42971 - DECAL OIL FILTER CHANGE X 1 NOTE: 97555 - FROM VB RETURN TO RETURN FILTER Page 18 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 25: Reservoir Subassembly - Pn 86117

    RSRVR 10GAL K MODEL W/ TANK TOP FILTER 86123 FILTER TANK TOP SFM 12 SAE 5591 WASHER 0.31 SAE FLAT YELLOW GR8 0420 CAP SCR 0.31-18X0.75 HHGR5 86129 HOSE 1.25X7.50 DOWN TUBE C4659 HOSE CLAMP #16 SS Stellar 108-12 Flex Owner’s Manual | Page 19 ®...

  • Page 26: Side Mount Reservoir Subassembly - Pn 88147

    RSRVR WLDMT 10GAL BLKHD/SIDE MNT 0420 CAP SCR 0.31-18X0.75 HHGR5 5591 WASHER 0.31 SAE FLAT YELLOW GR8 86123 FILTER TANK TOP SFM 12 SAE 88321 HOSE 1.25X16.50 DOWN TUBE C4659 HOSE CLAMP #16 SS Page 20 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 27: 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 108-12 Flex Owner’s Manual | Page 21 ®...

  • Page 28: 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 22 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 29: 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 108-12 Flex Owner’s Manual | Page 23 ®...

  • Page 30: Hose Kit - Pn 72355

    Hose Kit - PN 72355 RETURN TO TANK PRESSURE FROM PUMP PRESSURE FROM PUMP RETURN TO TANK Page 24 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 31: 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 108-12 Flex Owner’s Manual | Page 25 ®...

  • Page 32: Step 10: Route Electrical Components

    Page 26 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 33: Step 11: Install Cab And Pto Controls

    CONTROL CABLE 96 IN WESCON 20057 CAP SCR 0.31-18X6.50 HHGR5 0343 WASHER 0.31 USS FLAT 0342 NUT 0.31-18 HHGR5 NYLOC 16948 GROMMET 2.50ODX0.125X0.25ID 0486 CAP SCR 0.31-18X1.50 HHGR5 CONTROL CABLES TO VALVE BANK Stellar 108-12 Flex Owner’s Manual | Page 27 ®...

  • Page 34: Section 120 In Loader W/Ram Mount - Ford F550

    CAP SCR 0.31-18X4.50 HHGR5 0342 NUT 0.31-18 HHGR5 NYLOC 0343 WASHER 0.31 USS FLAT 111158 SPACER 3.63X3.63X1.50 UHMW 85637 BASE RAM MOUNT 2017 FORD F SERIES 97465 RAM MOUNT ADJUST-A-POLE BASE Page 28 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 35: Ram Mount Adjustment Instructions - Ford F550

    SCREW NOTE: CONFIGURE (PN 97465) AS SHOWN USING THE ADJUSTMENT SCREWS. ALIGN HANDLES SO THE MIDDLE SEAT CONSOLE CAN BE FOLDED DOWN AND GLOVE BOX CAN BE FULLY OPENED WITHOUT INTERFERENCE. Stellar 108-12 Flex Owner’s Manual | Page 29 ®...

  • Page 36: Section 120 In Loader W/Ram Mount - Ram 5500

    C0933 CAP SCR 0.31-18X4.50 HHGR5 0342 NUT 0.31-18 HHGR5 NYLOC 0343 WASHER 0.31 USS FLAT 111158 SPACER 3.63X3.63X1.50 UHMW 72957 BASE PEDESTAL ADAPT RAM 1500-5500 2008-2014 97465 RAM MOUNT ADJUST-A-POLE BASE Page 30 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 37: Ram Mount Adjustment Instructions - Ram 5500

    SCREW NOTE: CONFIGURE (PN 97465) AS SHOWN USING THE ADJUSTMENT SCREWS. ALIGN HANDLES SO THE MIDDLE SEAT CONSOLE CAN BE FOLDED DOWN AND GLOVE BOX CAN BE FULLY OPENED WITHOUT INTERFERENCE. Stellar 108-12 Flex Owner’s Manual | Page 31 ®...

  • Page 38: Air Controls

    LIGHT LED CONTROL PANEL RED 67296 NUT CLIP ON .25X.025-.15X.53 12813 GROMMET 1.25ODX0.125X0.625ID EXHAUST VALVE BANK SHOWN AS REFERENCE ONLY NOTE: PN 12813 IS ONLY USED WHEN A PTO SWITCH IS INSTALLED ON THE TOWER. Page 32 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 39: Electric Controls

    Electric Controls PN 97617 Stellar 108-12 Flex Owner’s Manual | Page 33 ®...

  • Page 40: Step 12: Install Hoist Up Light Sensor - Pn 83115

    INSTALL DUMP UP LIGHT (PN 61233) IN CONTROL TOWER IF AIR CONTROLS AND IN 61233 - LIGHT LED CONTROL PANEL RED X 1 DASH ON STREET SIDE OF STEERING WHEEL IF CABLE OR ELECTRIC CONTROLS. 88324 - ELEC SCHEM CONTROL TOWER X 1 Page 34 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 41: Step 13: Install Mud Flaps And Fenders

    C4765 MUD FLAP 14.00X20.00 STELLAR 89527 FENDER SUPPORT WELDMENT FOR FLEX 80044 U BOLT 0.38X4.00X4.00 ZP 0346 WASHER 0.38 USS FLAT 0347 NUT 0.38-16 HHGR5 NYLOC 0351 CAP SCR 0.38-16X1.00 HHGR5 Stellar 108-12 Flex Owner’s Manual | Page 35 ®...

  • Page 42: Step 14A: Apply Hooklift Assembly Decals

    25627 DECAL WARNING CRUSH 26134 DECAL WARNING MISUSE TABS 35234 DECAL STELLAR MADE IN THE USA 53850 DECAL STELLAR LOGO 4.00X11.50 55832 DECAL DANGER ELECTROCUTION HOOK 68024 DECAL WARNING UNTRAINED OPERATOR Page 36 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 43: Step 14B: Apply Chassis Decals

    DECAL HITCH CAPACITY 30K REAR BUMPER - ABOVE PINTLE LOCATION; DISCARD OTHERS 68222 DECAL HITCH CAPACITY 90K 45697 ENGINE SPEED PTO CAUTION IN CAB 69463 DECAL BACK-UP ALARM VERIFY IN CAB Stellar 108-12 Flex Owner’s Manual | Page 37 ®...

  • Page 44: Step 15: Fill Reservoir And Activate Hydraulic Flow

    108 CA 120 CA 13500 12500 11500 10500 9500 8500 7500 6500 5500 4500 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 SYSTEM RELIEF PRESSURE (P.S.I.) Page 38 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 45: 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. Stellar 108-12 Flex Owner’s Manual | Page 39 ®...
  • Page 46 This page intentionally left blank. Page 40 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 47: Chapter 3 - Assembly Drawings

    CAP SCR 0.25-20 X 1.50 HHGR5 0340 WASHER 0.25 FLAT 8622 CLAMP HOSE/TUBE AG-2 70693 TUBE ASM 0.50 108-12 FLEX TILT RETRACT YZ 70692 TUBE ASM 0.50 108-12 FLEX TILT EXTEND YZ 19112 PLUG PLASTIC CCF1.50-10-14 41776PC ROLLER 2.00X4.00X3.81X8.00 PWDRCT YEL Stellar 108-12 Flex Owner’s Manual | Page 41...

  • Page 48: Dump Assembly - Pn 34247

    Dump Assembly - PN 34247 PN 34247 ITEM PART DESCRIPTION QTY. 34248 DUMP 108-12 FLEX 36 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2257 SNAP RING INSIDE 2.00 0507 CAP SCR 0.50-13X4.50 HHGR5 0333 NUT 0.25-20 HHGR5 NYLOC C6106 NUT 0.50-13 HHGR5 NYLOC...

  • Page 49: Secondary Assembly - Pn 34249

    BUSHING 32DXR32 2.00X2.00 GARLOCK 0068 BUSHING QSI-1618-24 3875 SNAP RING 1.00 INTERNAL 2257 SNAP RING INSIDE 2.00 33462 CYLINDER ASM 5.50X52.38 c1592 ZERK 1/8 NPT STRAIGHT 22285CR PIN 1.00X15.00 22286CR PIN 2.00X16.00 Stellar 108-12 Flex Owner’s Manual | Page 43 ®...
  • Page 50 THRUST WASHER 33104PC COLLAR 1.03X2.00X1.00 0339 CAP SCR 0.25-20X2.50 HHGR5 0333 NUT 0.25-20 HHGR5 NYLOC c1592 ZERK 1/8 NPT STRAIGHT 0295PC LATCH 12,000# 14672 PIN CAP 0.44X1.50X0.63 9714 CAP SCR 0.38-16X1.00 SS Page 44 | Stellar 108-12 Flex Owner’s Manual ®...
  • Page 51 D0419 THRUST WASHER 33104 COLLAR 1.03X2.00X1.00 0339 CAP SCR 0.25-20X2.50 HHGR5 0333 NUT 0.25-20 HHGR5 NYLOC c1592 ZERK 1/8 NPT STRAIGHT 11 35066 PIN 1.00X18.38 SR 0867 MACHY WASHER 1.00ID 14GA Stellar 108-12 Flex Owner’s Manual | Page 45 ®...

  • Page 52: Main Cylinder Assembly - Pn 33462

    Note: This tilt cylinder uses Stellar Seal Kit PN: C6301. ® PN 35169 ITEM PART DESCRIPTION QTY. 1 35170 CYLINDER 3.00X10.00 0279 FTG 6-6 MFS-MORB STRAIGHT 0068 BUSHING QSI-1618-24 BUSHING SHOWN AS REFERENCE Page 46 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 53: Bumper Assembly - Pn 81300

    GLAD HANDS EMER SERV(RED) 441105 75647 GLAD HANDS AIR SERV(BLUE) 45DEG 441106 21661 FTG 6-6XCLOSE MP-MP NIPPLE STRAIGHT BRASS 0437 CAP SCR 0.25-20X1.25 HHGR5 0340 WASHER 0.25 USS FLAT 0333 NUT 0.25-20 HHGR5 NYLOC Stellar 108-12 Flex Owner’s Manual | Page 47 ®...

  • Page 54: Optional Tab Alarm Kit - Pn 43120

    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. Page 48 | Stellar 108-12 Flex Owner’s Manual ®...

  • Page 55: Optional Tab Alarm Wire Harness - Pn 26291

    Optional Tab Alarm Wire Harness - PN 26291 Stellar 108-12 Flex Owner’s Manual | Page 49 ®...

  • Page 56: Optional Proximity Switch Wire Harness - Pn 26416

    Page 50 | Stellar 108-12 Flex Owner’s Manual ®...
  • Page 60 Subject to Change without Notification. © 2021 Stellar Industries, Inc.

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