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190-24-40
190-24-32K
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 2
www.stellarindustries.com
© 2022 Stellar Industries, Inc.
PN 26734
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Table of Contents
Related Manuals for stellar labs Shuttle 190-24-40
Summary of Contents for stellar labs Shuttle 190-24-40
- Page 1 190-24-40 190-24-32K 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 2 www.stellarindustries.com © 2022 Stellar Industries, Inc. PN 26734...
- Page 2 Model 190-24-40 & 32K Manual Revisions Date of Revision Section Revised Description of Revision Page ii | Stellar 190-24-40 & 32K Shuttle Owner’s Manual ®...
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Page 3: Table Of Contents
Table of Contents Introduction iv Hooklift Nomenclature ...............................v Serial Tag Location..............................vi Chapter 1 - Specifications ............................1 Model 190-24-40 & 32K Shuttle Specifications ......................1 Acceptable Subframe Dimensions - Model 190-24-40 & 32K ...................2 Chapter 2 - Installation ..............................3 General Installation ..............................3 Installer Notice ...............................3 Torque Data Chart ..............................4 Installation Note ..............................5... -
Page 4: Introduction
Introduction A copy of this manual is provided with every hooklift and can be found in the hard plastic manu- al case that is installed on the chassis. A copy of this manual shall remain with the hooklift at all times. -
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: 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 7: Chapter 1 - Specifications
Chapter 1 - Specifications Model 190-24-40 & 32K Shuttle Specifications Models 190-24-40 & 190-24-32K Shuttle Lifting/Dumping Capacity - Model 190-24-40 40,000 lbs (18,144 kg) Lifting/Dumping Capacity - Model 190-24-32K 32,000 lbs (14,515 kg) A Dump Angle 51° B Lowest hook Height 50”... -
Page 8: Acceptable Subframe Dimensions - Model 190-24-40 & 32K
Acceptable Subframe Dimensions - Model 190-24-40 & 32K Page 2 | Stellar 190-24-40 & 32K 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 ® 190-24-40 and 190-24-32K 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 spec- ifications should be consulted when provided. Size Bolt DIA Plain Plated Plain Plated Plated (DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) -
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: Drill Mounting Holes
Step 2: Drill mounting holes. NOTE: FOR THE FRONT MOUNT AT LEAST THREE BOLTS ARE REQUIRED TO ANGLE THE LOADER TO THE MOUNT AND TWO BOLTS TO MOUNT THE ANGLE TO THE TRUCK FRAME. NOTE: MULTIPLE HOLES ARE PREDRILLED ON THE BASE MOUNTING FLATS, ADDITIONAL HOLES MAY NOT BE ADDED. ONLY THE FRONT ANGLE MOUNT REQUIRES 4 BOLTS TO INSTALL THE ANGLE MOUNT TO THE TRUCK FRAME AND 4 BOLTS TO INSTALL THE HOOK TO THE ANGLE MOUNT. -
Page 13: Step 3: Install Bumper
Step 3: Install bumper. • See NHTSA (National Highway Truck Safety Administration) Regulations for acceptable place- ment. • Modify the truck frame as necessary so that it ends 2” from the rear of the hooklift. 2.00 Step 4: Install tie-downs. Note: See torque chart at beginning of chapter: PN 57080 ITEM... -
Page 14: Step 5: Install Tarper Tower (If Applicable)
Mounting Kit - PN 16898 PN 16898 ITEM PART DESCRIPTION QTY. 79246 TIE DOWN 40,000# PC BLACK 1440 TIE DOWN, 40000# 80043 PLATE 0.50X8.00X16.00 W/HOLE 12169 CAP SCR 1.00-8X3.50 HHGR8 5199 CAP SCR 1.00X8X3.00 HHGR8 ZY C1025 CAP SCR 0.63-11X2.00 HHGR8 ZY 6538 WASHER 1.00 SAE FLAT YELLOW GR8 C5902... -
Page 15: Reservoir Assembly With Cable Controls - Pn 86463
Reservoir Assembly with Cable Controls - PN 86463 NOTE: ITEMS NOT SHOWN 25941 - DECAL LOADER VB VDM8 HOSE LOCATION X 1 42971 - DECAL OIL FILTER CHANGE X 1 PN 86463 ITEM PART No. DESCRIPTION QTY. 86006 RSRVR ASM 25GAL K MODEL W/ TANK TOP FILTER 7353 FTG 32-32 MP-MP HEX NIPPLE STRAIGHT C4750... -
Page 16: Reservoir Assembly With Air Controls - Pn 86467
Reservoir Assembly with Air Controls - PN 86467 NOTE: ITEMS NOT SHOWN 25941 - DECAL LOADER VB VDM8 HOSE LOCATION X 1 42971 - DECAL OIL FILTER CHANGE X 1 PN 86467 ITEM PART No. DESCRIPTION QTY. 86006 RSRVR ASM 25GAL K MODEL W/ TANK TOP FILTER 7353 FTG 32-32 MP-MP HEX NIPPLE STRAIGHT C4750... -
Page 17: Reservoir Subassembly - Pn 86006
Reservoir Subassembly - PN 86006 NOTE: REPLACEMENT OIL FILTER - PN 86010 NOTE: REPLACEMENT GASKET UNDER FILTER CAP - PN 109546 PN 86006 ITEM PART DESCRIPTION C2126 MAGNETIC PLUG DRAIN 3/4" 15463 THERMO SIGHT GAUGE ZINGA SG-O5-A-T-N 73278 CAP FILL 1PSI ZINGA THREADED 13002 DECAL HYD OIL SPECIFICATION MOBIL 86007... -
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 190-24-40 &... -
Page 19: Step 7: Install Pto And Pump
Step 7: Install PTO and pump. • Before installing the pump to the PTO, always check the direction of the PTO output shaft to de- termine which direction the hydraulic pump needs to rotate to operate the equipment. 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 8: Route hydraulic hoses. 1. -
Page 21: Hose Kit - Pn 95456
Stellar 190-24-40 & 32K 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. Kit No: 122069 Contains both 3/8”... -
Page 23: Step 9: Route Electrical Components
Step 9: Route Electrical Components EXISTING TRUCK WIRING HARNESS BACK-UP LIGHT (BLACK) LH, TURN, BRAKE, LIGHT (YELLOW) TAIL, CLEARANCE, LIGHT GROUND (WHITE) (BROWN) 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 10: Install Cab And Pto Controls
Step 10: 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 11: Install Hoist Up Alarm - Pn 83115
Step 11: Install Hoist Up Alarm - PN 83115 Install the hoist up alarm onto the base of the hooklift as shown: DETAIL A SCALE 1 : 8 NOTE: MOUNT SWITCH ON BRACKET ON BASE ITEM PART DESCRIPTION QTY. 94994 SWITCH LIMIT HONEYWELL 914CE20-Q 8330 CAP SCR #10-24X1.00 BTNHD SS... -
Page 27: Step 12: Install Mud Flaps And Fenders
Step 12: Install mud flaps and fenders. Poly Tandem Fender Assembly - PN 58217 PN 58217 ITEM PART No. DESCRIPTION QTY. 64060 FENDER POLY MIN 900 FRONT/REAR 102205 MNT KIT FENDER MID SUPPORT TANDEM POLY 5733 MTG KIT OFFSET POLY FENDER (FLEET) 7633 FENDER MOUNT ASM KIT Stellar... -
Page 28: Steel Tandem Fender Assembly - Pn 100617
Steel Tandem Fender Assembly - PN 100617 PN 100617 ITEM PART No. DESCRIPTION QTY. ITEM PART No. DESCRIPTION QTY. 46121 FENDER WLDMT STEEL TANDEM KP60 46119 WLDMT TUBE FRONT FENDER PC BLACK 0537 NUT 0.50-13 HH 46117 TUBE FRONT FENDER SUPPORT PC BLACK 46590 CAP SCR 0.50X1.50 SQ HD CP SS 46906... -
Page 29: Step 13A: Apply Hooklift Assembly Decals
Step 13A: 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. Keep hands and arms • Maintain safe clearance from high clear when operating voltage power sources. -
Page 30: Step 13B: Apply Chassis Decals
Step 13B: 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 31: Step 14: Fill Reservoir And Activate Hydraulic Flow
Step 14: Fill reservoir and activate hydraulic flow. • Fill reservoir to site gauge, within 3” from the top (Roughly 10 Gallons). Note: ISO 32 hydraulic oil is recommended. • When connections are secure, activate hydraulic flow by opening the ball valve on the bottom of the reservoir. -
Page 32: Set System Relief Pressure
Set System Relief Pressure 1. Engage the PTO. Run the PTO at 1200 RPM. 2. Push the lever labeled ‘lift’ until the boom bottoms out. Keep pushing the lever forward until the pressure is set. 3. Locate the main relief valve and release the jam nut using a 13 mm wrench: 4. -
Page 33: Chapter 3 - Assembly Drawings
Chapter 3 - Assembly Drawings Base Assembly - PN 93850 PN 93850 ITEM PART DESCRIPTION QTY. 93851 BASE 190-24-40K GEN2 92701CR PIN 2.50X14.00 SR/D&T ZC 26048CR PIN 2.50X36.44 ZC 23930 COLLAR 2.51X3.50X1.00 PC BLACK 0635 BUSHING BPC40DXR32 2.50X2.00 1593 MACHY WASHER 2.50ID 10GA 0636 SNAP RING 2.50 HD 32086... -
Page 34: Dump Assembly - Pn 93840
Dump Assembly - PN 93840 BUSHING AND ZERK SHOWN AS REFERENCE 22 25 26 PN 93840 ITEM PART DESCRIPTION QTY. ITEM PART DESCRIPTION QTY. 93841 DUMP 190-24-40K GEN2 93507 TAB LOADER WLDMT BREAK AWAY W/STOP C0929 CAP SCR 0.31-18X2.75 HHGR5 0635 BUSHING 40DXR32 GARLOCK 0481... -
Page 35: Secondary Assembly - Pn 26716
Secondary Assembly - PN 26716 PN 26716 ITEM PART DESCRIPTION 26717 SECONDARY 190-22-40K 44482 CYLINDER ASM 190-24-40K 5739 BUSHING 40DXR48 GARLOCK 26378ZP PIN 2.50X17.75 0635 BUSHING 40DXR32 GARLOCK 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 30243ZP PIN 2.00X17.75 SR 0108 SNAP RING 2.00 7200-200 22216 SNAP RING INSIDE 2.50 1546... -
Page 36: Tilt Assembly - Pn 94995
Tilt Assembly - PN 94995 PN 94995 ITEM PART DESCRIPTION 94996 TILT 190-24-40K GEN2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0822 CYLINDER 4.00X26.50 8818 PIN CAP 0.55X2.00X0.63 YZ 8457 CAP SCR 0.50-13X1.00 SS 24249CR PIN 2.00X15.88 SR ZC 0377 MACHY WASHER 2.00ID 14GA 0108 SNAP RING 2.00 7200-200 27768CR PIN WLDMT 2.00X9.38 ZC... -
Page 37: Main Cylinder - Pn 44482
Main Cylinder - PN 44482 NOTE: BUSHINGS ARE SHOWN FOR REFERENCE. PN 44482 ITEM NO. PART NO. DESCRIPTION QTY. 15995 MANIFOLD ASM DUAL T2A 5000PSI C2252 FTG ADAPT 8-10-F5OLO-S 1554 FTG ADAPT 8-F5OLO-S 18392 TUBE ASM 0.50X34.88 C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 5739 BUSHING 40DXR48 GARLOCK 26730... -
Page 38: Tilt Cylinder - Pn 23462
Tilt Cylinder - PN 23462 BUSHINGS SHOWN AS REFERENCE PN 23462 ITEM PART DESCRIPTION QTY. 0822 CYLINDER 4.00X26.50 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 3 C1854FTG 6-8 MFS-MORB STRAIGHT Page 32 | Stellar 190-24-40 & 32K Shuttle Owner’s Manual ®... -
Page 39: 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 40: Optional Tab Alarm Wire Harness - Pn 26291
Optional Tab Alarm Wire Harness - PN 26291 Page 34 | Stellar 190-24-40 & 32K Shuttle Owner’s Manual ®... -
Page 41: Optional Proximity Switch Wire Harness - Pn 26416
Stellar 190-24-40 & 32K Shuttle Owner’s Manual | Page 35 ®... -
Page 42: Optional Fender Kit - Pn 115695
Optional Fender Kit - PN 115695 PN 115695 ITEM PART No. DESCRIPTION QTY. 118143 FENDER TANDEM DPS CNE W/ PAINT 118842 ANGLE FORMED 3.50X11.25X0.38X11.00 0335 CAP SCR 0.38-16X1.25 HHGR5 C1026 CAP SCR 0.63-11X2.50 HHGR8 0347 NUT 0.38-16 HHGR5 NYLOC 24868 NUT 0.63-11 HHGR8 NYLOC 0346 WASHER 0.38 USS FLAT... -
Page 43: Optional Fender Kit - Pn 115695 Cont
Optional Fender Kit - PN 115695 cont. TYP 6 TYP 4 (.19) W=.28 TYP 4 (.19) (.19) W=.28 TYP 2 (.19) TYP 4 TYP 8 Stellar 190-24-40 & 32K Shuttle Owner’s Manual | Page 37 ®... -
Page 44: Optional Threshold Plate Kit - Pn 118281
Optional Threshold Plate Kit - PN 118281 TYP 2 PN 118281 ITEM PART No. DESCRIPTION QTY. 118277 PLATE BUMPER THRESHOLD TANDEM FENDER 24IN 0335 CAP SCR 0.38-16X1.25 HHGR5 0346 WASHER 0.38 USS FLAT 0347 NUT 0.38-16 HHGR5 NYLOC Page 38 | Stellar 190-24-40 &... - Page 48 Subject to Change without Notification. © 2022 Stellar Industries, Inc.
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