Stellar 190-24-65 Hooklift User Manual

Page 1
®
OWNERS MANUAL
Safety, Installation, Maintenance, and Operation
Stellar Shuttle Hooklifts
Models 138-18-52 174-20-52 190-24-52 138-18-65 174-20-65 190-24-65
Subject to Change without Notification. © 2007 Stellar Industries, Inc.
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
Manual Part No. 43502 Last Revision: 12/18/07
Page 2
52K/65K Hooklift Manual Revisions
Date of Revision Description of RevisionSection Revised
Page 3
Table of Contents
Table of Contents i
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Stellar Shuttle Hooklift Nomenclature . . . . .iv
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . .1
General Safety . . . . . . . . . . . . . . . . . . . . . . .1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . .1
Maintenance Safety . . . . . . . . . . . . . . . . . . .1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Load Safety . . . . . . . . . . . . . . . . . . . . . . . . . .2
Environment . . . . . . . . . . . . . . . . . . . . . . . . . .2
Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . .3
Operator Requirements . . . . . . . . . . . . . . . .3
Operator Conduct . . . . . . . . . . . . . . . . . . . .3
Job-Site Set-Up . . . . . . . . . . . . . . . . . . . . . . .3
Operation Overview . . . . . . . . . . . . . . . . . . .4
Hooklift Controls . . . . . . . . . . . . . . . . . . . . . . .4
Unloading Operation . . . . . . . . . . . . . . . . . .5
Loading Operation . . . . . . . . . . . . . . . . . . . .6
Dumping Operation . . . . . . . . . . . . . . . . . . .7
Chapter 3 - Maintenance . . . . . . . . . . . . . . . . .9
Choice Lubricants for DX Bearings . . . . . .10
Chapter 4 - Specifications . . . . . . . . . . . . . . . .11
Model 138-18-52 Specifications . . . . . . . . .12
Model 174-20-52 Specifications . . . . . . . . .13
Model 190-24-52 Specifications . . . . . . . . .14
Model 138-18-65 Specifications . . . . . . . . .15
Model 174-20-65 Specifications . . . . . . . . .16
Model 190-24-65 Specifications . . . . . . . . .17
Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . . . .19
Decals of Note . . . . . . . . . . . . . . . . . . . . . . .19
Decal Kit Placement - PN D0779 . . . . . . . .20
Chapter 6 - Installation
Basic Installation Overview . . . . . . . . . . . .21
52K Installation Steps - Basic Guidelines . .22
Installation Steps - Basic Guidelines
65K
Power Beyond VDM8 Valve . . . . . . . . . . . .26
Mounting Kit (All 52K Shuttles)
PN 17803 . . . . . . . . . . . . . . . . . . . . . . . . .27
Mounting Kit (All 65K Shuttles)
PN 16561 . . . . . . . . . . . . . . . . . . . . . . . . .28
Rotary Valve (All 52K Shuttles)
PN 24040
Rotary Valve (All 65K Shuttles)
PN D0000 Reservoir Assembly - PN 25927 Subframe - PN 3118
(138-18-52, 138-18-65) . . . . . . . . . . . . . .32
Subframe - PN 3117
. . . . . . . . . . . . . . . . . . . . . . . . .29
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .21
2
. .
30
. . . . . . . . . .
31
(174-20-52, 174-20-65, 190-24-65, 190-24-52) . . . . . .33
Dump Light Kit Installation . . . . . . . . . . . . .34
Controller Assembly Part 1 - PN 38841 . . .35 Controller Assembly Part 2 - PN 38841 . . .36
Hose Kit (138-18-52) - PN 17017 . . . . . . . . .37
Hose Kit (174-20-52) - PN 17794 . . . . . . . . .38
Hose Kit (190-24-52) - PN 17822 . . . . . . . . .39
Hose Kit (138-18-65) - PN 16624 . . . . . . . . .40
Hose Kit (174-20-65) - PN 32677 . . . . . . . . .41
Hose Kit (190-24-65) - PN 16708 . . . . . . . . .42
Chapter 7 - Assembly Drawings . . . . . . . . . . .43
Base (138-18-52) - PN 27196 . . . . . . . . . . . .43
Base (174-20-52) - PN 26862 . . . . . . . . . . . .44
Base (190-24-52) - PN 27244 . . . . . . . . . . . .45
Base (138-18-65) - PN 16570 . . . . . . . . . . . .46
Base (174-20-65) - PN 16648 . . . . . . . . . . . .47
Base (190-24-65) - PN 16705 . . . . . . . . . . . .48
Dump (138-18-52) - PN 27198 . . . . . . . . . . .49
Dump (174-20-52) - PN 26866 . . . . . . . . . . .50
Dump (190-24-52) - PN 27246 . . . . . . . . . . .51
Dump (138-18-65) - PN 16621 . . . . . . . . . . .52
Dump (174-20-65) - PN 16649 . . . . . . . . . . .53
Dump (190-24-65) - PN 16706 . . . . . . . . . . .54
Secondary (138-18-52) - PN 27200 . . . . . .55
Secondary (174-20-52) - PN 26870 . . . . . .56
Secondary (190-24-52) - PN 27248 . . . . . .57
Secondary (138-18-65) - PN 16623 . . . . . .58
Secondary (174-20-65) - PN 16650 . . . . . .59
Secondary (190-24-65) - PN 16650 . . . . . .60
Tilt (138-18-52) - PN 26874 . . . . . . . . . . . . . .61
ilt (174-20-52) - PN 26874 . . . . . . . . . . . . . .62
T
Tilt (190-24-52) - PN 26874 . . . . . . . . . . . . . .63
Tilt (138-18-65) - PN 16523 . . . . . . . . . . . . . .64
4
ilt (174-20-65) - PN 16523
T
Tilt (190-24-65) - PN 16707 . . . . . . . . . . . . . .66
Main Cylinder (138-18-52) - PN 27231 . . . .67
Main Cylinder (174-20-52) - PN 18064 . . . .68
Main Cylinder (190-24-52) - PN 27239
Main Cylinder (138-18-65) - PN 18397 . . . .70
Main Cylinder (174-20-65) - PN 19070 . . . .71
Main Cylinder (190-24-65) - PN 19070 Roller Assembly (138-16-65) - PN 22738 . .73 Roller Assembly (174-20-65) - PN 22747 Roller Assembly (190-24-65) - PN 22738
Chapter 8 - Troubleshooting . . . . . . . . . . . . . .77
Warranty Information . . . . . . . . . . . . . . . . . . . .78
. . . . . . . . . . . . . .
6
6
. . . .
. . . .72
74
. .
7
. .
5
9
5
Manual PN 43502
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ii Shuttle Owner’s Manual - PN 43502
AN OVERVIEW TO OWNER, OPERATOR AND
SERVICE PERSONNEL ABOUT SAFETY
As the owner or employer, it is your responsibility to instruct the operator in the safe opera­tion of this equipment and to provide the operator with properly maintained equipment.
FAILURE TO READ THIS MANUAL BY ANYONE WHO WILL OPERATE, SERVICE, OR WORK AROUND THIS HOOKLIFT IS A MISUSE OF THE EQUIPMENT. DEATH OR SERIOUS INJURY WILL RESULT FROM IMPROPER USE OR MAINTENANCE OF THIS MACHINE.
Occupational safety is a prime concern of Stellar Industries in the design and production of this hooklift. Our goal in writing this manual was the safety of the operator and others who work around this equipment.
It is your responsibility to know the specific requirements, governmental regulations, pre­cautions and work hazards that exist in the operation and maintenance of this hooklift. You shall make these available and known to all personnel working with and around the equipment, so that all of you will take the necessary and requir
FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
ed safety precautions.
It is also your responsibility to operate and maintain your hooklift with caution, skill, and good judgment. Following the recognized safety procedures will help you avoid acci­dents. Modification to any part of his hooklift can create a safety hazard and therefore shall not be made without the manufactur approved accessories, options, and parts on this equipment. The rebuilding or remounting of this equipment requires the mounting procedures and retesting to be in accordance with factory instructions. Safety covers and devices must remain installed and maintained in proper working condition. Safety decals must be maintained, be completely legible, and be properly located. If safety covers, devices, or decals are missing, they must be replaced with the proper designated Stellar part.
Be capable, careful, and concerned! Make safety your everyday business!
er’s written approval. Use only factory
Attention!
According to Federal Law (49 cfr part 571), each final-stage manufacturer shall com­plete the vehicle in such a manner that it conforms to the standar date of manufacture of the incomplete vehicle, the date of final completion, or a date between those two dates. This require­ment shall, however, be superseded by any conflicting provisions of a standard that applies by its terms to vehicles manufac­tured in two or more stages. Therefore, the installer of Stellar hooklifts is considered one of the manufacturers of the vehicle. As such a manufacturer
ds in ef
fect on the
, the
installer is responsible for compliance with all applicable federal and state regulations. They are required to certify that the vehicle is in compliance with the Federal Motor Vehicle Safety Standards and other regula­tions issued under the National Traffic and Motor Vehicle Safety Act.
ence the Code of Federal
Please r Regulations, title 49 - Transportation, Volume 5 (400-999), for further information, or visit www.gpoaccess.gov/nara/index.html for the full text of Code of Federal Regulations.
efer
Page 5

Introduction

Introduction iii
Stellar Hooklifts are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, these hooklifts will operate at peak performance for many years.
To promote this longevity, carefully study the information contained in this manual before putting the equipment into service. Though it is not intended to be a training manual for beginners, this manual should provide solid guidelines for the safe and proper usage of the hooklift.
Once you feel comfortable with the material contained in this manual, strive to
cise your knowledge as you safely
exer operate and maintain the hooklift. This process is vital to the proper use of the unit.
A few notes on this manual:
A copy of this manual is provided with every hooklift and shall remain with the hooklift at all times. Information contained within this manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations.
Please be awar manual contain information pertaining to
e that some sections of this
Stellar manufactured hooklifts in general and may or may not apply to your specific model.
This manual is not binding. Stellar Industries, Inc. reserves the right to change, at any time, any or all of the items, components, and parts deemed necessary for product improvement or commercial/production purposes. This right is kept with no requirement or obligation for immediate mandatory updating of this manual.
In closing:
If more information is required or technical assistance is needed, or if you feel that any part of this manual is unclear or incorrect, please contact the Stellar Customer Service Department by phone at 800-321-3741 or email at service@stellarindustries.com.
ATTENTION
Failure to adhere to the
instructions could result in
property damage or even serious
bodily injury to the operator or
others close to the hooklift.
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
Manual PN 43502
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iv Shuttle Owner’s Manual - PN 43502
HOOKLIFT
BASE
DUMP
SECONDARY
TILT
Stellar Shuttle Hooklift Nomenclature
The Stellar Shuttle is a hydraulic, body-loading device when mounted on a truck chassis. When mounted, the Stellar Shuttle can handle a variety of bodies ranging from flatbeds to recycling containers to dump bodies.
Two independently controlled cylinders operate all the functions of the Stellar Shuttle. By varying the cylinder operation, the Stellar Flex can be used to dump or unload a body.
The Stellar Shuttle consists of four basic parts: The base, dump, secondary, and tilt sec­tions. Familiarize yourself with the various components of this hooklift and the names of those components. Knowing the proper terminology is necessary to get full benefit from this manual
Page 7

Chapter 1 - Safety

Safety 1
Please Read the Following Carefully! This portion of the manual contains information regarding all Stellar manufactured hooklifts. Some items contained within this chapter may not apply to your specific equipment.
Safety should be the number one thought on every operator’s mind. Three factors should exist for safe operation: a qualified operator, well-maintained equipment, and the proper use of this equipment. The following information should be read and understood completely by everyone working with or near the hooklift before putting the unit into operation.
Please take note that Stellar Industries, Inc. is not liable for accidents incurred by the hooklift because of non-fulfillment from the operator’s side of current rules, laws, and regulations.

General Safety

It is the responsibility of the owner to instruct the operator in the safe operation of your equipment and to provide the operator with properly maintained equipment.
anti-noise headphones, protective glasses, breathing apparatus, and reflective jackets. Consult your employer regarding current safety regulations and accident-prevention equipment.
Do not wear rings, wristwatch, jewelry, loose­fitting or hanging clothing such as ties, torn garments, scarves, unbuttoned jackets or unzipped overalls, which could get caught up in the moving parts of the hooklift.
Keep a first-aid box and a fire extinguisher readily available on the truck. Regularly check to make sure the fire extinguisher is fully charged and the first-aid kit is stocked.
Do not use controls and hoses as handholds. These parts move and cannot provide sta­ble support.
Do not allow unauthorized personnel or equipment to enter within 10 feet of hooklift operating area.
Never allow anyone to ride the hooklift or load.
Trainees or untrained persons shall be under the direct supervision of qualified persons.
Do not operate equipment under the adverse influence of alcohol, drugs, or med­ication.
Read all Danger and Caution decals on the equipment and understand their meaning.

Personal Safety

Keep clear of all moving parts.
Always wear the pr devices.
Always wear appr clothing such as: protective helmets, anti­slip shoes with steel toes, protective gloves,
escribed personal safety
oved accident-prevention

Maintenance Safety

Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without Stellar Industries’ approval.
Do not perform any maintenance or repair work on the hooklift unless authorized and trained to do so. Release system pressure before attempting to make adjustments or repairs.
Do not attempt service or repair when PTO is engaged.
Decals are considered safety equipment. They must be maintained, as would other safety devices. Do not remove any decals.
Manual PN 43502
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2 Shuttle Owner’s Manual - PN 43502
Replace any decals that are missing, dam­aged, or not legible.
The safety instruction plates, notices, load charts and any other sticker applied to the hooklift must be kept legible and in good condition. If necessary, replace them.
Keep all surfaces of the hooklift free of oil and grease to avoid slippery surfaces and aid in inspections.

Stability

Know the hooklift components and their capabilities and limitations. Overloading the hooklift may result in serious damage of self, others, equipment or the surroundings.
Never exceed manufacturer’s load ratings. These ratings are based on the machine’s hydraulic, mechanical, and structural design rather than stability.

Load Safety

Full rated dump capacity assumes load will decrease as dump angle increases. Do not take full rated capacity to full dump angle without some unloading of weight as it may cause damage to the chassis and/or the hooklift.
Move the control lever slow and smooth for steady oil flow.
Avoid jerky or sudden movement of the con­trols.
weight can be lifted.
Keep everyone clear when loading, unload­ing, and dumping.
Do not push on fixed objects or bodies with­out rollers with the hooklift.
Do not permit loose objects on the hooklift.
Use a qualified person to assist in loading when the load is not visible to the operator.
Do not leave hooklift unattended with sus­pended load.
Take care when operating in areas support­ed by vehicle tires, because of the cushion­ing effect of springs and tires.
Never use the drivetrain of the chassis to assist the hydraulics in loading

Environment

Do not operate the hooklift during electrical storms.
In extreme cold, allow adequate time to warm the truck before engaging the PTO. Do not rev the truck engine and over speed the hydraulic pumps as permanent damage to the pumps may occur. Follow the vehicle owner’s manual regarding operating the vehicle in such adverse conditions.
In extreme cold, operate the controls slowly to allow for viscosity changes.
Be constantly aware of the hooklift position when operating the controls.
Do not attempt to lift fixed loads. Know the weight of your load to avoid over­loading the equipment.
Deduct the weight of the body from the maximum load rating to determine how much
ATTENTION
Stellar Industries, Inc. is not liable
for accidents incurred by the
hooklift because of the
operator’s non-fulfillment of
current rules, laws and
regulations.
Page 9

Chapter 2 - Operation

Operation 3

Job-Site Set-Up

Thoroughly plan the lift before positioning the vehicle. Consider the following:
1. The vehicle should be positioned in an area free from overhead obstructions to eliminate the need for repositioning.
2. Position the vehicle so that it is impossible for any portion of the equipment to come within the minimum required safe distance of any power line. Maintain a clearance of at least 10 feet between any part of the hooklift, load line, or load, and any electrical line or apparatus carrying up to 50,000 volts. One foot additional clear­ance is required for every additional 30,000 volts or less. Remember to allow for winds that cause power lines to sway. It is recommended that a signal person be used when the vehicle is set-up near power lines.
3. The vehicle should also be positioned on a firm and level surface that will provide adequate support for the body.

Operator Requirements

Operation is limited to the following peo­ple: A. Qualified individual. B. Trainees under direct supervision of the
qualified individual. C. Test or maintenance individual. D. Hooklift Inspector.
Operators must: A. Demonstrate the ability to understand
all decals, the owner’s manual, and any other information required for safe oper­ation of the hooklift.
B. Be able to demonstrate the ability to
safely control the hooklift. C. Know all safety r D. Be responsible for maintenance require-
ments.
E. Understand and be fully capable of
implementing all emergency proce-
dures. F. Understand the operating procedures as
outlined by this manual, Ansi B30.5 and Federal/State Laws.
egulations.
4. The parking brake must be removed to allow the truck to roll under the body while loading.
CAUTION
1.
When loading and unloading bodies, the tilt cylinder must be fully extended before operating the lift cylinder to prevent damage to the latch systems.
2. When the PTO is engaged, do not run the engine over 1400 RPM.
3. Do not hold the brakes while performing operations.

Operator Conduct

1. Operators will not engage in any opera­tion that would cause them to divert attention away fr the hooklift.
2. Operators are responsible for all opera tions under their direct control.
3. Operators will not leave a suspended load unattended.
4. Operators will be familiar with the equip­ment and the maintenance required for
oper care.
pr
om the operation of
-
Manual PN 43502
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4 Shuttle Owner’s Manual - PN 43502

Hooklift Controls

1. Be familiar with the sequence and oper­ation of the hooklift controls.
2. Each individual hooklift function should have control function decals. Replace them immediately if they are missing or illegible.
3. Keep hands, feet and control levers free from mud, grease and oil.
4. Be familiar with the control levers and how they operate before attempting to operate the hooklift.
5. Be prepared before beginning opera­tion of the hooklift:
• All pr
• Be sure all safety devices provided are
• Be prepared for all situations. Keep
• Be sure all regular maintenance has
• Visually inspect all aspects of the
• Check for fluid leaks.
otective guards must be in place. Be aware of the surroundings: low branches, power lines, unstable ground.
in place and in good operating condi­tion.
fire extinguisher and first aid kit near.
been performed.
hooklift for physical damage.

Operation Overview

Unloading Operation
. Stop the truck at the location you wish to unload.
1
2. Put the truck in neutral and engage the PTO. Run RPM as needed.
3. Locate the black control lever labeled tilt.
4. Pull the tilt lever until the cylinder is fully extend­ed, thus releasing tabs.
5. Locate the red lever labeled lift.
6. Pull lift lever until the body is on the ground and can be detached. Return the hooklift to the stored position and disengage the PTO.
Loading Operation
1. Position the truck in line with the body you intent to pick up.
2. Engage the hook to the body by maneuvering the hooklift with the red(lift) lever. Run RPM as needed.
3. Push the red(lift) lever until the main cylinder is fully retracted.
4. Push the black(tilt) lever until the tilt is fully extended.
5. Disengage the PTO.
NOTE: The controller assembly pictured in this
chapter may differ from model to model.
Dumping Operation
1. Stop the truck at the location you wish to dump the load.
2. Put the truck in neutral and engage the PTO. Run RPM as needed.
3. Locate the red lever labeled lift.
4. Pull the lever to dump the body.
5.Wait until dumping is complete, then push the
red(lift) lever until the main cylinder fully retracts.
6. Disengage the PTO.
Page 11
Operation Operation 5

Unloading Operation

1. Stop the truck at the location you wish to unload.
3. Locate the black control lever labeled tilt.
2. Put the truck in neutral and engage the PTO.
4. Pull tilt lever until full stroke is reached, thus releasing tabs.
5. Locate the r
ed lever labeled lift.
6. Pull lift lever until the body is on the ground and can be detached. Return the hooklift to the
stored position and disengage the PTO.
Manual PN 43502
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6 Shuttle Owner’s Manual - PN 43502 Operation 6

Loading Operation

1. Perform the steps for unloading a container.
3. Push the red(lift) lever until the main cylinder is fully retracted.
2. Engage the hook to the body by
maneuvering the hooklift with the red(lift)
lever and the black (tilt) lever..
4. Push the black(tilt) lever until the tilt is fully retracted.
5. Disengage the PTO.
Page 13

Dumping Operation

Operation 7
1. Stop the truck at the location you wish to dump the load.
3. Locate the red lever labeled lift.
2. Put the truck in neutral and engage the PTO.
4. Pull the lift lever to dump the body.
5. Wait until dumping is complete, then push the ed(lift) lever until the main cylinder fully r
r
etracts.
6. Disengage the PTO.
Manual PN 43502
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8 Shuttle Owner’s Manual - PN 43502
Page 15

Chapter 3 - Maintenance

Maintenance 9
9
Please read the following before performing any main­tenance on the hooklift.
1. Only authorized service personnel are to perform maintenance on the hooklift.
2. Disengage the PTO before any service or repair is performed.
3. Do not disconnect hydraulic hoses while there is still pressure in those components.
4. Before disconnecting hydraulic components, shut off the engine, release any air pressure on the hydraulic reservoir, and move control levers repeat­edly through their operating positions to relieve all pressures.
5. Keep the hooklift clean and free from grease build­up, oil and dirt to prevent slippery conditions.
6. Perform all safety and maintenance checks before each period of use.
7. Replace parts with Stellar Industries, Inc. approved parts only.
8. Immediately repair or have repaired any compo­nents found to be inadequate.
Maintenance Procedures
1. Position the hooklift where it will be out of the way of other operations or vehicles in the area.
2. Place all controls in the off position and secure oper­ating features from inadvertent motion.
3. Relieve hydraulic oil pressure from all hydraulic cir­cuits before loosening or removing hydraulic compo­nents.
4. Label or tag parts when disassembling.
Daily Inspection
Daily Inspection should occur each day before the hooklift is put into use. Each day, inspect the hooklift for all of the following:
1. Hydraulic oil level.
2. Loose parts or damage to structures or weld.
3. Cylinder movement due to leakage.
4. Hoses for evidence of oil leaks.
5. Controls for malfunction or adjustment.
6. Parking brake operation.
e such as cotter pins, snap
All securing har
7.
rings, hairpins, and pin keepers for proper installa­tion.
8. All safety covers for proper installation.
9. Cylinder holding valves for proper operation.
Equipment for missing, illegible, or defaced operat
10.
ing decals and safety signs.
Periodic Inspection
Periodic Inspection should occur while the hooklift is in use. For the duration of the usage, inspect the hooklift for all of the following:
1. Loose bolts and fasteners. All pins, bushings, shafts, and gears for wear
2. or distortion to include all pivot points, and bushings.
3. Hydraulic systems for proper operating pressure.
dwar
, cracks,
4. Main frame mount bolts.
5. Cylinders for: A. Damaged rods. B. Dented barrels. C. Drift from oil leaking internally. D. Leaks at rod seals or holding valves.
6. PTO and hydraulic pump(s) for leaks.
7. Hydraulic hose and tubing for evidence of damage
such as blistering, crushing, or abrasion.
8. Presence of this owner’s manual.
Monthly Inspection
Monthly Inspection should occur at the beginning of every work month. Each month, inspect the hooklift for all of the following:
1. Frame bolt tightness - turn barrel nuts and mounting
bolts during the first month of operation on new machines and then quarterly thereafter.
2. Cylinders and valves for leaks.
3. Lubrication.
4. Tilt hook for cracks.
5. Structural weldments for bends, cracks, or breaks.
6. All pins and keepers for proper installation.
7. All control, safety, and capacity placards for read-
ability and secure attachment.
8. Inspect all electrical wires and connections for worn,
cut, or deteriorated insulationand bare wire. Replace or repair wires as required.
10. Lubrication of all points requiring lubrication.
Service
The following general suggestions should be helpful in analyzing and servicing your hooklift. Using the follow­ing systematic approach should be helpful in finding and fixing problems:
1. Determine the problem.
2. List and record possible causes.
3. Devise checks.
4. Conduct checks in a logical order to determine the
cause.
5. Consider the remaining service life of components
against the cost of parts and labor necessary to
eplace them.
r
6. Make the necessary repair.
7. Recheck to ensur
looked.
8. Functionally test the new part in its system.
-
e that nothing has been over
Stellar Industries recommends the first filter change
to occur after the first 250 hours of service.* The
second, and every subsequent change, should
occur after every 1,000 hours of service. By
following these guidelines, the hydraulic oil should
last up to 6,500 hours.
*Note: These recommendations are based on normal working
parameters. If operating in less than favorable conditions
(excessive dust, moisture, etc.), be sure to check the filter gauge
often for filter change notice.
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Manual PN 43502
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10 Shuttle Owner’s Manual - PN 43502
Choice Lubricants for DX Bearings
Greases Recommended
Type of Grease Description
Premium Quality Multi-Purpose
Multi-Purpose Calcium Based, for General Automotive and Industrial Use
Anti-Friction Bearing Calcium Based with EP Additives
Extreme Pressure (EP) Lithium Based with EP Additives
High Temperature Modified Sodium Based, High Drop Point Transmission Semi-Fluid, Calcium Based Molybdenum Filled Lithium Based with 2% Molybdenum Disulfide Graphite Filled Sodium Based with 2% Graphite Block Grease Sodium Based Solid Grease White Grease Aluminum Complex Based with Anti-Oxidant & Rust
Silicone Lithium Based with Silicone Oil Lubricant
Stabilized, Anti-Oxidant Lithium Base Lithium Base with 3% Molybdenum Disulfide High Drop Point
Calcium Grease, Water Stabilized, High Drop Point
Lithium Based Sodium Based
Calcium Based with EP Additives
Inhibitors & Zinc Oxide Additives
Greases Not Recommended
Type of Grease Description
Cup Grease Light Service Calcium or Sodium Based Grease Graphite Filled Greases with More than 10% Graphite
Molybdenum Filled Greases with More than 10% Molybdenum Disulfide Fluorocarbon Low Molecular Weight Chlorofluoroethylene Polymer
with Inert Thickeners
White Grease Calcium Based, Zinc Oxide Filled
Page 17

Chapter 4 - Specifications

• Will accommodate bodies from 15-feet up to 21.5-feet long and still attain the maximum rated dump angle on a 41-inch high frame truck.
onger bodies may be accommodated with reduced dumping
L capabilities.
• Transmission-mounted PTO and hydraulic pump required to power the Hooklift loader.
Standard in-cab manual controls which allow for precise metering of
• the manual stack-type hydraulic valve. Solenoid-activated hydraulic control valve with electric remote control pendant is optional.
• Twenty-Five (25) gallon frame-mounted oil tank.
• Operating pressure is 4,200 psi.
• Hydraulic flow required is 20 gallons per minute (52,000 lbs models) and 25-gallons per minute (65,000 lb models).
• Patented dump/load interface on double pivot models.
• Hydraulic locks to prevent cylinder collapse in case of hose failure.
Specifications 11
11
Lifting/Dumping Capacity (pounds) Dump Angle
A
Lowest Hook Height
B
Effective Length
C
Truck Frame Height
D
Loader Height
E
Chassis Cab to Trunnion
F
Loader Length
G
Loader Center of Gravity
H
Max. Height When Loading
I
Longest Body to Dump
J
Max. Height When Dumping
K
Shipping Weight (pounds)
L
Hook Height (fr Shipping Dimensions (LxHxW) Min. Truck GVWR (pounds) Load Angle w/Shortest Body Length Recommended Body Lengths* Recommended Body Lengths**
*(Assumes 3ft. overhang from center of rear roller pin)
(Bumper typically 12” fr
**(Assumes 5ft. overhang from center of rear roller pin)
equir
(May r
om bottom of hook bar)
om center of r
e bumper and latch options)
oller pin)
• Hook latch to prevent body from becoming detached prematurely.
• Mechanical rear body tie-down latches.
• Resettable dump/tilt tabs.
• Hydraulic rotary valve to prevent front tilt movement when the dump frame is raised.
• Permanently lubricated and greaseless bushings used throughout.
138-18-52
52,000 50° 51” 176” 41”
53.06” 138” to 144” 190” 80” 170” 234” 237” 5,250
61.75” 190”x86”x49” 54,000 35° 15’ to 17.5’ To 19.5’
174-20-52
52,000 50° 36” 206” 41”
53.06” 160” to 174” 220” 92” 188” 264” 261” 5,500
61.75” 220”x86”x49” 54,000 33°
17.5’ to 20’ To 22’
190-24-52
52,000 50° 51” 223” 41”
53.06” 174” to 190” 237” 96” 195” 282” 273” 6,200
61.75” 237”x86”x49” 54,000 32° 19’ to 21.5’ To 23.5’
138.18-65
65,000 50° 45” 174” 41” 54” 138” to 144” 190” 82” 171” 234” 238” 6,300
61.75” 190”x86”x56” 65,000 34° 15’ to 17.5’ To 19.5’
174-20-65
65,000 51° 45” 204” 41” 54” 160” to 174” 220” 91” 188” 264” 262” 6,875
61.75” 220”x86”x56” 54,000 33° 17’ to 20’ To 22’
190-24-65
65,000 50° 42” 221” 41” 54” 174” to 190” 237” 96” 195” 282” 272” 7,300
61.75” 237”x86”x56” 54,000 29° 19’ to 21.5’ To 23.5’
Manual PN 43502
Page 18
12 Shuttle Owner’s Manual - PN 43502

Model 138-18-52 Specifications

ifting Capacity: 52,000 pounds gross weight evenly distributed in, or on, body.
L
Container Length: 15-foot through 17.5-foot from front A-frame to rear of skid rails. Longer bodies up to 19.5-feet may be
accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
Maximum Dump Angle: 50°
Operating Pressure: 4200 PSI maximum.
Weight of Loader: Loader weight not to exceed 5,250 pounds.
Height of Loader: Loader height not to exceed 12.06" as measured from top of truck frame to top of loader rollers.
Hook Height: 61.75-inches from bottom of skid rails to bottom of hook bar. Loader must be able to pick up body 10-
inches below grade, when mounted on a 41” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir.
Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all
loader functions.
Tilting Hook Assembly: Loader must have pivoting type front tilt section (jib) to provide a low degree
loading/unloading angle. Hook to include automatic mechanical safety latch which disengages only when the container/body is in proper position to be picked up or dropped off.
Tilt Cylinder: Single 5-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and
include dual integral pilot-operated counterbalance valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to prevent exposure of cylinder rod to corrosive road salts.
Tilt Section Operation: Loader must include a hydraulic lock-out device to prevent operation of the tilt section
while loader is in the dumping mode.
Lift/Dump Cylinder: Single 8-inch bore with 3.5-inch diameter rod cylinder. Cylinder must be double acting and include dual
integral pilot-operated counterbalance valves to pr case of hose failure.
Dump/T
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the loader
ilt Interlock:
Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 27” wide frame with front saddles to provide support for the container while in the dump mode. These sections for er/body mounted latches. The system must be protected from out of sequence operation.
ough all ranges of the dump mode. This must be accomplished without the use of steel springs and/or
thr hydraulic/air cylinders. Loader must be compatible with containers manufactured to ANSI Z245.60 rec­ommended standard for waste containers.
m this frame without the use of mechanical latches which r
event cylinder
ely on gravity, springs, or contain
collapse in
-
Rear Dump Hinge Pin: 3-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
Bushings: All bushings to be of the permanently lubricated variety.
Hoses & Hyd. Fittings:
Origin of Manufacture: Loader to be designed and manufactured in the United States of America.
All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Page 19
Specifications 13

Model 174-20-52 Specifications

ifting Capacity: 52,000 pounds gross weight evenly distributed in, or on, body.
L
Container Length: 17.5-foot through 20-foot from front A-frame to rear of skid rails. Longer bodies up to 22-feet may be
accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
Maximum Dump Angle: 50°
Operating Pressure: 4200 PSI maximum.
Weight of Loader: Loader weight not to exceed 5,500 pounds.
Height of Loader: Loader height not to exceed 12.06" as measured from top of truck frame to top of loader rollers.
Hook Height: 61.75-inches from bottom of skid rails to bottom of hook bar. Loader must be able to pick up body 10-
inches below grade, when mounted on a 41” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir.
Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all
loader functions.
Tilting Hook Assembly: Loader must have pivoting type front tilt section (jib) to provide a low degree
loading/unloading angle. Hook to include automatic mechanical safety latch which disengages only when the container/body is in proper position to be picked up or dropped off.
Tilt Cylinder: Single 5-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and
include dual integral pilot-operated counterbalance valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to prevent exposure of cylinder rod to corrosive road salts.
Tilt Section Operation: Loader must include a hydraulic lock-out device to prevent operation of the tilt section
while loader is in the dumping mode.
Lift/Dump Cylinder: Single 8-inch bore with 3.5-inch diameter rod cylinder. Cylinder must be double acting
and include dual integral pilot-operated counterbalance valves to pr collapse in case of hose failure.
Dump/T
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body
ilt Interlock:
Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 27” wide frame with front saddles to provide support for the container while in the dump mode. These sections for er/body mounted latches. The system must be protected from out of sequence operation.
to the loader thr use of steel springs and/or hydraulic/air cylinders. Loader must be compatible with containers manufac­tured to ANSI Z245.60 recommended standard for waste containers.
m this frame without the use of mechanical latches which r
ough all ranges of the dump mode. This must be accomplished without
event cylinder
ely on gravity, springs, or contain
the
-
Rear Dump Hinge Pin: 3-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
Bushings: All bushings to be of the permanently lubricated variety.
Hoses & Hyd. Fittings:
Origin of Manufacture: Loader to be designed and manufactured in the United States of America.
All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Manual PN 43502
Page 20
14 Shuttle Owner’s Manual - PN 43502

Model 190-24-52 Specifications

ifting Capacity: 52,000 pounds gross weight evenly distributed in, or on, body.
L
Container Length: 19-foot through 21.5-foot from front A-frame to rear of skid rails. Longer bodies up to 23.5-feet may be
accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
Maximum Dump Angle: 50°
Operating Pressure: 4200 PSI maximum.
Weight of Loader: Loader weight not to exceed 6,200 pounds.
Height of Loader: Loader height not to exceed 12.06" as measured from top of truck frame to top of loader rollers.
Hook Height: 61.75-inches from bottom of skid rails to bottom of hook bar. Loader must be able to pick up body 10-
inches below grade, when mounted on a 41” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir.
Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all
loader functions.
Tilting Hook Assembly: Loader must have pivoting type front tilt section (jib) to provide a low degree
loading/unloading angle. Hook to include automatic mechanical safety latch which disengages only when the container/body is in proper position to be picked up or dropped off.
Tilt Cylinder: Single 5-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and
include dual integral pilot-operated counterbalance valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to prevent exposure of cylinder rod to corrosive road salts.
Tilt Section Operation: Loader must include a hydraulic lock-out device to prevent operation of the tilt section
while loader is in the dumping mode.
Lift/Dump Cylinder: Single 8-inch bore with 3.5-inch diameter rod cylinder. Cylinder must be double acting
and include dual integral pilot-operated counterbalance valves to pr collapse in case of hose failure.
Dump/T
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body
ilt Interlock:
Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 27” wide frame with front saddles to provide support for the container while in the dump mode. These sections for er/body mounted latches. The system must be protected from out of sequence operation.
to the loader thr use of steel springs and/or hydraulic/air cylinders. Loader must be compatible with containers manufac­tured to ANSI Z245.60 recommended standard for waste containers.
m this frame without the use of mechanical latches which r
ough all ranges of the dump mode. This must be accomplished without
event cylinder
ely on gravity, springs, or contain
the
-
Rear Dump Hinge Pin: 3-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
Bushings: All bushings to be of the permanently lubricated variety.
Hoses & Hyd. Fittings:
Origin of Manufacture: Loader to be designed and manufactured in the United States of America.
All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Page 21
Specifications 15

Model 138-18-65 Specifications

ifting Capacity: 65,000 pounds gross weight evenly distributed in, or on, body.
L
Container Length: 15-foot through 17.5-foot from front A-frame to rear of skid rails. Longer bodies up to 19.5-feet may be
accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
Maximum Dump Angle: 50°
Operating Pressure: 4200 PSI maximum.
Weight of Loader: Loader weight not to exceed 6,300 pounds.
Height of Loader: Loader height not to exceed 13" as measured from top of truck frame to top of loader rollers.
Hook Height: 61.75-inches from bottom of skid rails to bottom of hook bar. Loader must be able to pick up body
10-inches below grade, when mounted on a 41” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir.
Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all
loader functions.
Tilting Hook Assembly: Loader must have pivoting type front tilt section (jib) to provide a low degree
loading/unloading angle. Hook to include automatic mechanical safety latch which disengages only when the container/body is in proper position to be picked up or dropped off.
Tilt Cylinder: Single 5-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and
include dual integral pilot-operated counterbalance valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to prevent exposure of cylinder rod to corrosive road salts.
Tilt Section Operation: Loader must include a hydraulic lock-out device to prevent operation of the tilt section
while loader is in the dumping mode.
Lift/Dump Cylinder: Dual 7-inch bore with 3-inch diameter rod cylinder. Cylinders must be double acting
and include pilot-operated counterbalance valving to pr hose failure.
Dump/T
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body
ilt Interlock:
Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 34” wide frame with front saddles to provide support for the container while in the dump mode. These sections for er/body mounted latches. The system must be protected from out of sequence operation.
to the loader thr the use of steel springs and/or hydraulic/air cylinders. Loader must be compatible with containers manu­factured to ANSI Z245.60 recommended standard for waste containers.
m this frame without the use of mechanical latches which r
ough all ranges of the dump mode. This must be accomplished without
event cylinder collapse in case of
ely on gravity, springs, or contain
-
Rear Dump Hinge Pin: 3-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
Bushings: All bushings to be of the permanently lubricated variety.
Hoses & Hyd. Fittings:
Origin of Manufacture: Loader to be designed and manufactured in the United States of America.
All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Manual PN 43502
Page 22
16 Shuttle Owner’s Manual - PN 43502

Model 174-20-65 Specifications

ifting Capacity: 65,000 pounds gross weight evenly distributed in, or on, body.
L
Container Length: 17-foot through 20-foot from front A-frame to rear of skid rails. Longer bodies up to 22-feet may be
accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
Maximum Dump Angle: 51°
Operating Pressure: 4200 PSI maximum.
Weight of Loader: Loader weight not to exceed 6,875 pounds.
Height of Loader: Loader height not to exceed 13" as measured from top of truck frame to top of loader rollers.
Hook Height: 61.75-inches from bottom of skid rails to bottom of hook bar. Loader must be able to pick up body 10-
inches below grade, when mounted in a 41” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir.
Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all
loader functions.
Tilting Hook Assembly: Loader must have pivoting type front tilt section (jib) to provide a low degree
loading/unloading angle. Hook to include automatic mechanical safety latch which disengages only when the container/body is in proper position to be picked up or dropped off.
Tilt Cylinder: Single 5-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and
include dual integral pilot-operated counterbalance valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to prevent exposure of cylinder rod to corrosive road salts.
Tilt Section Operation: Loader must include a hydraulic lock-out device to prevent operation of the tilt section
while loader is in the dumping mode.
Lift/Dump Cylinder: Dual 7-inch bore with 3-inch diameter rod cylinder. Cylinders must be double acting
and include pilot-operated counterbalance valving to pr hose failure.
Dump/T
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body
ilt Interlock:
Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 34” wide frame with front saddles to provide support for the container while in the dump mode. These sections for er/body mounted latches. The system must be protected from out of sequence operation.
to the loader thr use of steel springs and/or hydraulic/air cylinders. Loader must be compatible with containers manufac­tured to ANSI Z245.60 recommended standard for waste containers.
m this frame without the use of mechanical latches which r
ough all ranges of the dump mode. This must be accomplished without
event cylinder collapse in case of
ely on gravity, springs, or contain
the
-
Rear Dump Hinge Pin: 3-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
Bushings: All bushings to be of the permanently lubricated variety.
Hoses & Hyd. Fittings:
Origin of Manufacture: Loader to be designed and manufactured in the United States of America.
All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Page 23
Specifications 17

Model 190-24-65 Specifications

ifting Capacity: 65,000 pounds gross weight evenly distributed in, or on, body.
L
Container Length: 19-foot through 21.5-foot from front A-frame to rear of skid rails. Longer bodies up to 23.5-feet may be
accommodated if full dump angle is not required (may require special body-mounted or extendable truck-mounted bumper and additional latches to meet the Federal Motor Carrier Safety Administration (FMCSA) Rear End Protection regulation 393.86 and Securing Hooklift Containers regulation 393.134).
Maximum Dump Angle: 50°
Operating Pressure: 4200 PSI maximum.
Weight of Loader: Loader weight not to exceed 7,300 pounds.
Height of Loader: Loader height not to exceed 13" as measured from top of truck frame to top of loader rollers.
Hook Height: 61.75-inches from bottom of skid rails to bottom of hook bar. Loader must be able to pick up body 10-
inches below grade, when mounted on a 41” truck frame height.
Hydraulic Pump: Direct-coupled high-pressure gear pump.
Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir.
Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all
loader functions.
Tilting Hook Assembly: Loader must have pivoting type front tilt section (jib) to provide a low degree
loading/unloading angle. Hook to include automatic mechanical safety latch which disengages only when the container/body is in proper position to be picked up or dropped off.
Tilt Cylinder: Single 5-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and
include dual integral pilot-operated counterbalance valves to prevent cylinder collapse in case of hose failure. Cylinder must be fully retracted when in the transport mode to prevent exposure of cylinder rod to corrosive road salts.
Tilt Section Operation: Loader must include a hydraulic lock-out device to prevent operation of the tilt section
while loader is in the dumping mode.
Lift/Dump Cylinder: Dual 7-inch bore with 3-inch diameter rod cylinder. Cylinders must be double acting
and include pilot-operated counterbalance valving to pr hose failure.
Dump/T
Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body
ilt Interlock:
Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length 34” wide frame with front saddles to provide support for the container while in the dump mode. These sections for er/body mounted latches. The system must be protected from out of sequence operation.
to the loader thr use of steel springs and/or hydraulic/air cylinders. Loader must be compatible with containers manufac­tured to ANSI Z245.60 recommended standard for waste containers.
m this frame without the use of mechanical latches which r
ough all ranges of the dump mode. This must be accomplished without
event cylinder collapse in case of
ely on gravity, springs, or contain
the
-
Rear Dump Hinge Pin: 3-inch diameter type 304 or 17-4 stainless steel minimum.
Pins: All pins to be type 304 or 17-4 stainless steel.
Bushings: All bushings to be of the permanently lubricated variety.
Hoses & Hyd. Fittings:
Origin of Manufacture: Loader to be designed and manufactured in the United States of America.
All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized wherever possible.
Manual PN 43502
Page 24
18 Shuttle Owner’s Manual - PN 43502
Page 25

Chapter 5 - Decals

Decals of Note

Moving Tilt Hazard Decal
Location: On each side of the tilt. Function: To inform the operator of the
hazard associated with tilt operation, the possible consequences should the haz-
ard occur, and how to avoid the hazard. PN: C0865
Decals 19
19
Electrocution Hazard Decal
Location: Bottom of tilt. Function: To inform the operator of the hazard
associated with electrocution, the possible consequences should the hazar how to avoid the hazard. PN: C1179
d occur
, and
Misuse Hazard Decal
Location: Sides of the Breakaway Tabs. Function: T
d associated with impr
ar dump tabs, the possible consequences should the hazar the hazar
o infor
d. PN: 26134
m the operator of the haz
oper use of the
d occur, and how to avoid
-
Manual PN 43502
Page 26
20 Shuttle Owner’s Manual - PN 43502
.YTQNOITPIRCSEDTRAPMETI.YTQNOITPIRCSEDTRAPMETI
1NOITAREPO LACED15607*2EGRAL ELTTUHS LACED8026C1
2C6207 DECAL SHUTTLE SMALL 2 *8 4190 DECAL DANGER OPERATION CONDITION 2
2REGNAD LACED0454C9*1NOITUCORTCELE REGNAD LACED5454C3*
4 C1179 DECAL DANGER ELECTROCUTION HORTL 2 10 26134 DECAL DANGER MISUSE HAZARD 4
5C0865 DECAL WARNING ARMS 2 *11 26135 DECAL NOTICE FIX TABS 1
6 4214 DECAL CONTACT STELLAR 1
PN D0779
Notes:
1. Leftover Shuttle decals should be mounted on back of hooklift and on truck frame.
2. Extra electrocution decals should be shipped loose.
3. Place one of 26134 & 26135 in cab on controller assembly.
* These decals not shown (Mount in cab or on truck frame).

Decal Kit Placement - PN D0779

Page 27
Installation 21

Chapter 6 - Installation

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.
52K Model Installation Steps - Basic Guidelines . . . . . . . . 22
65K Model Installation Steps - Basic Guidelines . . . . . . . . 24
Power Beyond VDM8 Valve. . . . . . . . . . . . . . . . . . . . . . . . . 26
Mounting Kit (All 52K Shuttles) - PN 17803 . . . . . . . . . . . . . 27
Mounting Kit (All 65K Shuttles) - PN 16561 . . . . . . . . . . . . . 28
Rotary Valve (All 52K Shuttles) - PN 24040 . . . . . . . . . . . . . 29
Rotary Valve (All 65K Shuttles) - PN D0000 . . . . . . . . . . . . . 30
Reservoir Assembly - PN 25927 . . . . . . . . . . . . . . . . . . . . . . 31
Subframe - PN 3118
(138-18-52, 138-18-65) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Subframe - PN 3117
(174-20-52, 174-20-65, 190-24-65, 190-24-52). . . . . . . . . . . . . . . . . . . . 33
Dump Light Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Controller Assembly Part 1 - PN 38841 . . . . . . . . . . . . . . . . 35
Controller Assembly Part 2 - PN 38841 . . . . . . . . . . . . . . . . 36
Hose Kit (138-18-52) - PN 17017 . . . . . . . . . . . . . . . . . . . . . . 37
Hose Kit (174-20-52) - PN 17794 . . . . . . . . . . . . . . . . . . . . . . 38
Hose Kit (190-24-52) - PN 17822 . . . . . . . . . . . . . . . . . . . . . . 39
Hose Kit (138-18-65) - PN 16624 . . . . . . . . . . . . . . . . . . . . . . 40
Hose Kit (174-20-65) - PN 32677 . . . . . . . . . . . . . . . . . . . . . . 41
Hose Kit (190-24-65) - PN 16708 . . . . . . . . . . . . . . . . . . . . . . 42
21

Basic Installation Overview

1. Clear the truck frame.
2. Set the hooklift on the truck frame.
3. Shorten the truck frame so that it’s flush with the rear of the hooklift.
4. Install bumper.
5. Install tie down channels. (See corresponding Mounting Kit Drawing in this chapter)
6. Install tarper tower (If applicable).
7. Install cab and PTO controls.
8. Mount hydraulic reservoir tank and valve bank.
9. Mount PTO and Pump.
10. Run hydraulic hoses.
11. Connect suction and pressure to the reservoir tank and valve bank.
12. Install mud flaps and fenders.
13. Run hooklift.
Manual PN 43502
Page 28
22 Shuttle Owner’s Manual - PN 43502
52K Model Installation Steps - Basic Guidelines
1. Clear the truck frame.
2. Set the hooklift on the truck frame.
a. The front of the hooklift needs to be at least 2” behind the cab or any equipment
mounted behind the cab. b. Be sure to square the hooklift on the truck frame. c. Survey the chassis frame and look for any potential issues. For example:
Clearance problems, cross members extending too high, insufficient room in front
of the hooklift for tarpers, exhaust manifolds, etc, or insufficient room in the rear to
allow for bumper selection. Feel free to space up if needed.
3. Shorten the truck frame so that it’s flush with the rear of the hooklift.
4. Install bumper.
a. See Government Regulations for acceptable placement.
5. Install tie down channels. (See Mounting Kit Drawing 17803 on page 27)
a. Move anything on the truck frame that may be in the way of the tie down chan-
nels.
b. Using 1” bolts, washers, and nuts, fasten two (2) tie-down channels (PN 1425 &
1440) together with the narrow faces toward each other. Do this with all of the channels.
c. Place a tie down channel (PN 1425) on both sides of the base, within 2” of the
front plate.
d. Place a tie down channel (PN D0143) on both sides of the base, underneath the
tabs at the rear. Drill an 11/16” hole in each of the rear tabs, using the channels as a guide. Bolt these channels to the tab using 5/8” bolts, washers, and nuts.
e. The final tie down channels should be placed in the approximate position shown in
the corresponding mounting diagram. The top of the lower tie down should be flush with the top of the chassis frame rail.
f. Place three shear plates (PN 3596) on each side of the base in the approximate
locations shown in the mounting diagram. The top of the plates should be approxi-
mately even with the bottom of the base tube. g. Weld all of the shear plates to the base of the hooklift. h. Using the channels as a guide, drill four (4) 1-1/16” holes and two (2) 11/16” holes
through the truck frame. i. Drill two (2) 1-1/16” holes through each of the shear plates, and the truck frame. j. Using 1” bolts, washers, and nuts, secure the front tie down channels to the truck
frame. Using 5/8” bolts, washers, and nuts, secure the rear tie down channels to the truck frame. All 1” bolts must be torqued to 680 ft-lbs and all 5/8” bolts must be torqued to 160 ft-lbs.
K. Weld the upper tie down channels (PN 1425) to the hooklift base.
Page 29
6. Install tarper tower (If applicable).
a. See brand specific installation instructions.
7. Install cab and PTO controls.
a. Use PTO brand specific installation instructions. b. See Controller Assembly Drawing (PN 38841) for details. c. See Dump Light Kit Installation
8. Mount hydraulic reservoir tank and valve bank.
a. Make sure the tank isn’t too far away if cables are being used. b. Don’t raise the tank above the frame height. c. See Power Beyond Installation guide for valve bank details. d. See Reservoir Assembly Drawing PN 25629 for details.
9. Mount PTO and Pump.
a. Be sure to check the rotation of the pump to ensure proper installation. b. Use brand specific installation instructions.
Installation 23
23
10. Run hydraulic hoses.
a. Run hoses between the pump and r
eservoir tank. b. Run hoses between the valve bank and hooklift. c. Protect these lines with hose wrap when necessary. d. Keep these lines away from sharp edges. e. Keep these lines away from the exhaust or other temperature extreme items. f. Keep these lines away from the driveshaft or other moving items. g. See hydraulic schematics for details.
11. Connect suction and pressure to the reservoir tank and valve bank.
a. Fittings on the valve bank should be 3” lower than the long sills. b. Fill reservoir to site gauge, within 3” from the top (Roughly 10 Gallons). c. Petro-Canada Hydrex 32 (ISO 32) hydraulic oil is recommended. d. When connections are secure, turn reservoir on.
12. Install mud flaps and fenders.
13. Run Hooklift.
Bleed the air out of the hydraulic system.
a. b. Check the oil level and add oil if needed. c. Calibrate rotary valve. d. Calibrate dump light system. e. Be sure to check all clearances.
Manual PN 43502
Page 30
24 Shuttle Owner’s Manual - PN 43502
65K Model Installation Steps - Basic Guidelines
1. Clear the truck frame.
2. Set the hooklift on the truck frame.
a. The front of the hooklift needs to be at least 2” behind the cab or any equipment
mounted behind the cab. b. Be sure to square the hooklift on the truck frame. c. Take a survey of the chassis frame and look for any potential issues. For example:
Clearance problems, cross members extending too high, insufficient room in front
of the hooklift for tarpers, exhaust manifolds, etc, or insufficient room in the rear to
allow for bumper selection.
3. Shorten the truck frame to within 2” from the rear of the loader.
4. Install bumper.
a. See Government Regulations for acceptable placement.
Space the base up by 1/2”.
5. Install tie down channels. (See Mounting Kit Drawing 16561 on page 28)
a. Move anything on the truck frame that may be in the way of the tie downs. b. Using 1” bolts, washers, and nuts, fasten two (2) tie-down channels (PN 2891 &
2874) together with the narrow faces toward each other. Do this with all of the channels. Note: The hooklift should already have two tie down channels (PN
2874) welded on each side of the base.
c. The loose tie down channels should be placed in the approximate position shown
in the corresponding mounting diagram. The top of the lower tie down should be flush with the top of the chassis frame rail.
d. Place two angles (PN 3238) on each side of the base in the approximate locations
shown in the mounting diagram. The back of the r of the rear of the hooklift. The top flange of the angles should be touching the
bottom of the base tube and the other flange should touching the frame rail. e. Weld all of the angles to the base of the hooklift. f. Using the channels as a guide, drill six (6) 1-1/16” holes through the truck frame. g. Drill three (3) 1-1/16” holes through each of the angles, and the truck frame. h. Using 1” bolts, washers, and nuts, secure all tie downs to the truck frame. All 1”
bolts must be torqued to 680 ft-lbs.
i. Weld the upper tie down channels (PN 2874) to the hooklift base.
ear channels must be within 1”
6. Install tarper tower (If applicable).
a. See brand specific installation instructions.
Page 31
7. Install cab and PTO controls.
a. Use PTO brand specific installation instructions. b. See Controller Assembly Drawing (PN 38841) for details. c. See Dump Light Kit Installation
8. Mount hydraulic reservoir tank and valve bank.
a. Make sure the tank isn’t too far away if cables are being used. b. Don’t raise the tank above the frame height. c. See Power Beyond Installation guide for valve bank details. d. See Reservoir Assembly Drawing PN 25629 for details.
9. Mount PTO and Pump.
a. Be sure to check the rotation of the pump to ensure proper installation. b. Use brand specific installation instructions.
Installation 25
10. Run hydraulic hoses.
Run hoses between the pump and reservoir tank.
a. b. Run hoses between the valve bank and hooklift. c. Protect these lines with hose wrap when necessary. d. Keep these lines away from sharp edges. e. Keep these lines away from the exhaust or other temperature extreme items. f. Keep these lines away from the driveshaft or other moving items. g. See hydraulic schematics for details.
11. Connect suction and pressure to the reservoir tank and valve bank.
a. Fittings on the valve bank should be 3” lower than the long sills. b. Fill reservoir to site gauge, within 3” from the top (Roughly 10 Gallons). c. Petro-Canada Hydrex 32 (ISO 32) hydraulic oil is recommended. d. When connections are secure, turn reservoir on.
12. Install mud flaps and fenders.
13. Run Hooklift.
a. Bleed the air out of the hydraulic system. b. Check the oil level and add oil if needed. c. Calibrate rotary valve. d. Calibrate dump light system. e. Be sure to check all clearances.
Manual PN 43502
Page 32
26 Shuttle Owner’s Manual - PN 43502
Power Beyond VDM8 Valve
These instructions ar 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.
1. Remove cover/access plug to reveal the power beyond access point. Can also be used as the Return/Tank port.
3. The Power Beyond feature is now activated and will divert oil to alternate system via the port shown.
2. Install a 3/8” straight thread pipe plug into lower por­tion of cavity to activate the power beyond feature. Use thread sealer (tape sealers not recommended.
Note:
1. The return/tank line must be connected to the top or the side port, labeled “T”.
2. Using the return line to run auxillary equipment will directly result in a failure and will not in any cir­cumstance be covered under warranty.
3. A standard Stellar hooklift will have 6 hydraulic lines attached to the valve. A Stellar hooklift with Power Beyond will have 7 hydraulic lines attached to the valve.
Page 33
Installation 27
6
9
1
1
20
3
5
4
3
7
3
3
6
9
20
2
3
3
8
WELD HERE
10
9
19
ITEM PART DESCRIPTION QTY.
1 1440 TIE DOWN, 40000# 4 2 3596 PLATE 0.50X8.00X16.00 6 3 1443 WASHER 1.00 USS FLAT ZINC 40 4D0045 BACKUP ALARM .97 DECIBAL 1 5 12169 CAP SCR 1.00-8X3.50 HHGR8 4 6 5199 CAP SCR 1.00X8X3.00 HHGR8 ZY 16 7C1025 CAP SCR 0.63-11X2.00 HHGR8 ZY 2 824868 NUT 0.63-11 HHGR8 NYLOCK ZY 2
9 6294 NUT 1.00 HHGR8 NYLOC 20 10 C1038 WASHER 0.63 FLAT 4 18 26879 LOADER 174-20-52K 1 19 D0143 TIE DOWN CHANNEL 2 20 1425 TIE DOWN 40,000# 4
PN 17803
27
Mounting Kit (All 52K Shuttles) - PN 17803
Manual PN 43502
Page 34
28 Shuttle Owner’s Manual - PN 43502
6
1
2
FROM THE REAR OF THE LOADER
PLACE 1 INCH FORWARD
7
8
4
8
6
5
8
8
7
7
WELD BETWEEN OTHER TWO TIE DOWN CHANNELS
.YTQN
O
ITPIRC
SE
DTR
A
PMETI
6
000,56 NWOD EI
T
198
2
1
2000,56 NWOD EIT47822 4 3238 ANGLE 4.00X6.00X.50WX36.00 4 512169 CAP SCR 1.00-8X3.50 HHGR8 6 65199 CAP SCR 1.00X8X3.00 HHGR8 ZY 24 7 6294 NUT 1.00 HHGR8 NYLOC 30 86538 WASHER 1.00 SAE FLAT YELLOW GR8 60
PN 16561
Mounting Kit (All 65K Shuttles) - PN 16561
Page 35
Installation 29
7
10
10
5
4
11
3
1
7
9
6
6
6
2
8
12
7
12
.YTQNOITPIRC
SE
D
TRAPME
TI
122456 ROTARY VALVE ASM 1 2 22450 WLDMT ROTARY VALVE ECCENTRIC 1 3 D1638 O'RING 1.12X1.38X0.12 568-216 1 43748 WASHER ROTARY VALVE 1 50480 CAP SCR 0.25-20X1.00 HHGR5 1 60353 CAP SCR 0.38-16X2.00 HHGR5 3 7 0347 NUT 0.38-16 HH NYLOC 3 8 0977 O'RING 1.00X1.25X0.12 568-214 1
9 24236 PLATE ROTARY VALVE ARM 1 10 0482 CAP SCR 0.25-20 X 3.00 HHGR5 2 11 0333 NUT 0.25-20 HHGR5 NYLOC 2 12 C1854 FTG ADAPT 6-8 F5OLO-S 4
PN 24040
Rotary Valve (All 52K Shuttles) - PN 24040
29
To adjust rotary valve move hooklift into stowed position. Loosen the bolts that are attaching the valve block to the dump section. Adjust rotary arm so that it is in contact with the dump plate. Pull valve block towards rear of hooklift until snug. Tighten valve block bolts while making sure valve block is snug. Note: It should engage between 4 and 10 degrees.
Manual PN 43502
Page 36
30 Shuttle Owner’s Manual - PN 43502
6
5
4
9
9
1
0
1
0
1
3
7
8
2
41
41
1
1
31
31
11
41
41
21
.O
N
METI.
YT
Q.ONTRANP
OITP
IRCSED
11 77
8M0
SAEVLAVYRATOR
21 12
5T1
OV
IPEV
LAVYRATOR
31 7794012-86521.0X52.1X00.1GNIR
'O
41 8361
6D 12-86521.0X83.1X21.1GNIR'
O
51 847E3VLAVYRATO
RRE
HSAW
61 0
8
450
R
GH
H00.1X02-52.0RCSP
AC 71 35350RGHH00.2X61-83.0RCSPAC 81 743C0OLYNHH61-83.0TUN 92 2
8450RGHH00.3X02-52.0RCSPAC 012 333C0OLYN5RGHH02-52.0TUN 1
12 9
74N2IP61/
5D
RHT61/5EKOY 211 674)2MR(7BDRHT42-13.0DOR 3
12 8
742HH8
1-13.TU
N
4
14 31
160C.
1X490.
NIPRETT
OC
5
14 458
1SC-OLO5F
8-6
TPA
DAGTF
PN D0000
Rotary Valve (All 65K Shuttles) - PN D0000
Page 37
26
3
4
3
6
24
23
5
1
12
2
1
2
2
1
5
8
18
20
18
18
19
31
7
1
1
10
2
9
25
28
16
1
3
14
30
2
9
20
27
1
7
.YTQNOITPIRCSEDTRAPMET
I
1 26510 RSRVR ASM 25GAL K MODEL 1 2 7353 NIPPLE 2.00 HEX PIPE 2FF 1 3 C4694 ST EL 1.25 90 DEG BLK 2 4 D0024 NIPPLE 1.25X14.00 BLK 1 5 C6228 FILTER HEAD SF120-25 1.3 1
101-ES EGRAL RETLIF5226C6 1
00
.2
LLAB EVLAV0574C7
1
00
.2 BRA
B ES
OH GTF0374C
8
18MDV NOITCES-2 BV116429
3KCOL 52.0 REHSAW125001 11 0339 CAP SCR 0.25-20X2.50 HHGR5 3 12 C5968 FTG MF/MSTR 90 8-12 C5OLO-S 1 13 C1855 FTG ADAPT 6-10 F5OLO-S 2
.YTQNOITPIRCSEDTRAPMETI 14 C2252 FTG ADAPT 8-10-F5OLO-S 2 15 26737 HOSE 0.75(471TC-JC-J9-12-12-12-24) 1
2S-OL6C-6 TPADA GTF8422C61
2S-OL6C-8 TPADA GTF6732C71 18 0352 WASHER 0.50 USS FLAT ZINC 12 19 C6106 NUT 0.50-13 HHGR5 NYLOC 6 20 0506 CAP SCR 0.50-13X4.00 HHGR5 6 21 27119 HOSE 0.75(78C-12-JC-JC-12-12-12-120) 1 22 10094 GAUGE OIL LF 2.5" 0-500 BM 1
121-02-2010 UDER GTF5732C32
1S-OLF
21 TPAD
A GTF2
594
C
42 25 13325 SPACER TANK MOUNTING 25 GAL 2 26 16145 GAUGE PRES FILTER SERVICE CI20 1
.
YTQNOITPIRCSEDTRAPMET
I
200.2 PMA
LC ESOH9184C7
2
1TF01 00.
2 TCUS E
SOH667
718
2 29 25630 FTG ADAPT 10-1/4 F5OG 1 30 d1435 FTG ADAPT O'RING 12-10 1 31 c4903 FTG SL LOK SWIVEL 12-C6LO-S 1
PN 25927
Reservoir Assembly - PN 25927
Installation 31
31
Manual PN 43502
Page 38
32 Shuttle Owner’s Manual - PN 43502
PN 3118
Subframe (138-18-52, 138-18-65) - PN 3118
Page 39
Installation 33
PN 3117
Subframe (174-20-52, 174-20-65, 190-24-65, 190-24-52) - PN 3117
33
Manual PN 43502
Page 40
34 Shuttle Owner’s Manual - PN 43502
• Bolt L-bracket to front of base, drilling and tapping holes in appropriate area.
• Attach dump light switch to L-bracket.
• Drill and tap ¼-20 hole in bottom of secondary tube. Hole should be located directly above dump light switch when secondary is in lowered position.
• Screw in elevator bolt, and adjust so that switch is engaged when secondary is in lowered position.
• Install light in bracket provided with control console.
• Complete the wiring; following instructions provided with dump light kit.
Elevator bolt
L-bracket
Dump light switch
Detail A Scale 1 : 8
Dump Light Kit Installation
Page 41
4
17
15
1
2
6
7
CONTROLLER CABLES TO VALVE BANK
5
N
OTE: CONTROL LEVER, HANDLES, CONSOLE, AND CONTROLLER CABLES ARE INCLUDED WITH THE HYDRAULIC CONTROL VALVE.
19
18
In Cab Installation
At Valve Installation
PN 38841
Controller Assembly Part 1 - PN 38841
Installation 35
35
Manual PN 43502
Page 42
36 Shuttle Owner’s Manual - PN 43502
Installation Instructions:
Connect the 12 Volt ignition wire to a key-on battery source.
Hookup the wire harness in the cab to the wire harness from the loader
Alarm will now sound when dump tabs have been damaged.
Tab Alarm Installation IS Required
MISUSE HAZARD
Operation of loader when
dump tabs are not properly
fastened, can result in
unexpected personal and
equipment damage.
Inspect tabs daily.
26134
Danger
3
4
5
6
9
2
1
7
8
.YT
QN
OITPIRCSED
TRAP
METI 1 37474 CONTROLLER CTR LOCK RIGHT BEND 1 2 37475 CONTROLLER CTR LOCK LEFT BEND 1
1TNM MRALA BAT ETALP392623 4 37470 VALVE CTRL CONSOLE 2LEVER RVC 1 5 0491 CAP SCR 0.31-18X4.00 HHGR5 2 60343WASHER 0.31 USS FLAT ZINC 4
2COLYN HH 81-13.0 TUN24307 826031 BACKUP ALARM PIEZO JAMECO 123537 1 926135 DECAL NOTICE FIX TABS 1
10 D1711 CAP SCR #10-24X0.50 BTNHD SS 1 11 C6072 RELAY BOSCH 20-30 AMP 1 12 26288 LIGHT INDICATOR RED FORCE PTO 1 13 31806 DUMP UP LIGHT KIT BUYERS SK10 1 15 25933 BRKT CONTROLLER DECAL 1
1 COLYN
HH 42-01# T
UN
4306
2
61 17 37471 CONTROL CABLE 96" WESCON 2 18 37469 CABLE CONN. KIT FOR VD8A/VDM8 2
28MDV TCES-2
BV
1164291 20 26291 WIRE HARNESS TAB ALARM 1 21 26289 WIRE HARNESS PROXIMITY SWITCH 1
Controller Assembly Part 2 - PN 38841
Page 43
PN 17017
Hose Kit (138-18-52) - PN 17017
Installation 37
37
Manual PN 43502
Page 44
38 Shuttle Owner’s Manual - PN 43502
PN 17794
Hose Kit (174-20-52) - PN 17794
Page 45
PN 17822
Hose Kit (190-24-52) - PN 17822
Installation 39
39
Manual PN 43502
Page 46
40 Shuttle Owner’s Manual - PN 43502
PN 16624
Hose Kit (138-18-65) - PN 16624
Page 47
PN 32677
Hose Kit (174-20-65) - PN 32677
Installation 41
41
Manual PN 43502
Page 48
42 Shuttle Owner’s Manual - PN 43502
PN 16708
Hose Kit (190-24-65) - PN 16708
Page 49
Assembly Drawings 43
2
4
3
5
9
7
8
6
9
3
8
1
2
5
3
2
2
3
7
9
7
3
8
9
3
7
8
.Y
TQNOITPIRCSEDTR
APMETI
1
K25-81-831 ESAB521721 20865 BUSHING 48DXR32 GARLOCK 4 31589 MACHY WASHER 3.00ID 14GA 6
1
00.
51X00.3 NIP379624
200.3
GNIR
PANS690
2
5
113.73X00.3 NIP229626
400.1X05.4X30.3 RALLOC829627
8C0956 CAP SCR 0.38-16X5.50 HHGR5 4
4COLYN HH 61-83.0 TUN74309
PN 27196
Chapter 7 - Assembly Drawings
Base (138-18-52) - PN 27196
43
Manual PN 43502
Page 50
44 Shuttle Owner’s Manual - PN 43502
3
4
3
5
9
7
6
9
3
8
7
1
2
8
2
2
3
5
2
8
9
9
8
3
7
3
7
ITEM PART DESCRIPTION QTY.
126861 BASE 174-20-52K 1 20865 BUSHING 48DXR32 GARLOCK 4 31589 MACHY WASHER 3.00ID 14GA 6 426973 PIN 3.00X15.00 1 52096 SNAP RING 3.00 2 626922 PIN 3.00X37.31 1 726928 COLLAR 3.03X4.50X1.00 4 8C0956 CAP SCR 0.38-16X5.50 HHGR5 4 90347 NUT 0.38-16 HH NYLOC 4
PN 26862
Base (174-20-52) - PN 26862
Page 51
3
2
4
3
5
9
7
8
6
9
3
8
7
1
2
2
2
7
9
9
8
8
7
3
3
3
5
.YTQNOITPIRCSEDTRAPMETI
1
K25-42-091 ESAB3427
21 20865 BUSHING 48DXR32 GARLOCK 4 31589 MACHY WASHER 3.00ID 14GA 6
100.51X00.3 NIP379624
200.3 GNI
R PA
NS6
902
5
11
3.73X00.3 NIP229626
400.1X05.4X30.3 RALLOC829627
8C0956 CAP SCR 0.38-16X5.50 HHGR5 4
4COLYN HH 61-83.0 TUN74309
PN 27244
Base (190-24-52) - PN 27244
Assembly Drawings 45
45
Manual PN 43502
Page 52
46 Shuttle Owner’s Manual - PN 43502
ATTACHMENT POINT
9
8
7
6
6
7
8
9
2
11
2
3
12
9
8
4
5
10
1
5
4
8
9
DUMP ATTACHMENT POINT
MAIN CYLINDER
10
.YTQNOITPIRCSEDTRA
P
ME
TI
1 9224 PIN 3.00X43.00 D&T 1 2 0635 BUSHING 40DXR32 GARLOCK 2 3 9300 PIN 2.50X23.25 D&T 1 4 8597 PIN CAP 0.69x4.00x0.25 SS 2 512922 THRUST WASHER 0.64x4.00x0.125 2 612921 THRUST WASHER 0.64x3.50x0.125 2 7 8455 PIN CAP 0.69X3.50X0.25 SS 2 812711 THRUST WASHER 0.63 DIA 4
912673 CAP SCREW 0.50-13 SHOULDER 4 10 2227 BUSHING 48DXR48 GARLOCK 2 11 13343 BUSHING 40DXR16 GARLOCK 1
1
56-81-831 ESAB7023121
PN 16570
Base (138-18-65) - PN 16570
Page 53
ATTACHMENT POINT
12
12
11
10
9
9
1
0
11
12
4
5
4
6
1
12
11
8
7
2
8
11
7
3
MAIN CYLINDER
3
.YTQNOITPIRCS
ED
TRAPMETI
1H 56-02-471 ESAB75391
1T&D 00.34X00.3 NIP42292 3 2227 BUSHING 48DXR48 GARLOCK 2 4 0635 BUSHING 40DXR32 GARLOCK 2 513343 BUSHING 40DXR16 GARLOCK 1
1T&D 52.32X05.2 NIP00396 712922 THRUST WASHER 0.64x4.00x0.125 2 8 8597 PIN CAP 0.69x4.00x0.25 SS 2 912921 THRUST WASHER 0.64x3.50x0.125 2
10 8455 PIN CAP 0.69X3.50X0.25 SS 2 11 12711 THRUST WASHER 0.63 DIA 4 12 12673 CAP SCREW 0.50-13 SHOULDER 4
DUMP ATTACHMENT POINT
PN 16648
Base (174-20-65) - PN 16648
Assembly Drawings 47
47
Manual PN 43502
Page 54
48 Shuttle Owner’s Manual - PN 43502
11
5
3
6
10
8
9
7
1
0
3
9
8
1
2
11
12
3
8
10
9
1
0
3
9
2
12
1
1
3
6
3
8
4
12
.YTQNOITPIRCSEDTRAPMETI
1K04-02-471 ESAB436621 20635 BUSHING 40DXR32 GARLOCK 2 31593 MACHY WASHER 2.50ID 10GA 6 425574 BUSHING 40DXR20 2.50X1.25 2
183.21X0
5.2 NIP75805 2DH 05.2 GNIR PANS63606
144.63X05.2 NIP840627 4 00.1X05.3X15.2 RALLO
C039
32
8 932086 CAP SCR 0.38-16X4.25 HHGR5 4
4COLYN HH 61-83.0 TUN743001 6
P
P 0914 NL PMALC ESOH733011
12 0333 NUT 0.25-20 HHGR5 NYLOC 6
PN 26635
Base (190-24-65) - PN 16705
Page 55
Assembly Drawings 49
2
6
5
7
16
12
15
13
3
2
8
14
2
11
2
10
9
11
20
17
2
1
3
11
4
1
19
18
21
21
12
2
16 20
14
BUSHING AND ZERK SHOWN AS REFERENCE
15
.YTQNOITPIRCSEDTRAPMETI
1K25-81-831 PMUD791721 20865 BUSHING 48DXR32 GARLOCK 10 30332 CAP SCR 0.31-18X1.75 HHGR5 2 40333 NUT 0.25-20 HHGR5 NYLOC 2 50506 CAP SCR 0.50-13X4.00 HHGR5 2 6C6106 NUT 0.50-13 HHGR5 NYLOC 2
100.72X0
0.3 NI
P09027
257.61X00.
3 NIP7
616
2
8 922432 ROLLER 52000# W/GREASE ZERK 2
10 13344 BUSHING 48DXR32 GARLOCK 2 11 1548 THRUST WASHER 3.01DIA UHMW .12 THK 6
4THGIARTS TPN 8/1 KREZ2951c21
4 00
.1X0
0.4X10.3 RALLOC8616
231
14 C0954 CAP SCR 0.38-16X4.50 HHGR5 4
4COLYN HH 61-83.0 TUN743051
16 2200 SNAP RING INSIDE 3.00 3000-X300 2 17 23301 TAB LOADER BREAK AWAY 2 18 26287 SWITCH PROXIMITY CARLO GAVAZZI 1 19 26290 COVER SWITCH PROXIMITY 1 20 2227 BUSHING 48DXR48 GARLOCK 2 21 26930 GROMMET 1.25ODX.25X.38ID 2
PN 27198
49
Dump (138-18-52) - PN 27198
Manual PN 43502
Page 56
50 Shuttle Owner’s Manual - PN 43502
2
7
16
1
2
15
13
2
8
14
2
11
2
10
9
11
20
2
1
3
11
1
19
18
21
21
1
2
14
4
5
6
17
3
1
6
20
15
BUSHING AND ZERK SHOWN AS REFERENCE
2
.
YTQNOITPIRCSEDTRAPMETI
1K25-02-471 PMUD568621 20865 BUSHING 48DXR32 GARLOCK 10 30332 CAP SCR 0.31-18X1.75 HHGR5 2 40333 NUT 0.25-20 HHGR5 NYLOC 2 50506 CAP SCR 0.50-13X4.00 HHGR5 2 6C6106 NUT 0.50-13 HHGR5 NYLOC 2
100.72X0
0.3 NI
P09027
257.61X00.3 NIP761628
922432 ROLLER 52000# W/GREASE ZERK 2
10 13344 BUSHING 48DXR32 GARLOCK 2 11 1548 THRUST WASHER 3.01DIA UHMW .12 THK 6
4THGIARTS TPN 8/1 KREZ2951c21
4 00
.1X0
0.4X10.3 RALLOC8616
231
14 C0954 CAP SCR 0.38-16X4.50 HHGR5 4
4COLYN HH 61-83.0 TUN743051
16 2200 SNAP RING INSIDE 3.00 3000-X300 2 17 23301 TAB LOADER BREAK AWAY 2 18 26287 SWITCH PROXIMITY CARLO GAVAZZI 1 19 26290 COVER SWITCH PROXIMITY 1 20 2227 BUSHING 48DXR48 GARLOCK 2 21 26930 GROMMET 1.25ODX.25X.38ID 2
PN 26866
Dump (174-20-52) - PN 26866
Page 57
Assembly Drawings 51
20
6
5
7
1
6
12
15
13
3
2
8
14
2
1
1
2
10
9
11
20
17
2
13
11
4
1
19
18
2
1
21
12
2
2
14
15
BUSHING AND ZERK SHOWN AS REFERENCE
16
.
YTQNOITPIRCSEDTRAPMETI
1K25-42-091 PMUD542721 20865 BUSHING 48DXR32 GARLOCK 10 30332 CAP SCR 0.31-18X1.75 HHGR5 2 40333 NUT 0.25-20 HHGR5 NYLOC 2 50506 CAP SCR 0.50-13X4.00 HHGR5 2 6C6106 NUT 0.50-13 HHGR5 NYLOC 2
100.72X00.3 NIP09027
257.61X00.3 NIP761628
922432 ROLLER 52000# W/GREASE ZERK 2
10 13344 BUSHING 48DXR32 GARLOCK 2 11 1548 THRUST WASHER 3.01DIA UHMW .12 THK 6
4THGIARTS TPN 8/1 KREZ2951c21
4 00.1X00.4X10.3 RALLOC8616231
14 C0954 CAP SCR 0.38-16X4.50 HHGR5 4
4C
OLYN
HH 61-83
.0 TUN7430
5
1 16 2200 SNAP RING INSIDE 3.00 3000-X300 2 17 23301 TAB LOADER BREAK AWAY 2 18 26287 SWITCH PROXIMITY CARLO GAVAZZI 1 19 26290 COVER SWITCH PROXIMITY 1 20 2227 BUSHING 48DXR48 GARLOCK 2 21 26930 GROMMET 1.25ODX.25X.38ID 2
PN 27246
Dump (190-24-52) - PN 27246
51
Manual PN 43502
Page 58
52 Shuttle Owner’s Manual - PN 43502
7
4
3
2
1
5
6
1
2
3
4
5
5
5
.YTQNOITPIRCSE
D
TRAP
M
ET
I
112922 THRUST WASHER 0.64x4.00x0.125 2 2 8597 PIN CAP 0.69x4.00x0.25 SS 2 312711 THRUST WASHER 0.63 DIA 2 412673 CAP SCREW 0.50-13 SHOULDER 2 5 2227 BUSHING 48DXR48 GARLOCK 6 6 9225 PIN 3.00X33.75 D&T 1 733584 DUMP 138-18-65H OFF ROAD 1
PN 16621
Dump (138-18-65) - PN 16621
Page 59
Assembly Drawings 53
7
4
3
2
1
5
6
1
2
3
4
5
S
ECONDARY
ATTACHMENT POINT
5
5
ITEM PART DESCRIPTION QTY.
112922 THRUST WASHER 0.64x4.00x0.125 2 28597 PIN CAP 0.69x4.00x0.25 SS 2 312711 THRUST WASHER 0.63 DIA 2 412673 CAP SCREW 0.50-13 SHOULDER 2 5 2227 BUSHING 48DXR48 GARLOCK 6 69225 PIN 3.00X33.75 D&T 1 73947 DUMP 174-20-65 OFF ROAD 1
PN 16649
Dump (174-20-65) - PN 16649
53
Manual PN 43502
Page 60
54 Shuttle Owner’s Manual - PN 43502
7
4
3
2
1
5
6
1
2
3
4
5
SECONDARY ATTACHMENT POINT
5
5
.YTQNOITPIRCSEDTRAPMETI 112922 THRUST WASHER 0.64x4.00x0.125 2 2 8597 PIN CAP 0.69x4.00x0.25 SS 2 312711 THRUST WASHER 0.63 DIA 2 412673 CAP SCREW 0.50-13 SHOULDER 2 5 2227 BUSHING 48DXR48 GARLOCK 6 6 9225 PIN 3.00X33.75 D&T 1 733498 DUMP 190-24-65 H OFF ROAD 1
PN 16706
Dump (190-24-65) - PN 16706
Page 61
Assembly Drawings 55
6
9
7
7
8
2
1
10
4
10
5
5
3
3
6
6
9
7
7
11
6
ITEM NO. QTY. PART NO. DESCRIPTION
1 1 27199 SECONDARY 138-18-52 K 2 1 27231 CYLINDER ASM 27232 8.00X56.50 3 2 0865 BUSHING 48DXR32 GARLOCK 4126883 PIN 3.00X18.50 5 2 2227 BUSHING 48DXR48 GARLOCK 6 4 0635 BUSHING 40DXR32 GARLOCK 744381 BUSHING 32DXR32 2.00X2.00 GARLOCK 812723 PIN 2.00X18.75
9 2 0108 SNAP RING 2.00 7200-200 10 2 2200 SNAP RING INSIDE 3.00 3000-X300 11 2 c1592 ZERK 1/8 NPT STRAIGHT
PN 27200
Secondary (138-18-52) - PN 27200
55
Manual PN 43502
Page 62
56 Shuttle Owner’s Manual - PN 43502
3
9
7
7
8
1
1
0
4
10
5
5
3
7
7
9
6
6
6
6
11
2
ITEM NO. QTY. PART NO. DESCRIPTION
1 1 26869 SECONDARY 174-20-52 K 2 1 18064 CYLINDER ASM 1992/52000 LOADER 3 2 0865 BUSHING 48DXR32 GARLOCK 4126883 PIN 3.00X18.50 5 2 2227 BUSHING 48DXR48 GARLOCK 6 4 0635 BUSHING 40DXR32 GARLOCK 744381 BUSHING 32DXR32 2.00X2.00 GARLOCK 812723 PIN 2.00X18.75
9 2 0108 SNAP RING 2.00 7200-200 10 2 2200 SNAP RING INSIDE 3.00 3000-X300 11 2 c1592 ZERK 1/8 NPT STRAIGHT
PN 26870
Secondary (174-20-52) - PN 26870
Page 63
Assembly Drawings 57
9
7
7
8
2
1
10
4
10
5
5
3
3
1
1
6
7
9
ITEM NO. QTY. PART NO. DESCRIPTION
1 1 27247 SECONDARY 190-24-52 K 2 1 27239 CYLINDER ASM 27238 8.00X76.63 3 2 0865 BUSHING 48DXR32 GARLOCK 4126883 PIN 3.00X18.50 5 2 2227 BUSHING 48DXR48 GARLOCK 6 4 0635 BUSHING 40DXR32 GARLOCK 744381 BUSHING 32DXR32 2.00X2.00 GARLOCK 812723 PIN 2.00X18.75
9 2 0108 SNAP RING 2.00 7200-200 10 2 2200 SNAP RING INSIDE 3.00 3000-X300 11 2 c1592 ZERK 1/8 NPT STRAIGHT
PN 27248
Secondary (190-24-52) - PN 27248
57
Manual PN 43502
Page 64
58 Shuttle Owner’s Manual - PN 43502
2
1
14
1
3
12
11
4
4
8
11
12
13
14
6
5
14
13
10
9
3
7
9
10
13
14
3
ATTACHMENT POINT
T
ILT CYLINDER
15
4
4
3
3
3
2
16
3
.YTQNOITPIRCS
ED
TRA
PMET
I
113209 SECONDARY 138-18-65 1 2 2227 BUSHING 48DXR48 GARLOCK 2 30635 BUSHING 40DXR32 GARLOCK 8 44381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 513817 BUSHING 40DXR24 2.50X1.50 GARLOCK 1 6 13343 BUSHING 40DXR16 GARLOCK 1
105.72X05.2 NIP73447 1T&D 57.42X00.2 NIP81798
912921 THRUST WASHER 0.64x3.50x0.125 2 10 8455 PIN CAP 0.69X3.50X0.25 SS 2 11 12719 THRUST WASHER 0.64x3.00x0.125 2 12 8454 PIN CAP 0.69x3.00x0.25 SS 2 13 12711 THRUST WASHER 0.63 DIA 4 14 12673 CAP SCREW 0.50-13 SHOULDER 4 15 18397 CYLINDER ASM 1449 65,000 LOADER 1 16 c1592 ZERK 1/8 NPT STRAIGHT 2
PN 16623
Secondary (138-18-65) - PN 16623
Page 65
Assembly Drawings 59
3
14
4
4
15
6
7
13
8
9
2
5
2
6
7
8
13
2
2
3
11
12
8
13
10
3
11
12
8
13
2
2
1
2
3
.YTQNOITPIRCSEDTRAPMETI 1 9143 SECONDARY 174-20-65 1 2 0635 BUSHING 40DXR32 GARLOCK 8 3 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 4 2227 BUSHING 48DXR48 GARLOCK 2
105.72X05.2 NIP73445 612921 THRUST WASHER 0.64x3.50x0.125 2 78455 PIN CAP 0.69X3.50X0.25 SS 2 812711 THRUST WASHER 0.63 DIA 4
.YTQ
N
OITPIRCSEDTRAP
ME
TI
917320 BUSHING 40DXR40 GARLOCK 1
1T&D
57.42X00.2 NIP817901
11 12719 THRUST WASHER 0.
64x3.00x0.125 2 12 8454 PIN CAP 0.69x3.00x0.25 SS 2 13 12673 CAP SCREW 0.50-13 SHOULDER 4 14 19070 CYLINDER ASM 190-24-65 1 15 c1592 ZERK 1/8 NPT STRAIGHT 2
PN 16650
Secondary (174-20-65) - PN 16650
59
Manual PN 43502
Page 66
60 Shuttle Owner’s Manual - PN 43502
3
14
4
4
15
6
7
13
8
9
2
5
2
6
7
8
13
2
2
3
11
12
8
13
10
3
11
12
8
13
2
2
1
2
3
.YTQNOITPIRCSEDTRAPMETI 1 9143 SECONDARY 174-20-65 1 2 0635 BUSHING 40DXR32 GARLOCK 8 3 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 4 2227 BUSHING 48DXR48 GARLOCK 2
105.72X05.2 NIP73445 612921 THRUST WASHER 0.64x3.50x0.125 2 78455 PIN CAP 0.69X3.50X0.25 SS 2 812711 THRUST WASHER 0.63 DIA 4
.YTQ
N
OITPIRCSEDTRAP
ME
TI
917320 BUSHING 40DXR40 GARLOCK 1
1T&D
57.42X00.2 NIP817901
11 12719 THRUST WASHER 0.
64x3.00x0.125 2 12 8454 PIN CAP 0.69x3.00x0.25 SS 2 13 12673 CAP SCREW 0.50-13 SHOULDER 4 14 19070 CYLINDER ASM 190-24-65 1 15 c1592 ZERK 1/8 NPT STRAIGHT 2
PN 16650
Secondary (190-24-65) - PN 16650
Page 67
Assembly Drawings 61
12
6
7
16
9
1
10
14
11
18
4
13
17
19
19
2
3
2
6
6
7
7
9
10
3
15
.YTQNOITPIRCSED.ON TRAP.ON METI
1K 25-02-471 TLIT378621 20635 BUSHING 40DXR32 GARLOCK 4 34381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 423457 CYLINDER ASM 5.00X24.50 1
336.0X00.2X36.0 PAC NI
P
81
88
6
3SS 00.1X31-05.0 RCS PAC75487 90377 MACHY WASHER 2.00ID 10GA 2
2
002-0027 00.2 G
NIR P
ANS80100
1 11 26971 PIN WLDMT 2.50X9.38 D&T 2 12 12921 THRUST WASHER 0.64x3.50x0.125 2 13 8455 PIN CAP 0.69X3.50X0.25 SS 2 14 12711 THRUST WASHER 0.63 DIA 2 15 12673 CAP SCREW 0.50-13 SHOULDER 2
157.61X00.2 NIP129061
1
K00004 SC HC
TAL
6
678
271
1K00004 SS HCTAL5678281
2THGIARTS TPN 8/1 KREZ2951c91
PN 26874
61
Tilt (138-18-52) - PN 26874
Manual PN 43502
Page 68
62 Shuttle Owner’s Manual - PN 43502
12
6
7
16
9
1
10
14
11
18
4
13
17
19
19
2
3
2
6
6
7
7
9
10
3
15
.YTQNOITPIRCSED.ON TRAP.ON METI
1K 25-02-471 TLIT378621 20635 BUSHING 40DXR32 GARLOCK 4 34381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 423457 CYLINDER ASM 5.00X24.50 1
336.0X00.2X36.0 PAC NI
P
81
88
6
3SS 00.1X31-05.0 RCS PAC75487 90377 MACHY WASHER 2.00ID 10GA 2
2
002-0027 00.2 G
NIR P
ANS80100
1 11 26971 PIN WLDMT 2.50X9.38 D&T 2 12 12921 THRUST WASHER 0.64x3.50x0.125 2 13 8455 PIN CAP 0.69X3.50X0.25 SS 2 14 12711 THRUST WASHER 0.63 DIA 2 15 12673 CAP SCREW 0.50-13 SHOULDER 2
157.61X00.2 NIP129061
1
K00004 SC HC
TAL
6
678
271
1K00004 SS HCTAL5678281
2THGIARTS TPN 8/1 KREZ2951c91
PN 26874
Tilt (174-20-52) - PN 26874
Page 69
Assembly Drawings 63
12
6
7
16
9
1
10
14
11
18
4
13
1
7
19
19
2
3
2
6
6
7
7
9
1
0
3
15
.YTQNOITPIRCSED.ON TRAP.ON METI
1K 25-02-471 TLIT378621 20635 BUSHING 40DXR32 GARLOCK 4 34381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 423457 CYLINDER ASM 5.00X24.50 1
336.0X00.2X36.0 PAC NI
P
81
88
6
3SS 00.1X31-05.0 RCS PAC75487 90377 MACHY WASHER 2.00ID 10GA 2
2
002-0027 00.2 G
NIR P
ANS80100
1 11 26971 PIN WLDMT 2.50X9.38 D&T 2 12 12921 THRUST WASHER 0.64x3.50x0.125 2 13 8455 PIN CAP 0.69X3.50X0.25 SS 2 14 12711 THRUST WASHER 0.63 DIA 2 15 12673 CAP SCREW 0.50-13 SHOULDER 2
157.61X00.2 NIP129061
1
K00004 SC HC
TAL
6
678
271
1K00004 SS HCTAL5678281
2THGIARTS TPN 8/1 KREZ2951c91
PN 26874
63
Tilt (190-24-52) - PN 26874
Manual PN 43502
Page 70
64 Shuttle Owner’s Manual - PN 43502
14
12
11
9
11
12
1
8
7
6
5
16
15
5
6
7
8
17
8
7
4
3
13
2
16
10
.YTQNOITPIRCSEDTRAPMETI
1H 56-42-091 TLIT00681 28598 PIN WLDMT 2.50X8.38 D&T 2 312921 THRUST WASHER 0.64x3.50x0.125 2 48455 PIN CAP 0.69X3.50X0.25 SS 2 512719 THRUST WASHER 0.64x3.00x0.125 2 68454 PIN CAP 0.69x3.00x0.25 SS 2 712711 THRUST WASHER 0.63 DIA 4 812673 CAP SCREW 0.50-13 SHOULDER 4
1SS HCTAL KOOH89829
1SC HCTAL KOOH998201
11 8818 PIN CAP 0.63X2.00X0.63 2 12 8457 CAP SCR 0.50-13X1.00 SS 2 13 13817 BUSHING 40DXR24 2.50X1.50 GARLOCK 2 14 0635 BUSHING 40DXR32 GARLOCK 2
1T&D 52.81X00.2 NIP29
2951 16 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 17 23457 CYLINDER ASM 5.00X24.50 1
PN 16523
Tilt (138-18-65) - PN 16523
Page 71
14
12
11
9
11
12
1
8
7
6
5
16
15
5
6
7
8
17
8
7
4
3
13
2
16
10
.YTQNOITPIRCSEDTRAPMETI
1H 56-42-091 TLIT00681 28598 PIN WLDMT 2.50X8.38 D&T 2 312921 THRUST WASHER 0.64x3.50x0.125 2 48455 PIN CAP 0.69X3.50X0.25 SS 2 512719 THRUST WASHER 0.64x3.00x0.125 2 68454 PIN CAP 0.69x3.00x0.25 SS 2 712711 THRUST WASHER 0.63 DIA 4 812673 CAP SCREW 0.50-13 SHOULDER 4
1SS HCTAL KOOH89829
1SC HCTAL KOOH998201
11 8818 PIN CAP 0.63X2.00X0.63 2 12 8457 CAP SCR 0.50-13X1.00 SS 2 13 13817 BUSHING 40DXR24 2.50X1.50 GARLOCK 2 14 0635 BUSHING 40DXR32 GARLOCK 2
1T&D 52.81X00.2 NIP29
2951 16 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 17 23457 CYLINDER ASM 5.00X24.50 1
PN 16523
Assembly Drawings 65
65
Tilt (174-20-65) - PN 16523
Manual PN 43502
Page 72
66 Shuttle Owner’s Manual - PN 43502
14
12
1
1
9
11
12
1
8
7
6
5
16
15
5
6
7
8
17
8
7
4
3
18
2
16
1
0
.YTQNOITPIRCS
ED
TRA
PMET
I
1H 56-42-091 TLIT00681 28598 PIN WLDMT 2.50X8.38 D&T 2 312921 THRUST WASHER 0.64x3.50x0.125 2 48455 PIN CAP 0.69X3.50X0.25 SS 2 512719 THRUST WASHER 0.64x3.00x0.125 2 68454 PIN CAP 0.69x3.00x0.25 SS 2 712711 THRUST WASHER 0.63 DIA 4 812673 CAP SCREW 0.50-13 SHOULDER 4
1SS HCTAL KOOH89829
1SC HCTAL KOOH9982
0
1 11 8818 PIN CAP 0.63X2.00X0.63 2 12 8457 CAP SCR 0.50-13X1.00 SS 2 14 0635 BUSHING 40DXR32 GARLOCK 2
1T&D 52.81X00.2 NIP292951
16 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 17 23463 CYLINDER ASM 5.00X22.50 1 18 13343 BUSHING 40DXR16 GARLOCK 2
PN 16707
Tilt (190-24-65) - PN 16707
Page 73
Assembly Drawings 67
3
NOTE: BUSHINGS ARE SHOWN FOR REFERENCE ONLY.
4
4
9
8
8
3
6
8
10
5
8
7
2
10
7
1
4
9
.YTQNOITPIRCSEDTRAPMETI 1 27232P CYLINDER 27232 8.00X56.50 PAINT 1 215995 MANIFOLD ASM DUAL T2A 5000PSI 1 3C2252 FTG ADAPT 8-10-F5OLO-S 2 4 1554 FTG ADAPT 8-F5OLO-S 4 5 19142 TUBE ASM 0.50 X 23.63 65,000 LOADER 1 619867 TUBE ASM 0.50 X 27.25 1 7C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2 8 2227 BUSHING 48DXR48 GARLOCK 4 918701 CLAMP PORT TUBE ZR518 2 10 19371 HOSE CLAMP 7.13-10.00 5416K43 2
PN 27231
Main Cylinder (138-18-52) - PN 27231
67
Manual PN 43502
Page 74
68 Shuttle Owner’s Manual - PN 43502
9
6
6
5
3
6
6
2
4
1
3
5
4
Note: BUSHINGS ARE SHOWN FOR REFERENCE.
8
7
8
7
3
9
.YTQNOITPIRCSEDTRAPMETI 134243 CYLINDER 8.00X71.63 1 215995 MANIFOLD ASM DUAL T2A 5000PSI 1 31554 FTG ADAPT 8-F5OLO-S 4 4C2252 FTG ADAPT 8-10-F5OLO-S 2 517968 TUBE ASM 0.50X32.50 2 6 2227 BUSHING 48DXR48 GARLOCK 4 718701 CLAMP PORT TUBE ZR518 2 819371 HOSE CLAMP 7.13-10.00
5416K43 2
9 c1592 ZERK 1/8 NPT STRAIGHT 2
PN 18064
Main Cylinder (174-20-52) - PN 18064
Page 75
Assembly Drawings 69
9
11
8
8
1
6
8
8
5
3
7
2
7
3
4
4
Bushings are shown for reference.
9
10
10
4
11
.YT
Q
NOITPIRC
S
EDTR
AP
MET
I
134242 CYLINDER 8.00X77.63 1 215995 MANIFOLD ASM DUAL T2A 5000PSI 1 3C2252 FTG ADAPT 8-10-F5OLO-S 2 41554 FTG ADAPT 8-F5OLO-S 4 519069 TUBE ASM 0.50 X 32.25 65,000 LOADER 1 618702 TUBE ASM 0.50X39.97 1 7 C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2 8 2227 BUSHING 48DXR48 GARLOCK 4
918701 CLAMP PORT TUBE ZR518 2 10 19371 HOSE CLAMP 7.13-10.00 5416K43 2 11 c1592 ZERK 1/8 NPT STRAIGHT 2
PN 27239
Main Cylinder (190-24-52) - PN 27239
69
Manual PN 43502
Page 76
70 Shuttle Owner’s Manual - PN 43502
NOTE: BUSHINGS ARE SHOWN FOR REFERENCE
4
6
12
2
1
1
7
11
5
5
8
12
6
4
7
4
9
10
3
4
11
11
11
10
12
3
.
YTQ
NOIT
PIRC
SED.ON TRAP.ON
20
5.65X0
0.7 R
ED
NILYC
9
441
1 215995 MANIFOLD ASM DUAL T2A 5000PSI 1 3C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2
6S-OLO5F-8 TPADA GTF455
1
4 5C2252 FTG ADAPT 8-10-F5OLO-S 2
2S-OL6R-8 EET GTF5610D6 7 19142 TUBE ASM 0.50 X 23.63 65,000 LOADER 2 8 19143 TUBE ASM 0.50 X 24.75 65,000 LOADER 1 9 19144 TUBE ASM 0.50 X 24.75 65,000 LOADER 1
10 5739 BUSHING 40DXR48 GARLOCK 8 11 18701 CLAMP PORT TUBE ZR518 4 12 19370 HOSE CLAMP 5.63-8.50 5416K39 4
PN 18397
Main Cylinder (138-18-65) - PN 18397
Page 77
Assembly Drawings 71
2
8
6
1
11
5
5
11
12
5
9
NOTE: BUSHINGS ARE SHOWN FOR REFERENCE
5
11
7
8
3
6
11
4
4
1
3
10
10
12
12
.YTQNOITPIRCSED.ON TRAP.ON
236.17X00.7 REDNILYC11801 215995 MANIFOLD ASM DUAL T2A 5000PSI 1 3C2252 FTG ADAPT 8-10-F5OLO-S 2 4C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2
6S-OLO5F-8 TPADA GTF45515 2
S
-OL6R-8 EE
T G
TF5610D
6 7 19141 TUBE ASM 0.50 X 33.38 65,000 LOADER 1 819069 TUBE ASM 0.50 X 32.25 65,000 LOADER 2 919068 TUBE ASM 0.50 X 33.38 65,000 LOADER 1
10 5739 BUSHING 40DXR48 GARLOCK 8 11 18701 CLAMP PORT TUBE ZR518 4 12 19370 HOSE CLAMP 5.63-8.50 5416K39 4
PN 19070
Main Cylinder (174-20-65) - PN 19070
71
Manual PN 43502
Page 78
72 Shuttle Owner’s Manual - PN 43502
2
8
6
1
11
5
5
11
12
5
9
NOTE: BUSHINGS ARE SHOWN FOR REFERENCE
5
11
7
8
3
6
11
4
4
1
3
10
10
12
12
.YTQNOITPIRCSED.ON TRAP.ON
236.17X00.7 REDNILYC11801 215995 MANIFOLD ASM DUAL T2A 5000PSI 1 3C2252 FTG ADAPT 8-10-F5OLO-S 2 4C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2
6S-OLO5F-8 TPADA GTF45515 2
S
-OL6R-8 EE
T G
TF5610D
6 7 19141 TUBE ASM 0.50 X 33.38 65,000 LOADER 1 819069 TUBE ASM 0.50 X 32.25 65,000 LOADER 2 919068 TUBE ASM 0.50 X 33.38 65,000 LOADER 1
10 5739 BUSHING 40DXR48 GARLOCK 8 11 18701 CLAMP PORT TUBE ZR518 4 12 19370 HOSE CLAMP 5.63-8.50 5416K39 4
PN 19070
Main Cylinder (190-24-65) - PN 19070
Page 79
Assembly Drawings 73
15
13
1
2
10
7
18
9
16
11
2
3
4
5
14
6
17
4
3
11
9
8
10
12
13
1
SHOWN AS REFERENCE
BUSHING AND ZERK
BUSHING AND ZERK SHOWN AS REFERENCE
18
ITEM NO. PART NO. DESCRIPTION QTY.
1
0
0.65X00.3 N
IP
917
21 2 22732 ROLLER DOUBLE 190-24-65H SS 1 3 0865 BUSHING 48DXR32 GARLOCK 4 41548 THRUST WASHER 3.01DIA UHMW .12 THK 4
2
RENIATER RALLOC72725
60507 CAP SCR 0.50-13X4.50 HHGR5 2
2DO "4 RELLOR694127 2DO "4 RELLOR537228
9 13343 BUSHING 40DXR16 GARLOCK 4
10 0635 BUSHING 40DXR32 GARLOCK 4
4REHSAW TSURHT
7
451
1
1 12 1583 MACHY WASHER 2.50ID 14GA 4
4DH 05.2 GNIR PANS636031 14 C6106 NUT 0.50-13 HHGR5 NYLOC 2 15 22737 ROLLER DOUBLE 190-24-65H CS 1
2
318.X05.3X15.2 RALLOC9781261
2834.X05.3X15.2 RALLOC8781271
18 c1592 ZERK 1/8 NPT STRAIGHT 4
PN 22738
73
Roller Assembly (138-16-65) - PN 22738
Manual PN 43502
Page 80
74 Shuttle Owner’s Manual - PN 43502
1
13
12
10
7
18
9
16
11
3
4
5
14
6
17
4
3
11
9
8
10
12
13
15
BUSHING AND ZERK SHOWN AS REFERENCE
2
BUSHING AND ZERK SHOWN AS REFERENCE
.YTQN
OITPIRCSE
D
T
RAPMET
I
100.65X00.3 NIP
9172
1 222748 ROLLER DOUBLE 190-24-65H SS 1 3 0865 BUSHING 48DXR32 GARLOCK 4 41548 THRUST WASHER 3.01DIA UHMW .12 THK 4
2
RENIATER
RALLO
C72725
60507 CAP SCR 0.50-13X4.50 HHGR5 2
2DO "4 RELLOR694127 2DO "4 RELLOR537228
9 13343 BUSHING 40DXR16 GARLOCK 4
10 0635 BUSHING 40DXR32 GARLOCK 4
4REHSAW TSURHT
7451
11
12 1583 MACHY WASHER 2.50ID 14GA 4
4DH 05.2 GNIR PANS636031 14 C6106 NUT 0.50-13 HHGR5 NYLOC 2 15 22749 ROLLER DOUBLE 190-24-65H CS 1
2
318.X05.3X15.2 RALLOC9781261
2834.X05.3X15.2 RALLOC8781271
18 c1592 ZERK 1/8 NPT STRAIGHT 4
PN 22747
Roller Assembly (174-20-65) - PN 22747
Page 81
Assembly Drawings 75
15
13
1
2
10
7
18
9
16
11
2
3
4
5
14
6
17
4
3
11
9
8
10
12
13
1
SHOWN AS REFERENCE
BUSHING AND ZERK
BUSHING AND ZERK SHOWN AS REFERENCE
18
ITEM NO. PART NO. DESCRIPTION QTY.
1
0
0.65X00.3 N
IP
917
21 2 22732 ROLLER DOUBLE 190-24-65H SS 1 3 0865 BUSHING 48DXR32 GARLOCK 4 41548 THRUST WASHER 3.01DIA UHMW .12 THK 4
2
RENIATER RALLOC72725
60507 CAP SCR 0.50-13X4.50 HHGR5 2
2DO "4 RELLOR694127 2DO "4 RELLOR537228
9 13343 BUSHING 40DXR16 GARLOCK 4
10 0635 BUSHING 40DXR32 GARLOCK 4
4REHSAW TSURHT
7
451
1
1 12 1583 MACHY WASHER 2.50ID 14GA 4
4DH 05.2 GNIR PANS636031 14 C6106 NUT 0.50-13 HHGR5 NYLOC 2 15 22737 ROLLER DOUBLE 190-24-65H CS 1
2
318.X05.3X15.2 RALLOC9781261
2834.X05.3X15.2 RALLOC8781271
18 c1592 ZERK 1/8 NPT STRAIGHT 4
PN 22738
75
Roller Assembly (190-24-65) - PN 22738
Manual PN 43502
Page 82
76 Shuttle Owner’s Manual - PN 43502
Page 83
Chapter 8 - Troubleshooting
Troubleshooting 77
77
This chapter will list a number of
potential problems that may occur
while operating the Hooklift. Most
problems are easily solved using the
solutions portion of this chapter. If
problems persist, please contact
Customer Service at Stellar Industries
1-800-321-3741.
Problem: Hooklift will not operate or operates slow. Solutions:
• Make sure the PTO is engaged.
• Make sure the control lever/cable assembly or air actuator are shifting the spool valves on the valve section
• Make sure that the hydraulic pump is operating at its rated flow or GPMs under load. Check the flow by using a flow meter to determine the GPMs. To find the proper flow the equipment is to operate at, see Chapter 6 of the Hooklift Owner’s Manual.
• Make sure the relief pressure is properly set per the specifications page of the hooklift owners manual.
• Make sure the spool valves on the valve bank are adjusted and operating smoothly.
Problem: Lift cylinder operates, but the tilt cylinder operates slow or does not operate at all. Solutions:
• Make sure the rotary valve arm is properly adjust­ed. See Rotary Valve Drawing in the Installation Chapter of this manual.
• Make sure the rotary valve arm is not damaged or has become disconnected.
Problem: Tab alarm sounds off inside chassis cab. Solutions:
eak away tabs on dump weldment have broken
• Br loose. Re-install break away tabs using a Grade 5
5
16” bolt.
Problem: Hydraulic system gets extremely hot. Solutions:
Make sure the hydraulic filter has been changed
• per the maintenance page of the Hooklift Owner’s Manual.
• Make sure the filter strainer of the hydraulic reser­voir is not plugged.
• Make sure that the hydraulic pump is operating at its rated flow or GPMs.
• Make sure the relief pressure is set properly. See Table 1.1 of Chapter 6: Installation for proper setting.
Problem: Hooklift will not lift or pickup a loaded con­tainer. Solutions:
• Make sure the container contents are evenly dis­tributed.
• Make sure the container and its load does not exceed the rated capacity.
• Make sure the relief pressure is properly set per Table 1.1 in the Installation Chapter of this manual.
• Make sure the hydraulic pump is operating at its rated flow or GPMs. See Chapter 4: Specifications.
• Make sure that the container is not fixed to the ground or frozen down.
Problem: Dump weldment lifts upward while picking up a container. Solutions:
• Make sure the rear hooklift rollers spin freely and smoothly.
• Make sure the body hold down brackets are not worn or bent.
Problem: Cylinders drift upward or downward while hydraulics are dis-engaged. Solutions:
• Make sure valve spools are shifting to three neutral position.
• Possible contamination keeping the holding valve open.
• Possible internal piston seals rolled or damaged.
Problem: Hooklift binds at pivot points. Solutions:
• Make sure the pivot points are lubricated.
• Make sure pivot pins are not seized to the bushing.
• Make sure the weldments or pins are not mis­aligned or bent.
Contact Customer Service at Stellar Industries:
1-800-321-3741
Manual PN 43502
Page 84
Limited Warranty Statement
®®
Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. The warranty period shall cover the following:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture, Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of manufacture, and Thirty-six (36) month warranty on all Stellar Crane and Hooklift structural parts from the date recorded by Stellar as the in-service date, not to extend beyond forty-eight (48) months from date of manufacture.
The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, the factory ship date will be used.
Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option) of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24­hours of notification by the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.
Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged parts must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of the warranty claim.
Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service provider.
All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellar­manufactured product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any way not approved, in writing, by Stellar.
The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear, accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.
The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of delay, or for any special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use, wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.
All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not participate in, or obligate itself to, any such warranty.
Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products theretofore manufactured.
This warranty will apply to all Stellar Hooklifts, Stellar Service Trucks, & Truck-mounted Cranes shipped from Stellar’s factory after July 1, 2005. The warranty is for the use of the original owner only and is not transferable without prior written permission from Stellar.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Revision Date: February 2007 Document Number: 37040
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