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 This requirement shall, however, be superseded by any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 Informationservice@stellarindustries.com
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
Page 8
2Shuttle 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
Page 10
4Shuttle 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
Page 12
6Shuttle Owner’s Manual - PN 43502Operation 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
Page 14
8Shuttle 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.
-
Manual PN 43502
Page 16
10Shuttle Owner’s Manual - PN 43502
Choice Lubricants for DX Bearings
Greases Recommended
Type of GreaseDescription
Premium Quality
Multi-Purpose
Multi-PurposeCalcium Based, for General Automotive and Industrial Use
Anti-Friction BearingCalcium Based with EP Additives
Extreme Pressure (EP)Lithium Based with EP Additives
High TemperatureModified Sodium Based, High Drop Point
TransmissionSemi-Fluid, Calcium Based
Molybdenum FilledLithium Based with 2% Molybdenum Disulfide
Graphite FilledSodium Based with 2% Graphite
Block GreaseSodium Based Solid Grease
White GreaseAluminum Complex Based with Anti-Oxidant & Rust
SiliconeLithium 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 GreaseDescription
Cup GreaseLight Service Calcium or Sodium Based Grease
Graphite FilledGreases with More than 10% Graphite
Molybdenum FilledGreases with More than 10% Molybdenum Disulfide
FluorocarbonLow Molecular Weight Chlorofluoroethylene Polymer
with Inert Thickeners
White GreaseCalcium 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’
61.75”
237”x86”x56”
54,000
29°
19’ to 21.5’
To 23.5’
Manual PN 43502
Page 18
12Shuttle 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 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 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
14Shuttle 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 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 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
16Shuttle 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 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 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
18Shuttle 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
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.
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
22Shuttle 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
24Shuttle 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
26Shuttle 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.
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
30Shuttle Owner’s Manual - PN 43502
6
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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 2007Document Number: 37040
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