Stellar 190-24-65 Hooklift User Manual

®

OWNER’S 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: [phone]

www.stellarindustries.com

Manual Part No. 43502
Last Revision: 12/18/07

52K/65K Hooklift Manual Revisions

Date of Revision Description of RevisionSection Revised

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

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

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 [e-mail].

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 [e-mail]

Order Parts [e-mail]

Warranty Information [e-mail]

Manual PN 43502

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

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

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.

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

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.

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

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.

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

8 Shuttle Owner’s Manual - PN 43502

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

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

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

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.

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

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.

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

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.

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

18 Shuttle Owner’s Manual - PN 43502

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

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

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

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.

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

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.

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

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.

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

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

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

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

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

32 Shuttle Owner’s Manual - PN 43502

PN 3118

Subframe (138-18-52, 138-18-65) - PN 3118

Installation 33

PN 3117

Subframe (174-20-52, 174-20-65, 190-24-65, 190-24-52) - PN 3117

33

Manual PN 43502

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

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

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

PN 17017

Hose Kit (138-18-52) - PN 17017

Installation 37

37

Manual PN 43502

38 Shuttle Owner’s Manual - PN 43502

PN 17794

Hose Kit (174-20-52) - PN 17794

PN 17822

Hose Kit (190-24-52) - PN 17822

Installation 39

39

Manual PN 43502

40 Shuttle Owner’s Manual - PN 43502

PN 16624

Hose Kit (138-18-65) - PN 16624

PN 32677

Hose Kit (174-20-65) - PN 32677

Installation 41

41

Manual PN 43502

42 Shuttle Owner’s Manual - PN 43502

PN 16708

Hose Kit (190-24-65) - PN 16708

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

76 Shuttle Owner’s Manual - PN 43502

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

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