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- Page 1 120-16-20 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 24254...
- Page 2 Model 120-16-20 Manual Revisions Date of Revision Section Revised Description of Revision Page ii | Stellar 120-16-20 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 120-16-20 Shuttle Specifications ....................... 1 Acceptable Subframe Dimensions - Model 120-16-20 ..................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 120-16-20 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 120-16-20 Shuttle Owner’s Manual | Page v ®... -
Page 6: 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 vi | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 7: Chapter 1 - Specifications
17' (5.18 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 120-16-20 Shuttle Owner’s Manual | Page 1 ®... -
Page 8: Acceptable Subframe Dimensions - Model 120-16-20
Acceptable Subframe Dimensions - Model 120-16-20 Page 2 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 9: Chapter 2 - Installation
Shuttle ® 120-16-20 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. -
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 120-16-20 Shuttle 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 10.13 4.78 Stellar 120-16-20 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 120-16-20 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 120-16-20 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 120-16-20 Shuttle Owner’s Manual ®... -
Page 15: Reservoir Assembly (Cable Controls) - Pn 87078
Stellar 120-16-20 Shuttle Owner’s Manual | Page 9 ®... -
Page 16: Reservoir Assembly (Air Controls) - Pn 87081
Page 10 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 17: 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 120-16-20 Shuttle Owner’s Manual | Page 11 ®... - Page 18 FROM THE FOLLOWING LIST ARE USED. TILT ASM'S: PN 83048 USES PORT RELIEF PN 69172 - PORT RELIEF VDM8 3600 PSI PN 85778 USES PORT RELIEF PN 26184 - PORT RELIEF VDM8 3300 PSI Page 12 | Stellar 120-16-20 Shuttle Owner’s Manual ®...
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Page 19: 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 120-16-20 Shuttle Owner’s Manual | Page 13 ®... -
Page 20: 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 14 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 21: 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 120-16-20 Shuttle Owner’s Manual | Page 15 ®... -
Page 22: Hose Kit - Pn 81682
Page 16 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 23: 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 120-16-20 Shuttle Owner’s Manual | Page 17 ®... -
Page 24: 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 18 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 25: 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 120-16-20 Shuttle Owner’s Manual | Page 19 ®... -
Page 26: 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 20 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 27: Step 12: Install Hoist Up Alarm - 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 Stellar 120-16-20 Shuttle Owner’s Manual | Page 21 ®... -
Page 28: Step 13: Install Mud Flaps And Fenders
MTG KIT OFFSET POLY FENDER (FLEET) 80044 U BOLT 0.38X4.00X4.00 ZP 0347 NUT 0.38-16 HHGR5 NYLOC 0346 WASHER 0.38 USS FLAT 11693 CAP SCR 0.63-11X1.75 HHGR8 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 Page 22 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 29: Step 14A: Apply Hooklift Assembly Decals
25627 DECAL WARNING CRUSH 26134 DECAL WARNING MISUSE TABS 35234 DECAL STELLAR MADE IN THE USA 52681 DECAL STELLAR LOGO 6.00X16.50 55832 DECAL DANGER ELECTROCUTION HOOK 68024 DECAL WARNING UNTRAINED OPERATOR Stellar 120-16-20 Shuttle Owner’s Manual | Page 23 ®... -
Page 30: 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 Page 24 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 31: 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 120-16-20 Shuttle Owner’s Manual | Page 25 ®... -
Page 32: 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 26 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 33: Chapter 3 - Assembly Drawings
VALVE PLUNGER VILLA HYD NORMALLY CLOSED 57735 FTG 8-8 MBSPP-MFS STRAIGHT 8622 CLAMP HOSE/TUBE AG-2 81686 TUBE ASM 0.50 120-16-20 TILT RETRACT YZ 81685 TUBE ASM 0.50 120-16-20 TILT EXTEND YZ 0220 CAP SCR 0.25-20X1.50 HHGR5 0340 WASHER 0.25 USS FLAT 0521 WASHER 0.25 LOCK... -
Page 34: Dump Assembly - Pn 81460
CAP SCR 0.50-13X4.50 HHGR5 0481 CAP SCR 0.25-20X2.00 HHGR5 38263 CAP SCR 0.31-18X0.75 SH 0340 WASHER 0.25 USS FLAT 8622 CLAMP HOSE/TUBE AG-2 C0929 CAP SCR 0.31-18X2.75 HHGR5 0343 WASHER 0.31 USS FLAT Page 28 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 35: Secondary Assembly - Pn 81461
0377 MACHY WASHER 2.00ID 14GA 81462 SECONDARY 120-16-20K GEN2 2257 SNAP RING INSIDE 2.00 0108 SNAP RING 2.00 7200-200 c1592 ZERK 1/8 NPT STRAIGHT 58052 SET SCREW 0.50-13X0.50 W/ RED PATCH Stellar 120-16-20 Shuttle Owner’s Manual | Page 29 ®... -
Page 36: 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 30 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 37: Tilt Assembly 61.75" Hook Height - Pn 85778
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 26184 - PORT RELIEF VDM8 3300 PSI X 1 Stellar 120-16-20 Shuttle Owner’s Manual | Page 31 ®... -
Page 38: Main Cylinder - Pn 19026
NOTE: BUSHINGS ARE SHOWN FOR REFERENCE. PN 19026 15822 MANIFOLD DOUBLE T11A 5000 PSI 18701 CLAMP PORT TUBE ZR518 19369 HOSE CLAMP 4.13-7.00 5416K38 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON Page 32 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 39: 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 120-16-20 Shuttle Owner’s Manual | Page 33 ®... -
Page 40: Optional Tab Alarm Kit - Pn 43120
ITEMS NOT SHOWN: 97097 - INSTRUCTIONS TAB ALARM KIT X 1 NOTE: WHEN USED WITH AIR CONTROL TOWERS BRACKET (PN 26293) IS NOT USED B/C COMPONENTS ARE TO BE INSTALLED IN TOWER ASSEMBLY Page 34 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 41: Optional Tab Alarm (Cont.) - Pn 43120
DUMP TUBE AND OUT. FROM THERE THE HARNESS RUNS TO THE FRONT OF THE TRUCK ATTACHING TO THE BASE OR INBETWEEN THE TRUCK FRAME RAILS TO BE CONNECTED TO WIRE HARNESS PN 26291. Stellar 120-16-20 Shuttle Owner’s Manual | Page 35 ®... -
Page 42: Optional Tab Alarm Wire Harness - Pn 26291
Optional Tab Alarm Wire Harness - PN 26291 Page 36 | Stellar 120-16-20 Shuttle Owner’s Manual ®... -
Page 43: Optional Proximity Switch Wire Harness - Pn 26416
Stellar 120-16-20 Shuttle Owner’s Manual | Page 37 ®... - Page 44 Subject to Change without Notification. © 2021 Stellar Industries, Inc.
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