Stellar 96-10-24 Hooklift User Manual

®

OWNER’S MANUAL

Safety, Installation, Maintenance, and Operation

Stellar Shuttle Hooklifts

Models

108-11-20

108-12-20/36

120-16-20
138-18-20
168-20-20
190-24-20

96-10-24

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. 43301
Last Revision: 12/18/07

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

Chapter 3 - Maintenance . . . . . . . . . . . . . . . . .9

Choice Lubricants for DX Bearings . . . . . .10

Chapter 4 - Specifications . . . . . . . . . . . . . . . .

Model 108-12-20/36 Specifications . . . . . .12

Model 108-11-20 Specifications . . . . . . . . .13

Model 120-16-20 Specifications

Model 138-18-20 Specifications . . . . . . . . .15

Model 168-20-20 Specifications . . . . . . . . .16

Model 190-24-20 Specifications

Model 96-10-24 Specifications . . . . . . . . . .18

Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . . . .19

Decals of Note . . . . . . . . . . . . . . . . . . . . . . .19

Decal Kit Placement - PN D0779

Chapter 6 - Installation

Basic Installation Overview . . . . . . . . . . . . .21

Installation Steps - Basic Guidelines . . . . .22

Power Beyond VDM8 Valve . . . . . . . . . . . .24

Mounting Kit - PN 1022

(138-18-20, 168-20-20, 190-24-20) . . . . . . . . . . . . . . .

Mounting Kit - PN 2966

(96-10-24,108-11-20, 108-12-20/36, 120-16-20) . . . . .26

Reservoir Assembly - PN 25629 . . . . . . . . . .27

Rotary Valve - PN 24040 . . . . . . . . . . . . . . .28

Subframe (108-11-20) - PN 3123
Subframe (108-12-20/36) - PN 3126

Subframe (120-16-20) - PN 3122 . . . . . . . . .31

Subframe (168-20-20) - PN 3118 . . . . . . . . .32

Subframe (190-24-20) - PN 3117 . . . . . . . . .33

Subframe (96-10-24) - PN 3123 . . . . . . . . . .34

. . . . . . . . . . . . . . . . . . .7

. . . . . . . . .14

. . . . . . . . .17

. . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . .

. . . . . .

11

20

21

25

2
30

Dump Light Kit Installation . . . . . . . . . . . . .35

Controller Assembly Part 1 - PN 38841 . . .36
Controller Assembly Part 2 PN - 38841 . . .37

Hose Kit (108-11-20) - PN 42843 . . . . . . . . .38

Hose Kit (108-12-20/36) - PN 42846 . . . . . .39

Hose Kit (120-16-20) - PN 42849 . . . . . . . . .40

Hose Kit (138-18-20) - PN 42851 . . . . . . . . .41

Hose Kit (168-20-20) - PN 15728 . . . . . . . . .42

Hose Kit (190-24-20) - PN 15729 . . . . . . . . .43

Chapter 7 - Assembly Drawings . . . . . . . . . . .45

Base (108-11-20) - PN 23705 . . . . . . . . . . . .45

Base (108-12-20/36) - PN 25723 . . . . . . . . .46

Base (120-16-20) - PN 23832 . . . . . . . . . . . .47

Base (138-18-20) - PN 23882 . . . . . . . . . . . .48

Base (168-20-20) - PN 23934 . . . . . . . . . . . .49

Base (190-24-20) - PN 23987 . . . . . . . . . . . .50

Base (96-10-24) - PN 25230 . . . . . . . . . . . . .51

Dump (108-11-20) - PN 23706

Dump (108-12-20/36) - PN 25726 . . . . . . . .53

Dump (120-16-20) - PN 23833 . . . . . . . . . . .54

Dump (138-18-20) - PN 23884 . . . . . . . . . . .

Dump (168-20-20) - PN 23939 . . . . . . . . . . .56

Dump (190-24-20) - PN 23989 . . . . . . . . . . .57

Dump (96-10-24) - PN 25233

Secondary (108-11-20) - PN 23836 . . . . . . .59

Secondary (108-12-20/36) - PN 25729 . . . .60

Secondary (120-16-20) - PN 23845

Secondary (138-18-20) - PN 23886 . . . . . . .62

Secondary (168-20-20) - PN 23941 . . . . . . .63

Secondary (190-24-20) - PN 23991 . . . . . . .64

Secondary (96-10-24) - PN 25238

ilt (108-11-20) - PN 23707

T

Tilt (108-12-20/36) - PN 22223 . . . . . . . . . . .67

Tilt (120-16-20) - PN 23707 . . . . . . . . . . . . . .68

Tilt (138-18-20) - PN 23707 . . . . . . . . . . . . . .69

Tilt (168-20-20) - PN 23943 . . . . . . . . . . . . . .70

ilt (190-24-20) - PN 23943

T

Tilt (96-10-24) - PN 23707 . . . . . . . . . . . . . . .72

Main Cylinder (108-11-20) - PN 21880 . . . .73

Main Cylinder (180-12-20/36) - PN 25734 .74

Main Cylinder (120-16-20) - PN 19026 . . . .75

9

Main Cylinder (138-18-20) - PN 21882
Main Cylinder (168-20-20) - PN 21884

Main Cylinder (190-24-20) - PN 21884 . . . .78

Main Cylinder (96-10-24) - PN 25244 . . . . .79

Chapter 8 - Troubleshooting . . . . . . . . . . . . . .81

Warranty Information . . . . . . . . . . . . . . . . . . . .82

. . . . . . . . . . .52

. . . . . . . . . . . .58

. . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

55

. . . . . . .61

6
6

70

7

. . . .

7

. . . .

5
6

6
7

Manual PN 43301

ii Shuttle Owner’s Manual - PN 43301

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 manufacturer’s written approval. Use only factory
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!

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 43301

iv Shuttle Owner’s Manual - PN 43301

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 43301

2 Shuttle Owner’s Manual - PN 43301

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

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 proce­dures.

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 43301

4 Shuttle Owner’s Manual - PN 43301

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.

Unloading Operation

5

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 43301

6 Shuttle Owner’s Manual - PN 43301 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

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 43301

8 Shuttle Owner’s Manual - PN 43301

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.

Loose parts or damage to structures or weld.

2.

3. Cylinder movement due to leakage.

4. Hoses for evidence of oil leaks.

5. Contr

6. Parking brake operation.

7.

8. All safety covers for pr

9. Cylinder holding valves for proper operation.

10. Equipment for missing, illegible, or defaced operat-

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.

2. All pins, bushings, shafts, and gears for wear, cracks,

3. Hydraulic systems for proper operating pressure.

ols for malfunction or adjustment.

e such as cotter pins, snap

All securing har
rings, hairpins, and pin keepers for pr
tion.

ing decals and safety signs.

or distortion to include all pivot points, and bushings.

dwar

oper installa

oper installation.

-

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.

d possible causes.

2. List and r

3. Devise checks.

4. Conduct checks in a logical order to determine the

cause.
Consider the remaining service life of components

5.

against the cost of parts and labor necessary to

eplace them.

r

6. Make the necessary r

7. Recheck to ensure that nothing has been over-

looked.

8. Functionally test the new part in its system.

ecor

epair

.

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 43301

10 Shuttle Owner’s Manual - PN 43301

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 11-feet up to 21.5-feet long and still

•
attain the maximum rated dump angle on a 41-inch high frame truck.
Longer bodies may be accommodated with reduced dumping

apabilities.

c

• Transmission-mounted PTO and hydraulic pump required to power the

ooklift.

H

• Standard in-cab manual controls which allow for precise metering of

he manual hydraulic valve. Solenoid-activated hydraulic control

t
valve with electric remote control pendant is optional.

• Ten (10) gallon frame-mounted oil tank.

• Operating pressure is 4,200 psi.

• Hydraulic flow required is 15-gallons per minute.

• 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
Dump Angle

A

Lowest Hook Height

B

Effective Length

C

ruck Frame Height

T

D

Hooklift Height

E

Hooklift Length

G

Hooklift Center of Gravity

H

Chassis Cab to Axle

I

Max. Height when Loading

J

Longest Body to Dump

K

Max. Height when Dumping

L

Shipping Weight

om bottom of hook bar)

Hook Height

(fr

Shipping Dimensions
Min. Truck GVWR
Load Angle w/ SBL
Rec. Body Lengths*
Rec. Body Lengths**

*(Assumes 3ft. overhang from center

oller pin)

ear r

of r
(Bumper typically 12” from center of
roller pin)

om cen

**(Assumes 5ft. over
ter of rear roller pin)
(May require bumper and latch
options)

hang fr

108-12-20/36

20,000
53°
30”
126”
39”

47.38”
138”
62”

102” to 108”

133”
183”
177”
2,400

35.63”

138”x52”x47”

25,000
46°

12’ to 13.5’

o 15.5’

T

-

• 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.

108-11-20

20,000
45°
44”
127”
41”

49.38”
139”
55”

102” to 108”

134”
186”
187”
2,570
54”

139”x74”x47”

25,000
37°

11’ to 13.5’

o 15.5’

T

120-16-20

20,000
48°
44”
146”
41”

49.38”
159”
61”

114” to 130”

143”
204”
204”
2,625
54”

159”x74”x47”

25,000
35°

12.5’ to 15’

o 17’

T

138-18-20

20,000
52°
44”
171”
41”

50.13”
183”
71”

130” to 144”

162”
228”
227”
3,175
54”

183”x74”x47”

25,000
38°

14.5’ to 17’

o 19’

T

168-20-20

20,000
50°
43”
195”
41”

50.13”
207”
79”

168” to 180”

173”
252”
248”
3,660

61.75”

207”x82”x47”

25,000
30°

16.5’ to 19’

To 21’

190-24-20

20,000
45°
51”
222”
41”

50.13”
234”
91”

190” to 200”

185”
288”
259”
3,900

61.75”

234”x82”x47”

25,000
29°

18.5’ to 21.5’

To 23.5’

96-10-24

24,000
54°
44”
115”
41”

49.38”
128”
52”

84” to 102”

134”
174”
183”
2,500
54”

128”x74”x47”

25,000
45°

10’ to 12.5’

To 14.5’

Manual PN 43301

12 Shuttle Owner’s Manual - PN 43301

Model 108-12-20/36 Specifications

ifting Capacity: 20,000 pounds gross weight evenly distributed in, or on, body.

L

Container Length: 12-foot through 13.5-foot from front A-frame to rear of skid rails. Longer bodies up to 15.5-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: 53°

Operating Pressure: 4,200 PSI maximum.

Weight of Hooklift: Hooklift weight not to exceed 2,400 pounds.

Height of Hooklift: Hooklift height not to exceed 8.38" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body 6-

inches below grade, when mounted on a 39” 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

hooklift functions.

Tilting Hook Assembly: Hooklift 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 3-inch bore with 1.5-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: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in

the dumping mode.

Lift/Dump Cylinder: Single 6-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and include dual

integral pilot-operated counterbalance valves to pr

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length

25” wide frame to pr
frame without the use of mechanical latches which rely on gravity, springs, or container/body mounted
latches. The system must be pr

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift

through all ranges of the dump mode. This must be accomplished without the use of steel springs and/or
hydraulic/air cylinders.

ovide support for the container while in the dump mode. These sections for

otected fr

om out of sequence operation.

event cylinder collapse in case of hose failur

e.

m this

Rear Dump Hinge Pin: 2.5-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: All hoses and fittings are to be SAE; metrics are not to be allowed. O-ring face seal fittings to be utilized

ever possible.

wher

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

Specifications 13

Model 108-11-20 Specifications

ifting Capacity: 20,000 pounds gross weight evenly distributed in, or on, body.

L

Container Length: 11-foot through 13.5-foot from front A-frame to rear of skid rails. Longer bodies up to 15.5-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: 45°

Operating Pressure: 4200 PSI maximum.

Weight of Hooklift: Hooklift weight not to exceed 2,570 pounds.

Height of Hooklift: Hooklift height not to exceed 8.38" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 54-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body 10-inch-

es 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.

13

Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all

hooklift functions.

Tilting Hook Assembly: Hooklift 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 4-inch bore with 2-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 preventexposure of cylinder rod to corro­sive road salts.

Tilt Section Operation: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is

in the dumping mode.

Lift/Dump Cylinder: Single 5-inch bore with 2-inch diameter rod cylinder. Cylinder must be double acting and include dual

integral pilot-operated counterbalance valves to pr

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length

25” wide frame to pr
frame without the use of mechanical latches which rely on gravity, springs, or container/body mounted
latches. The system must be pr

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift

through all ranges of the dump mode. This must be accomplished without the use of steel springs
and/or hydraulic/air cylinders. Hooklift must be compatible with containers manufactur
Z245.60 recommended standard for waste containers.

ovide support for the container while in the dump mode. These sections for

otected fr

om out of sequence operation.

event cylinder collapse in case of hose failur

ed to ANSI

e.

m this

Rear Dump Hinge Pin:

Pins:

Bushings: All bushings to be of the permanently lubricated variety.

Hoses & Hyd. Fittings:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America

2-inch diameter type 304 or 17-4 stainless steel minimum.

All pins to be type 304 or 17-4 stainless steel.

All hoses and fittings ar
wher

ever possible.

e to be SAE; metrics ar

e not to be allowed. O-ring face seal fittings to be utilized

Manual PN 43301

14 Shuttle Owner’s Manual - PN 43301

Model 120-16-20 Specifications

ifting Capacity: 20,000 pounds gross weight evenly distributed in, or on, body.

L

Container Length: 12.5-foot through 15-foot from front A-frame to rear of skid rails. Longer bodies up to 17-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: 48˚

Operating Pressure: 4200 PSI maximum.

Weight of Hooklift: Hooklift weight not to exceed 2,625 pounds.

Height of Hooklift: Hooklift height not to exceed 8.38" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 54-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body 10-inch-

es 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

hooklift functions.

Tilting Hook Assembly: Hooklift 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 4-inch bore with 2-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: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is

in the dumping mode.

Lift/Dump Cylinder: Single 5-inch bore with 2-inch diameter rod cylinder. Cylinder must be double acting and include dual

integral pilot-operated counterbalance valves to pr

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length

25” wide frame to pr
frame without the use of mechanical latches which rely on gravity, springs, or container/body mounted
latches. The system must be pr

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift

through all ranges of the dump mode. This must be accomplished without the use of steel springs
and/or hydraulic/air cylinders. Hooklift must be compatible with containers manufactur
Z245.60 recommended standard for waste containers.

ovide support for the container while in the dump mode. These sections for

otected fr

om out of sequence operation.

event cylinder collapse in case of hose failur

ed to ANSI

e.

m this

Rear Dump Hinge Pin:

Pins:

Bushings: All bushings to be of the permanently lubricated variety.

Hoses & Hyd. Fittings:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

2-inch diameter type 304 or 17-4 stainless steel minimum.

All pins to be type 304 or 17-4 stainless steel.

All hoses and fittings ar
wher

ever possible.

e to be SAE; metrics ar

e not to be allowed. O-ring face seal fittings to be utilized

Specifications 15

Model 138-18-20 Specifications

ifting Capacity: 20,000 pounds gross weight evenly distributed in, or on, body.

L

Container Length: 14.5-foot through 17-foot from front A-frame to rear of skid rails. Longer bodies up to 19-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: 52°

Operating Pressure: 4,200 PSI maximum.

Weight of Hooklift: Hooklift weight not to exceed 3,175 pounds.

Height of Hooklift: Hooklift height not to exceed 9.13" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 54-inches from bottom of skid rails to bottom of hook bar. Hooklift must be able to pick up body 10-inch-

es 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.

15

Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all

hooklift functions.

Tilting Hook Assembly: Hooklift 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 4-inch bore with 2-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: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is in

the dumping mode.

Lift/Dump Cylinder: Single 5-inch bore with 2-inch diameter rod cylinder. Cylinder must be double acting and include dual

integral pilot-operated counterbalance valves to pr

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length

25” wide frame to pr
frame without the use of mechanical latches which rely on gravity, springs, or container/body mounted
latches. The system must be pr

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift

through all ranges of the dump mode. This must be accomplished without the use of steel springs and/or
hydraulic/air cylinders. Hooklift must be compatible with containers manufactur
ommended standard for waste containers.

ovide support for the container while in the dump mode. These sections for

otected fr

om out of sequence operation.

event cylinder collapse in case of hose failur

ed to ANSI Z245.60 r

e.

m this

ec

-

Rear Dump Hinge Pin:

Pins:

Bushings: All bushings to be of the permanently lubricated variety.

Hoses & Hyd. Fittings:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

2-inch diameter type 304 or 17-4 stainless steel minimum.

All pins to be type 304 or 17-4 stainless steel.

All hoses and fittings ar
wher

ever possible.

e to be SAE; metrics ar

e not to be allowed. O-ring face seal fittings to be utilized

Manual PN 43301

16 Shuttle Owner’s Manual - PN 43301

Model 168-20-20 Specifications

ifting Capacity: 20,000 pounds gross weight evenly distributed in, or on, body.

L

Container Length: 16.5-foot through 19-foot from front A-frame to rear of skid rails. Longer bodies up to 21-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 Hooklift: Hooklift weight not to exceed 3,660 pounds.

Height of Hooklift: Hooklift height not to exceed 9.13" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 61.75-inches from bottom of skid rails to bottom of hook bar. Hooklift 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

hooklift functions.

Tilting Hook Assembly: Hooklift 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 4-inch bore with 2-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: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section

while hooklift is in the dumping mode.

Lift/Dump Cylinder: Single 5-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and include

m this

ec

e.

-

dual integral pilot-operated counterbalance valves to pr

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full length

25” wide frame to pr
frame without the use of mechanical latches which rely on gravity, springs, or container/body mounted
latches. The system must be pr

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift

through all ranges of the dump mode. This must be accomplished without the use of steel springs and/or
hydraulic/air cylinders. Hooklift must be compatible with containers manufactur
ommended standard for waste containers.

ovide support for the container while in the dump mode. These sections for

otected fr

om out of sequence operation.

event cylinder collapse in case of hose failur

ed to ANSI Z245.60 r

Rear Dump Hinge Pin:

Pins:

Bushings: All bushings to be of the permanently lubricated variety.

Hoses & Hyd. Fittings:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

2-inch diameter type 304 or 17-4 stainless steel minimum.

All pins to be type 304 or 17-4 stainless steel.

All hoses and fittings ar
wher

ever possible.

e to be SAE; metrics ar

e not to be allowed. O-ring face seal fittings to be utilized

Specifications 17

Model 190-24-20 Specifications

ifting Capacity: 20,000 pounds gross weight evenly distributed in, or on, body

L

Container Length: 18.5-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: 45°

Operating Pressure: 4200 PSI maximum

Weight of Hooklift: Hooklift weight not to exceed 3,900 pounds

Height of Hooklift: Hooklift height not to exceed 9.13" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 61.75-inches from bottom of skid rails to bottom of hook bar. Hooklift 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 or piston-type pump

Hydraulic Control Valve: Hydraulic valve mounted directly onto the oil reservoir.

17

Controls: Dual manual levers with sealed cable actuators mounted in the truck cab to allow full feathering of all

hooklift functions.

Tilting Hook Assembly: Hooklift 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 4-inch bore with 2-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: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is

in the dumping mode.

Lift/Dump 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 pr

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full

length 25” wide frame to pr
this frame without the use of mechanical latches which rely on gravity, springs, or container/body
mounted latches. The system must be pr

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift

through all ranges of the dump mode. This must be accomplished without the use of steel springs
and/or hydraulic/air cylinders. Hooklift must be compatible with containers manufactur
Z245.60 recommended standard for waste containers.

ovide support for the container while in the dump mode. These sections for

otected fr

event cylinder collapse in case of hose failur

om out of sequence operation.

ed to ANSI

e.

m

Rear Dump Hinge Pin:

Pins:

Bushings: All bushings to be of the permanently lubricated variety.

Hoses & Hyd. Fittings:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

2-inch diameter type 304 or 17-4 stainless steel minimum.

All pins to be type 304 or 17-4 stainless steel.

All hoses and fittings ar
wher

ever possible.

e to be SAE; metrics ar

e not to be allowed. O-ring face seal fittings to be utilized

Manual PN 43301

18 Shuttle Owner’s Manual - PN 43301

Model 96-10-24 Specifications

ifting Capacity: 24,000 pounds gross weight evenly distributed in, or on, body.

L

Container Length: 10-foot through 12.5-foot from front A-frame to rear of skid rails. Longer bodies up to 14.5-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: 54°

Operating Pressure: 4200 PSI maximum.

Weight of Hooklift: Hooklift weight not to exceed 2,500 pounds.

Height of Hooklift: Hooklift height not to exceed 8.38" as measured from top of truck frame to top of hooklift rollers.

Hook Height: 54-inches from bottom of skid rails to bottom of hook bar. Hooklift 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

hooklift functions.

Tilting Hook Assembly: Hooklift 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 4-inch bore with 2-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: Hooklift must include a hydraulic lock-out device to prevent operation of the tilt section while hooklift is

in the dumping mode.

Lift/Dump Cylinder: Single 5.5-inch bore with 2.5-inch diameter rod cylinder. Cylinder must be double acting and include

dual integral pilot-operated counterbalance valves to pr

Dump/Tilt Interlock: Dumping must be accomplished through a rear pivot. Tilt and lift sections must lock into a rigid full

length 25” wide frame to pr
form this frame without the use of mechanical latches which rely on gravity, springs, or container/body
mounted latches. The system must be pr

Rear Body Hold-downs: Dual fixed-position hold down devices mounted to the dump frame to secure the body to the hooklift

through all ranges of the dump mode. This must be accomplished without the use of steel springs
and/or hydraulic/air cylinders. Hooklift must be compatible with containers manufactur
Z245.60 recommended standard for waste containers.

ovide support for the container while in the dump mode. These sections

otected fr

event cylinder collapse in case of hose failur

om out of sequence operation.

ed to ANSI

e.

Rear Dump Hinge Pin:

Pins:

Bushings: All bushings to be of the permanently lubricated variety.

Hoses & Hyd. Fittings:

Origin of Manufacture: Hooklift to be designed and manufactured in the United States of America.

2-inch diameter type 304 or 17-4 stainless steel minimum.

All pins to be type 304 or 17-4 stainless steel.

All hoses and fittings ar
wher

ever possible.

e to be SAE; metrics ar

e not to be allowed. O-ring face seal fittings to be utilized

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 43301

20 Shuttle Owner’s Manual - PN 43301

.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.

Basic Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Installation Steps - Basic Guidelines . . . . . . . . . . . . . . . . . . . . . . . .22

Power Beyond VDM8 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Mounting Kit - PN 1022

(138-18-20, 168-20-20, 190-24-20) . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Mounting Kit - PN 2966

(96-10-24,108-11-20, 108-12-20/36, 120-16-20) . . . . . . . . . . . . . . . .26

Reservoir Assembly - PN 25629 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Rotary Valve - PN 24040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Subframe (108-11-20) - PN 3123 . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Subframe (108-12-20/36) - PN 3126 . . . . . . . . . . . . . . . . . . . . . . . . .30

Subframe (120-16-20) - PN 3122 . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Subframe (168-20-20) - PN 3118 . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Subframe (190-24-20) - PN 3117 . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Subframe (96-10-24) - PN 3123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Dump Light Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Controller Assembly Part 1 - PN 38841 . . . . . . . . . . . . . . . . . . . . . .36

Controller Assembly Part 2 PN - 38841 . . . . . . . . . . . . . . . . . . . . . .37

Hose Kit (108-11-20) - PN 42843 . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Hose Kit (108-12-20/36) - PN 42846 . . . . . . . . . . . . . . . . . . . . . . . . .39

Hose Kit (120-16-20) - PN 42849 . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Hose Kit (138-18-20) - PN 42851 . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Hose Kit (168-20-20) - PN 15728 . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Hose Kit (190-24-20) - PN 15729 . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

21

Basic Installation Overview

1. Clear the truck frame.

2. Set the hooklift on the truck frame.

3. Shorten the truck frame to within 2” from the rear of the loader.

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 43301

22 Shuttle Owner’s Manual - PN 43301

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. Feel free to space up if needed.

3. Shorten the truck frame to within 2” from the rear of the loader.

4. Install bumper.

a. See Government Regulations for acceptable placement.

5. Install tie down channels. (See corresponding Mounting Kit Drawing in this chapter)

a. Move anything on the truck frame that may be in the way of the tie down chan-

nels.
b. Place a tie down channel on both sides of the base, within 2” of the front plate.
c. Place a tie down channel on both sides of the base, underneath the tabs at the

rear.
d. The final channels should be placed in the approximate position shown in the cor-

responding mounting diagram. The top of the lower channel should be flush with

the top of the chassis frame rail.

1

1

e. Using the channels as a guide, drill ten (10)

⁄16” holes through the truck frame.

(Note: For Models 96-10-24, 108-11-20, 108-12-20/36, and 120-16-20 you only need

1

to drill eight (8) holes.) Also, drill a

1

⁄16” hole in the rear tab to allow bolting of the

rear mount.
f. Using 5/8” bolts, washers, and nuts, secure all tie down channels to the truck

frame. All bolts should be torqued to 160 ft-lbs.

h. Weld the upper tie down channels to the hooklift base. Use 5/8” washers to

space the channels up. Remove washers when finished.

g. Using 5/8” bolts, washers, and nuts, fasten two (2) tie-down channels together with

the narrow faces toward each other. Do this with all of the channels.

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 reservoir 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.

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 43301

24 Shuttle Owner’s Manual - PN 43301

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 25

4

5

3

1

5

4

3

3

2

ITEM PART DESCRIPTION QTY.

1D0143 TIE DOWN CHANNEL 18
2D0045 BACKUP ALARM .97 DECIBAL 1
3C1038 WASHER 0.63 FLAT 40
424868 NUT 0.63-11 HHGR8 NYLOCK ZY 20
5C10 26 CAP SCR 0.63-11X2.50 HHGR8 ZY 2 0

Tie Down Channel

Long Side:
Welded to Hooklift Base.

Long Side:
B

olted to Truck Frame Rail.

Torqued to 160 ft-lbs.

S

hort Sides:
Bolted together. Bottom Tie Down
is flush with top of truck frame rail.

Once the back tie downs are attached
to the mounting flange, shorten the truck
frame to within 2” of the hooklift base.

Two sets of tie downs should be
placed as close to the pivot
point as possible.

Front tie down must be
within 2” of the front
plate of the hooklift. Be
sure to allow plenty of
room if using optional
tarper system.

Mounting Kit (138-18-20, 168-20-20, 190-24-20) - PN 1022

25

Manual PN 43301

26 Shuttle Owner’s Manual - PN 43301

PN 2966

.YTQNOITPIRCSEDTRAPMETI

1 D0143 TIE DOWN CHANNEL 14
2 D0045 BACKUP ALARM .97 DECIBAL 1
3 24868 NUT 0.63-11 HH NYLOC 16
4 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 32
5C1026 CAP SCR 0.63-11X2.50 HHGR8 ZY 16

Front tie down must be
within 2” of the front
p

late of the hooklift.

Tie Down Channel

Long Side:
W

elded to Hooklift Base.

Long Side:
B

olted to Truck Frame Rail.

Torqued to 160 ft-lbs.

Short Sides:
B

olted together. Bottom Tie Down

is flush with top of truck frame rail.

Two sets of tie downs should be
placed as close to the pivot
point as possible.

Once the back tie downs are attached
to the mounting flange, shorten the truck
frame to within 2” of the hooklift base.

Mounting Kit (96-10-24,108-11-20, 108-12-20/36, 120-16-20) - PN 2966

28

3

4

3

5

7

6

1

26

8

21

20

19

18

9

20

2

14

15

16

17

15

26

12

11

10

2

2

28

29

25

13

23

27

.YT

Q

NOITPIRCSEDTRAPMETI
1 26455 RSRVR ASM 10GAL K MODEL 1
2 1115 FTG NIPPLE HEX MALE 0101-20-20 1
3 c2242 ST EL 0.75 90 DEG BLK 2
4 3320 NIPPLE 0.75X12.00 PIPE 1

1DAEH RETLIF6226c5
6 C6229 FILTER LARGE AE-10L 1
7 C6014 FTG ADAPT 8-12 FOLO-S 1

152.1 LLA

B

E

VLAV1155C8

9 C2282 FTG 1.25 NPT TO 1.25 BARB 1

10 24611 VB 2-SECTION VDM8 1

3KCOL 52.0 REHSAW125011

12 0339 CAP SCR 0.25-20X2.50 HHGR5 3

.YTQNOITPIRCSEDTRAPMETI
13 C4227 FTG MF/MSTR 90 8-12 C5OLO-S 1
14 26731 HOSE 0.50(381-JC-J9-8-8-8-18-0) 1
15 0352 WASHER 0.50 USS FLAT ZINC 8
16 C6106 NUT 0.50-13 HHGR5 NYLOC 4
17 0506 CAP SCR 0.50-13X4.00 HHGR5 4
18 D0549 FTG ADAPT 16-8 F5OG5-S 1
19 17767 HOSE SUCT 1.25 10FT 1
20 C1123 HOSE CLAMP 88 DB-20 2
21 C4747 NIPPLE O'RING 45 4603-20-16 1
22 10094 GAUGE OIL LF 2.5" 0-500 BM 1
23 9892 SPACER TANK MOUNTING 10 GAL 2
24 16145 GAUGE PRES FILTER SERVICE CI20 1

.YTQNOITPIRCSEDTRAPMETI
25 25630 FTG ADAPT 10-1/4 F5OG 1
26 C1855 FTG ADAPT 6-10 F5OLO-S 5
27 C2248 FTG ADAPT 6-C6LO-S 5
28 14927 HOSE 0.38(381-JC-JC-6-6-6-120) 1
29 C1854 FTG ADAPT 6-8 F5OLO-S 1

PN 25629

Reservoir Assembly - PN 25629

Installation 27

27

Manual PN 43301

28 Shuttle Owner’s Manual - PN 43301

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 - PN 24040

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.

PN 3123

Subframe (108-11-20) - PN 3123

Installation 29

Manual PN 43301

30 Shuttle Owner’s Manual - PN 43301

PN 3126

Subframe (108-12-20/36) - PN 3126

PN 3122

Subframe (120-16-20) - PN 3122

Installation 31

Manual PN 43301

32 Shuttle Owner’s Manual - PN 43301

PN 3118

Subframe (168-20-20) - PN 3118

PN 3117

190-24-20

Subframe (190-24-20) - PN 3117

Installation 33

Manual PN 43301

34 Shuttle Owner’s Manual - PN 43301

PN 3123

Subframe (96-10-24) - PN 3123

Installation 35

• 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

Manual PN 43301

36 Shuttle Owner’s Manual - PN 43301

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 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

UN43062

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

Installation 37

Manual PN 43301

38 Shuttle Owner’s Manual - PN 43301

PN 42843

Hose Kit (108-11-20) - PN 42843

Hose Kit (108-12-20/36) - PN 42846

PN 42846

Installation 39

Manual PN 43301

40 Shuttle Owner’s Manual - PN 43301

PN 42849

Hose Kit (120-16-20) - PN 42849

Hose Kit (138-18-20) - PN 42851

PN 42851

Installation 41

Manual PN 43301

42 Shuttle Owner’s Manual - PN 43301

PN 15728

Hose Kit (168-20-20) - PN 15728

Hose Kit (190-24-20) - PN 15729

PN 15729

Installation 43

Manual PN 43301

44 Shuttle Owner’s Manual - PN 43301

Assembly Drawings 45

3

3

9

10

8

4

5

4

3

6

10

8

9

7

10

2

3

9

8

1

11

12

6

3

11

12

11

12

9

2

8

10

3

.YTQNOITPIRCSEDTRAPMETI

102-11-801 ESA

B975

321
24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2
30427 MACHY WASHER 2.00ID 10GA 6
423699 BUSHING 32DXR20 2.00X1.25 2

157.9X0

0.2 NIP022225
2002-0027 00.2 GNIR PANS80106

144.63X00.2 NIP716427
400

.1X0

0.3X10.2 RALLOC467228

90532 CAP SCR 0.38-16X3.75 HHGR5 4

4COLYN HH 61-83.0 TUN743001
6PP0413BL PMALC ES

OH50

51D1

1
12 0333 NUT 0.25-20 HHGR5 NYLOC 6

PN 23705

Chapter 7 - Assembly Drawings

Base (108-11-20) - PN 23705

45

Manual PN 43301

46 Shuttle Owner’s Manual - PN 43301

9

4

5

4

3

6

10

8

9

7

1

0

2

3

9

8

1

11

12

6

3

11

1

2

11

12

2

9

8

10

3

3

8

1

0

3

.Y

TQNOITPIRCSEDTRAPMETI

1K63/02-21-801 ESAB42752

1
20635 BUSHING 40DXR32 GARLOCK 2
31593 MACHY WASHER 2.50ID 10GA 6
425574 BUSHING 40DXR20 2.50X1.25 2

1

83.21X05

.2 NIP75

80

5

2

DH 05.2

GNIR P

ANS6360

6

144.63X05.2 NIP840627
4 00.1X05.3X15.2 RALLOC039328

932086 CAP SCR 0.38-16X4.25 HHGR5 4

4

COLYN HH 61-83.0 TUN74300

1

6PP0413BL PMALC ESOH5051D11

12 0333 NUT 0.25-20 HHGR5 NYLOC 6

PN 25723

Base (108-12-20/36) - PN 25723

6

4

5

4

6

7

6

9

2

3

1

0

9

6

1

1

0

8

8

11

1

2

7

6

12

11

1

2

11

12

1

1

2

8

10

6

9

10

8

9

.YTQNOITPIRCSEDTRAPMETI

1k02-41-021 ESAB217321

24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2

1

4

4.63X00.

2 NI

P71642

3
423699 BUSHING 32DXR20 2.00X1.25 2

157.9X00.2 NIP022225

60427 MACHY WASHER 2.00ID 10GA 6

2002-0027 00.2 GNIR PANS801

0

7

4

00.1X00

.3X10.2 RALLO

C467

228

90532 CAP SCR 0.38-16X3.75 HHGR5 4

4COLYN HH 61-83.0 TUN743001
8PP0413BL PMALC ESOH5051D11

12 0333 NUT 0.25-20 HHGR5 NYLOC 8

PN 23832

Base (120-16-20) - PN 23832

Assembly Drawings 47

47

Manual PN 43301

48 Shuttle Owner’s Manual - PN 43301

11

4

5

4

6

7

2

3

10

9

6

1

8

11

12

6

7

1

1

12

1

1

12

11

1

2

9

9

6

10

6

8

1

0

8

9

6

8

2

1

0

12

.YTQNOITPIRCSEDTRAPMETI

1k02-81-831 ESAB188321

24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2

14

4.63X0

0.2 NIP716

423

423699 BUSHING 32DXR20 2.00X1.25 2

157.9X00.2 NIP022225

60427 MACHY WASHER 2.00ID 10GA 6

2002-0027 00.2 GNIR PANS

80

107

400.1X00.3X10.2 RALLOC467228

90532 CAP SCR 0.38-16X3.75 HHGR5 4

4COLYN H

H 6

1-83.0 TUN743001

01PP0413BL PMALC ESOH505

1D

11

12 0333 NUT 0.25-20 HHGR5 NYLOC 10

PN 23882

Base (138-18-20) - PN 23882

7

4

5

4

6

7

9

8

1

0

6

2

3

10

9

6

1

11

12

6

9

10

8

6

6

2

8

6

9

10

6

8

.YTQNOITPIRCSEDTRAPMETI

1

K02-81-86

1 ESAB02732

1
24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2

144.63X00.2 NIP716423

423699 BUSHING 32DXR20 2.00X1.25 2

157.9X00.

2 NIP022225

60427 MACHY WASHER 2.00ID 10GA 8

2002-0027 00.2 GNIR PANS80107

400.1X00.3X

10.2 RALLOC4

6722

8
90532 CAP SCR 0.38-16X3.75 HHGR5 4

4COLYN HH 61-83.0 TUN743001
8PP0413BL PMALC ESOH5051D11

12 0333 NUT 0.25-20 HHGR5 NYLOC 8

PN 23934

Base (168-20-20) - PN 23934

Assembly Drawings 49

49

Manual PN 43301

50 Shuttle Owner’s Manual - PN 43301

12

4

5

4

6

7

2

3

1

10

6

9

8

11

12

10

1

0

10

9

1

8

9

9

8

2

7

6

8

11

12

1

1

12

6

6

11

.YTQ

N

OITP

IRC

SE

DTR

APMETI

102-42-091 ESAB689321

2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2

144.63X00

.2 NIP716

423

4 23699 BUSHING 32DXR20 2.00X1.25 2

157.9X00.2 NIP02222

5
6 0427 MACHY WASHER 2.00ID 10GA 8

2002-0027 00.2 GNIR PANS80107

400.1X00.3X10.2 RALLOC46722

8
9 0532 CAP SCR 0.38-16X3.75 HHGR5 4

4COLYN HH 61-83.0 TUN743001
8PP0413BL PMALC ESOH5051D11

12 0333 NUT 0.25-20 HHGR5 NYLOC 8

PN 23987

Base (190-24-20) - PN 23987

9

4

5

4

3

6

10

8

9

7

10

2

3

9

8

1

11

12

6

3

11

12

1

1

12

2

9

8

10

3

10

8

3

3

.YTQNOITPIRCSEDTRAPMET

I

1K42-01-69 ESAB132521
24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2
30427 MACHY WASHER 2.00ID 10GA 6
423699 BUSHING 32DXR20 2.00X1.25 2

152.01X00.2 NIP765525

2

002-002

7 00.2 GN

IR PANS80106

144.63X00.2 NIP716427

400.1X00.3X10.2 RALLOC467228

90532 CAP SCR 0.38-16X3.75 HHGR5 4

4COLYN HH 61-83.0 TUN743

0

01

6

P

P 0914 NL PMALC ESOH733011

12 0333 NUT 0.25-20 HHGR5 NYLOC 6

PN 25230

Base (96-10-24) - PN 25230

Assembly Drawings 51

51

Manual PN 43301

52 Shuttle Owner’s Manual - PN 43301

2

18

5

3

7

6

9

18

10

13

8

14

1

1

1

2

1

3

17

15

15

1

7

13

8

1

4

8

16

16

20

19

2

1

21

2

14

BUSHING AND ZERK
SHOWN AS REFERENCE

2

.YTQNOITPIRCSEDTRAPMETI

1

K02

-11-801 PMUD185321
24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
323301 TAB LOADER BREAK AWAY 2
40332 CAP SCR 0.31-18X1.75 HHGR5 2
50333 NUT 0.25-20 HHGR5 NYLOC 2
60506 CAP SCR 0.50-13X4.00 HHGR5 2
7C6106 NUT 0.50-13 HHGR5 NYLOC 2
80635 BUSHING 40DXR32 GARLOCK 6

152.52X00.2 NIP7222

2

9

257.51X05.2 NIP1393201
2DO "4 RELLO

R

6941

2

1

1
12 13343 BUSHING 40DXR16 GARLOCK 2

6REHSAW TSURHT745131
4THGIARTS TPN 8/1 KREZ2951c4

1

4 00.1X05.3X15

.2 RALLO

C

03

93251

16 C0953 CAP SCR 0.38-16X4.00 HHGR5 4

4COLYN HH 61-83.0 TUN743071

200.2 EDISNI

GNIR PANS75

22

8

1
19 26290 COVER SWITCH PROXIMITY 1
20 26287 SWITCH PROXIMITY CARLO GAVAZZI 1
21 26930 GROMMET 1.25ODX.25X.38ID 2

PN 23706

Dump (108-11-20) - PN 23706

Assembly Drawings 53

17

5

3

7

6

8

17

9

12

2

13

10

11

12

16

14

14

16

12

1

4

2

15

15

18

19

20

20

13

2

BUSHING AND ZERK
SHOWN AS REFERENCE

2

12

.YTQNOITPIRCSEDTRAPMETI

1

K63

/02

-21

-801 PMUD727521
2 0635 BUSHING 40DXR32 GARLOCK 12
323301 TAB LOADER BREAK AWAY 2
4 0332 CAP SCR 0.31-18X1.75 HHGR5 2
5 0333 NUT 0.25-20 HHGR5 NYLOC 2
6 0506 CAP SCR 0.50-13X4.00 HHGR5 2
7C6106 NUT 0.50-13 HHGR5 NYLOC 2

1

52.52X05.

2 NIP2855

28

257.51X05.2 NIP139329
2DO "4 RE

LL

OR6941201

11 13343 BUSHING 40DXR16 GARLOCK 2

6R

EHSAW TSURHT74512

1

4THGIARTS TPN 8/1 KR

EZ29

51c31

4 00.1X05.3X15.2 RALLOC0393241

15 C0953 CAP SCR 0.38-16X4.00 HHGR5 4

4COLYN HH 61-83

.0 TUN

743

0

61

200.2

EDI

SNI GNI

R PANS

752

271
18 26287 SWITCH PROXIMITY CARLO GAVAZZI 1
19 26290 COVER SWITCH PROXIMITY 1
20 26930 GROMMET 1.25ODX.25X.38ID 2

PN 25726

Dump (108-12-20/36) - PN 25726

53

Manual PN 43301

54 Shuttle Owner’s Manual - PN 43301

2

5

3

7

6

9

18

1

0

1

3

8

1

4

1

1

12

13

1

7

15

1

5

1

7

1

3

8

1

4

8

16

16

1

9

20

21

21

1

4

18

2

2

BUSHING AND ZERK
SHOWN AS REFERENCE

2

.YTQNOITPIRCSEDTRAPMETI

1K02-41

-021 PMU

D417321
24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
323301 TAB LOADER BREAK AWAY 2
40332 CAP SCR 0.31-18X1.75 HHGR5 2
50333 NUT 0.25-20 HHGR5 NYLOC 2
60506 CAP SCR 0.50-13X4.00 HHGR5 2
7C6106 NUT 0.50-13 HHGR5 NYLOC 2
80635 BUSHING 40DXR32 GARLOCK 6

152.52X00.2 NIP722229

257.51X05.2 NIP1393201
2DO "4 RELLOR6941211

12 13343 BUSHING 40DXR16 GARLOCK 2

6REHSAW TSURHT745131
4THGIARTS TPN 8/1 KREZ2951c41
4

00.1X05.3X15.2

RALLOC

0393251

16 C0953 CAP SCR 0.38-16X4.00 HHGR5 4

4COLYN HH 61-83.0 TUN743071

200.2 EDISNI GNIR PANS752281
19 26287 SWITCH PROXIMITY CARLO GAVAZZI 1
20 26290 COVER SWITCH PROXIMITY 1
21 26930 GROMMET 1.25ODX.25X.38ID 2

PN 23833

Dump (120-16-20) - PN 23833

Assembly Drawings 55

18

5

3

7

6

9

1

0

1

3

8

14

1

1

12

13

17

1

5

15

1

7

1

3

8

1

4

8

2

18

19

20

21

21

16

1

6

1

4

2

2

BUSHING AND ZERK
SHOWN AS REFERENCE

2

.YTQNOITPIRCSEDTRAPMETI

102-81

-831

PM

UD

388321
2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
324255 TAB LOADER BREAK AWAY 2
4 0332 CAP SCR 0.31-18X1.75 HHGR5 2
5 0333 NUT 0.25-20 HHGR5 NYLOC 2
6 0506 CAP SCR 0.50-13X4.00 HHGR5 2
7C6106 NUT 0.50-13 HHGR5 NYLOC 2
8 0635 BUSHING 40DXR32 GARLOCK 6

152.52X00.2 NIP72222

9

25

7.51X0

5.2 NIP1393201
2D

O "4

RELLOR6941211

.YTQNOITPIRCSEDTRAPMETI

12 13343 BUSHING 40DXR16 GARLOCK 2

6REHSAW T

SUR

HT74513

1

4THGIARTS TPN 8/1 KREZ2951c41
4 00.1X05.3X15.2 RALLOC0393251

16 C0954 CAP SCR 0.38-16X4.50 HHGR5 4

4

COLYN HH 6

1-83.0 TUN7

430

71

200.2 EDISNI GNIR PANS752281
19 26287 SWITCH PROXIMITY CARLO GAVAZZI 1
20 26290 COVER SWITCH PROXIMITY 1
21 26930 GROMMET 1.25ODX.25X.38ID 2

PN 23884

Dump (138-18-20) - PN 23884

55

Manual PN 43301

56 Shuttle Owner’s Manual - PN 43301

2

5

3

7

6

18

10

13

8

14

11

12

13

17

15

1

5

1

7

1

3

8

1

4

2

8

1

6

2

16

19

20

2

1

21

14

2

7

4

5

3

6

18

2

B

USHING AND ZERK

S

HOWN AS REFERENC

E

9

.YTQNOITPIRCSE

DT

R

AP

METI

102-81-861 PMUD63932

1
2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
323301 TAB LOADER BREAK AWAY 2
4 0332 CAP SCR 0.31-18X1.75 HHGR5 2
5 0333 NUT 0.25-20 HHGR5 NYLOC 2
6 0506 CAP SCR 0.50-13X4.00 HHGR5 2
7C6106 NUT 0.50-13 HHGR5 NYLOC 2
8 0635 BUSHING 40DXR32 GARLOCK 6

152.52X00.2 NIP72222

9

257.51X05.2 NIP1393201
2DO "4 RELLOR6941211

.

YTQNOITPI

R

CSEDTRAP

MET

I

12 13343 BUSHING 40DXR16 GARLOCK 2

6

REHSAW TSURH

T7

4

5131

4THGI

ART

S TPN 8/1 KREZ

295

1c

41

4 00.1X05

.3X15.2 RALLOC0393251

16 C0953 CAP SCR 0.38-16X4.00 HHGR5 4

4

COLYN HH 61-83.0 TU

N74

30

71

2

0

0.2 EDISNI G

NIR PANS752281
19 26287 SWITCH PROXIMITY CARLO GAVAZZI 1
20 26290 COVER SWITCH PROXIMITY 1
21 26930 GROMMET 1.25ODX.25X.38ID 2

PN 23939

Dump (168-20-20) - PN 23939

Assembly Drawings 57

16

4

18

2

1

7

5

5

7

5

6

7

ATTACHMENT POINT

3

10

9

1

2

8

11

12

1

1

8

4

19

20

2

1

21

10

S

ECONDARY

15

4

4

13

14

17

BUSHING AND ZERK
SHOWN AS REFERENCE

1

8

.YTQNOITPIRCSED

TRAPMETI

102-42

-091 PMUD88932

1

152.52X00.2 NIP722222

257.51X05.2 NIP139323
4 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
5 0635 BUSHING 40DXR32 GARLOCK 6
6 13343 BUSHING 40DXR16 GARLOCK 2

6REHSAW TSURHT74517
4

00

.1X05.3X15.2 RALLOC039328

2

D

O "4 RELLOR694129

4THGIARTS TPN 8/1 KREZ2951c01

11 C0953 CAP SCR 0.38-16X4.00 HHGR5 4

.YTQNOITPIRCSEDTRAPMETI

4COLYN HH 61-83.0 TU

N

743021
13 23301 TAB LOADER BREAK AWAY 2
14 0506 CAP SCR 0.50-13X4.00 HHGR5 2
15 0332 CAP SCR 0.31-18X1.75 HHGR5 2
16 0333 NUT 0.25-20 HHGR5 NYLOC 2
17 C6106 NUT 0.50-13 HHGR5 NYLOC 2

200.2 EDISNI GNIR PANS752281
19 26287 SWITCH PROXIMITY CARLO GAVAZZI 1
20 26290 COVER SWITCH PROXIMITY 1
21 26930 GROMMET 1.25ODX.25X.38ID 2

PN 23989

Dump (190-24-20) - PN 23989

57

Manual PN 43301

58 Shuttle Owner’s Manual - PN 43301

2

18

5

3

7

6

9

18

10

13

8

14

11

12

13

17

15

15

17

13

8

1

4

8

16

16

19

20

21

21

2

14

BUSHING AND ZERK
SHOWN AS REFERENCE

2

.YTQNOITPIRCSEDTRAPMETI

1K42-01-69 PMUD432521
2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
323301 TAB LOADER BREAK AWAY 2
4 0332 CAP SCR 0.31-18X1.75 HHGR5 2
5 0333 NUT 0.25-20 HHGR5 NYLOC 2
6 0506 CAP SCR 0.50-13X4.00 HHGR5 2
7C6106 NUT 0.50-13 HHGR5 NYLOC 2
8 0635 BUSHING 40DXR32 GARLOCK 6

152.52X00.2 NIP722229

257.51X05.2 NIP1393201

2DO "4 RELLOR6941211

12 13343 BUSHING 40DXR16 GARLOCK 2

6REHSAW TSURHT7

451

31

4THGIARTS TPN 8/1

KREZ29

51c41

4 00.1X05.3X15.2 RALLOC0393251

16 C0953 CAP SCR 0.38-16X4.00 HHGR5 4

4COLYN HH 61-83.

0 T

UN743071

200.2

EDI

SNI GNIR P

AN

S7

522

81
19 26287 SWITCH PROXIMITY CARLO GAVAZZI 1
20 26290 COVER SWITCH PROXIMITY 1
21 26930 GROMMET 1.25ODX.25X.38ID 2

PN 25233

Dump (96-10-24) - PN 25233

Assembly Drawings 59

2

5

3

7

8

4

6

1

8

7

2

2

2

2

2

2

6

2

2

2

2

2

9

.YT

Q

NOITPIRCSEDTRAPMET

I

102-11-801 YRADNOCES738321

2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 14

157.61X00.2 NIP12903

100.61X00.2 NIP682224

521880 CYLINDER ASM 5.00X40.38 1

200.2 EDISNI

GNIR

PANS75226

7 0377 MACHY WASHER 2.00ID 10GA 2

2002-0027 00.2 GNIR PANS80108
2THGIARTS TPN 8/1 KREZ2951c9

PN 23836

Secondary (108-11-20) - PN 23836

59

Manual PN 43301

60 Shuttle Owner’s Manual - PN 43301

9

2

9

8

4

4

6

7

5

1

3

10

6

11

5

5

3

4

2

ITEM NO. QTY. PART NO. DESCRIPTION

1 1 25730 SECONDARY 108-12-20/36K
2 2 0635 BUSHING 40DXR32 GARLOCK
3 2 17320 BUSHING 40DXR40 GARLOCK
4 4 0067 BUSHING QSI-2426-24
5 4 0069 BUSHING QSI-1618-16
623875 SNAP RING 1.00 INTERNAL
7 1 22285 PIN 1.00X15.00
8 1 25586 PIN 2.50X15.75

9 2 22216 SNAP RING INSIDE 2.50
10 1 25734 CYLINDER ASM 25735
11 2 c1592 ZERK 1/8 NPT STRAIGHT

PN 22223

Secondary (108-12-20/36) - PN 25729

Assembly Drawings 61

2

5

3

7

8

2

4

1

6

2

2

2

2

7

8

2

6

2

2

9

9

2

2

2

.YT

Q

NOITPIRCSEDTRAPMET

I

1K

02-41-021 YRADNOCES448321

2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 14

157.61X00.2 NIP12903

100.61X00.2 NIP682224

183.2

5 X 5

MSA RED

NILYC62091

5

200.2 EDISNI

GNIR

PANS75226

7 0377 MACHY WASHER 2.00ID 10GA 2

2002-0027 00.2 GNIR PANS80108
2THGIARTS TPN 8/1 KREZ2951c9

PN 23845

Secondary (120-16-20) - PN 23845

61

Manual PN 43301

62 Shuttle Owner’s Manual - PN 43301

9

6

3

5

8

2

4

1

7

2

2

5

8

2

2

2

7

2

2

2

2

9

2

2

.YTQNOITPIRCSEDTRAPMETI

1K02-81-831 YRADNOCES588321

24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 14

157.61X00.2 NIP12903
1

00.61X00.2 NIP682224
50377 MACHY WASHER 2.00ID 10GA 2
621882 CYLINDER ASM 5.00X63.25 1

200.2 EDISNI GNIR PANS75227
2002-0027

00

.2 GNIR PANS80108

2THGIARTS TPN 8/1 KREZ2951

c

9

PN 23886

Secondary (138-18-20) - PN 23886

Assembly Drawings 63

11

10

7

9

8

9

10

10

10

5

4

10

3

10

1

2

1

3

4

5

6

10

10

11

.YT

QNOITPIRCS

ED

TRAPMETI

112719 THRUST WASHER 0.64x3.00x0.125 2

1T&D 00.61X00.2 NIP11392
3 8454 PIN CAP 0.69x3.00x0.25 SS 2
412711 THRUST WASHER 0.63 DIA 2
512673 CAP SCREW 0.50-13 SHOULDER 2
621884 CYLINDER ASM 5.00X71.00 W/2.50 ROD 1
723940 SECONDARY 168-18-20 1

100.61X00.2 NIP682228

9 2257 SNAP RING INSIDE 2.00 2

10 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 12
11 c1592 ZERK 1/8 NPT STRAIGHT 2

PN 22223

Secondary (168-20-20) - PN 23941

63

Manual PN 43301

64 Shuttle Owner’s Manual - PN 43301

11

9

8

7

10

8

10

10

10

10

5

4

3

10

1

10

2

1

3

4

5

10

A

TTACHMENT POINT

6

TILT CYLINDER

11

.YTQNOITPIRCSEDTRAPMETI

112719 THRUST WASHER 0.64x3.00x0.125 2

1T&D 00.61X00.2 NIP11392
3 8454 PIN CAP 0.69x3.00x0.25 SS 2
412711 THRUST WASHER 0.63 DIA 2
512673 CAP SCREW 0.50-13 SHOULDER 2
621884 CYLINDER ASM 5.00X71.00 W/2.50 ROD 1

100.61X00.2 NIP682227

2

00.2 E

DISNI GNI

R PANS

75228

102-42-091 YRADNOCES099329

10 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 14

2THGIARTS TPN 8/1 KREZ2951c11

PN 23991

Secondary (190-24-20) - PN 23991

Assembly Drawings 65

2

5

3

7

2

8

2

4

6

1

8

7

2

2

2

2

2

2

6

9

9

2

2

.YTQNOITPIRCSEDTRAPMETI

102-11-801 YRADNOCES738321

2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 14

157.61X00.2 NIP12903

100.61X00.2 NIP682224

525244 CYLINDER ASM 5.00X40.38 1

200.2 EDISNI GNIR PANS75226

7 0377 MACHY WASHER 2.00ID 10GA 2

2

002-

0027 00.2 GNIR PANS80

108

2THGIARTS TPN 8/1 KREZ2951c9

PN 25238

Secondary (96-10-24) - PN 25238

65

Manual PN 43301

66 Shuttle Owner’s Manual - PN 43301

10

5

6

1

4

9

10

12

11

13

7

4

2

3

8

1

1

5

16

16

6

5

2

3

9

2

9

.YTQNOITPIRCSEDTRAPMETI

1K02-11-801 TLIT385321
2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
3 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2

188.51X00.2 NIP942424

2SS 00.1X31-05.0 RCS PAC75485

236.0X00.2X36.0 PAC NIP81886
724250 PIN WLDMT 2.00X10.50 WLDMT 2
823159 CYLINDER ASM 4.00X14.50 1
9 0427 MACHY WASHER 2.00ID 10GA 4

2002-0027 00.2 GNIR PANS801001

200.1X00.3X10.2 RALLOC4672211

12 C0953 CAP SCR 0.38-16X4.00 HHGR5 2

2

COLYN HH 61-83.0 TUN743031

1K00004 SS HCTAL5678241
1K00004 SC HCTAL6678251
2THGIARTS TPN 8/1 KREZ2951c61

PN 23707

Tilt (108-11-20) - PN 23707

Assembly Drawings 67

8

1

1

10

9

1

4

5

7

12

2

3

14

13

6

5

ITEM NO. PART NO. DESCRIPTION QTY.

141-11-48 TLIT257121
223460 CYLINDER ASM 3.00X17.00 1
3 0069 BUSHING QSI-1618-16 1

18

3.3X00.1 NI

P

4600

4
50110 SNAP RING 1.00 ID 7200-100 2
6 0067 BUSHING QSI-2426-24 4
723297 PIN WELDM'T 1.50X10.50 2
8D0419 THRUST WASHER 2
9 0295 LATCH 12,000# 1

10 14672 PIN CAP 0.44X1.50X0.63 1
11 9714 CAP SCR 0.38-16X1.00 SS 1
12 24237 COLLAR 1.53X2.50X1.00 2
13 C0949 CAP SCR 0.38-16X3.00 HHGR5 2
14 0347 NUT 0.38-16 HH NYLOC 2

PN 22223

67

Tilt (108-12-20/36) - PN 22223

Manual PN 43301

68 Shuttle Owner’s Manual - PN 43301

1

0

5

6

14

9

10

12

11

13

7

4

2

3

8

1

15

16

16

6

5

2

3

9

2

9

.YTQNOITPIRCSEDTRAPMETI

1K02-11-801 TLIT385321
2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
3 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2

188.51X00.2 NIP942424

2SS 00.1X31-05.0 RCS PAC75485

236.0X00.2X36.0 PAC NIP81886
724250 PIN WLDMT 2.00X10.50 WLDMT 2
823159 CYLINDER ASM 4.00X14.50 1
9 0427 MACHY WASHER 2.00ID 10GA 4

2002-0027 00.2 GNIR PANS801001

200.1X00.3X10.2 RALLOC4672211

12 C0953 CAP SCR 0.38-16X4.00 HHGR5 2

2

COLYN HH 61-83.0 TUN743031

1K00004 SS HCTAL5678241
1K00004 SC HCTAL6678251
2THGIARTS TPN 8/1 KREZ2951c61

PN 23707

Tilt (120-16-20) - PN 23707

Assembly Drawings 69

10

5

6

14

9

10

12

11

13

7

4

2

3

8

1

15

16

16

6

5

2

3

9

2

9

.YTQNOITPIRCSEDTRAPMETI

1K02-11-801 TLIT385321
2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
3 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2

188.51X00.2 NIP942424

2SS 00.1X31-05.0 RCS PAC75485

236.0X00.2X36.0 PAC NIP81886
724250 PIN WLDMT 2.00X10.50 WLDMT 2
823159 CYLINDER ASM 4.00X14.50 1
9 0427 MACHY WASHER 2.00ID 10GA 4

2002-0027 00.2 GNIR PANS801001

200.1X00.3X10.2 RALLOC4672211

12 C0953 CAP SCR 0.38-16X4.00 HHGR5 2

2

COLYN HH 61-83.0 TUN743031

1K00004 SS HCTAL5678241
1K00004 SC HCTAL6678251
2THGIARTS TPN 8/1 KREZ2951c61

PN 23707

69

Tilt (138-18-20) - PN 23707

Manual PN 43301

70 Shuttle Owner’s Manual - PN 43301

3

1

8

15

16

8

1

5

4

3

2

13

9

2

3

4

5

11

12

13

2

4

5

10

17

17

13

14

.YTQNOITPIRCSEDTRAPMETI
1 8457 CAP SCR 0.50-13X1.00 SS 2
212719 THRUST WASHER 0.64x3.00x0.125 4
3 8454 PIN CAP 0.69x3.00x0.25 SS 4
412711 THRUST WASHER 0.63 DIA 4
512673 CAP SCREW 0.50-13 SHOULDER 4

236.0X00.2X36.0 PAC NIP81888

160.5

1X00

.2 NIP5

89

519

10 23462 CYLINDER ASM 4.00X26.50 1

102-02-861 TLIT2493211

205.9X00.2 TMDLW NIP5473221
13 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
14 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2

1K00004 S

C HC

TAL

6678251

1K00004 SS HCTAL567826

1
17 c1592 ZERK 1/8 NPT STRAIGHT 2

PN 23943

Tilt (168-20-20) - PN 23943

Assembly Drawings 71

3

1

8

15

16

8

1

5

4

3

2

13

9

2

3

4

5

11

12

13

2

4

5

10

17

17

13

14

.YTQNOITPIRCSEDTRAPMETI
1 8457 CAP SCR 0.50-13X1.00 SS 2
212719 THRUST WASHER 0.64x3.00x0.125 4
3 8454 PIN CAP 0.69x3.00x0.25 SS 4
412711 THRUST WASHER 0.63 DIA 4
512673 CAP SCREW 0.50-13 SHOULDER 4

236.0X00.2X36.0 PAC NIP81888

160.5

1X00

.2 NIP5

89

519

10 23462 CYLINDER ASM 4.00X26.50 1

102-02-861 TLIT2493211

205.9X00.2 TMDLW NIP5473221
13 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
14 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2

1K00004 S

C HC

TAL

6678251

1K00004 SS HCTAL567826

1
17 c1592 ZERK 1/8 NPT STRAIGHT 2

PN 23943

71

Tilt (190-24-20) - PN 23943

Manual PN 43301

72 Shuttle Owner’s Manual - PN 43301

10

5

6

14

9

10

12

11

13

7

4

2

3

8

1

15

16

16

6

5

2

3

9

2

9

.YTQNOITPIRCSEDTRAPMETI

1K02-11-801 TLIT385321
2 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 6
3 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2

188.51X00.2 NIP942424

2SS 00.1X31-05.0 RCS PAC75485

236.0X00.2X36.0 PAC NIP81886
724250 PIN WLDMT 2.00X10.50 WLDMT 2
823159 CYLINDER ASM 4.00X14.50 1
9 0427 MACHY WASHER 2.00ID 10GA 4

2002-0027 00.2 GNIR PANS801001

200.1X00.3X10.2 RALLOC4672211

12 C0953 CAP SCR 0.38-16X4.00 HHGR5 2

2

COLYN HH 61-83.0 TUN743031

1K00004 SS HCTAL5678241
1K00004 SC HCTAL6678251
2THGIARTS TPN 8/1 KREZ2951c61

PN 23707

Tilt (96-10-24) - PN 23707

Assembly Drawings 73

2

5

5

3

6

7

7

NOTE: BUSHINGS ARE SHOWN FOR REFERENCE.

4

8

4

4

1

4

2

9

.YTQNOITPIRCSE

D

TRAPMETI

1

8

3.04X00.5 REDNILYC75

00

1

24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4

315822 MANIFOLD DOUBLE T11A 5000 PSI 1

6S-OLO5F-6 TPAD

A GTF

972

0

4

5C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2

1

65.72 X 83.0 MSA EBUT18812

6

2815RZ EBUT TROP PMALC107817

819369 HOSE CLAMP 4.13-7.00 5416K38 2

915888 TUBE ASM 0.38X7.22 TM14160 1

PN 21880

73

Main Cylinder (108-11-20) - PN 21880

Manual PN 43301

74 Shuttle Owner’s Manual - PN 43301

4

3

10

4

6

6

3

7

5

9

8

9

7

1

NOTE: BUSHINGS ARE SHOWN FOR REFERENCE.

2

5

10

.YTQNOITPIRCSEDTRAPMETI
125735 CYLINDER 6.00X46.25 1
215995 MANIFOLD ASM DUAL T2A 5000PSI 1
326548 TUBE ASM 0.50 X 19.53 2
4C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2
5 0635 BUSHING 40DXR32 GARLOCK 4
6C2252 FTG ADAPT 8-10-F5OLO-S 2
7 1554 FTG ADAPT 8-F5OLO-S 2
819370 HOSE CLAMP 5.63-8.50 5416K39 2
918701 CLAMP PORT TUBE ZR518 2
10 C1854 FTG ADAPT 6-8 F5OLO-S 2

PN 25734

Main Cylinder (180-12-20/36) - PN 25734

Assembly Drawings 75

7

7

8

3

3

2

8

2

5

1

2

NOTE: BUSHINGS ARE SHOWN FOR REFERENCE.

5

2

6

4

.

YTQNOITPIRCSED

.ON TRA

P.ON

115822 MANIFOLD DOUBLE T11A 5000 PSI 1

6S-O

LO

5F

-6 TPADA GTF97202
2

52.32 X 83.0 MSA EBUT720913
1

83.25X00.5 REDNILYC97004
518701 CLAMP PORT TUBE ZR518 2
619369 HOSE CLAMP 4.13-7.00 5416K38 2
74381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4
8C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2

PN 19026

75

Main Cylinder (120-16-20) - PN 19026

Manual PN 43301

76 Shuttle Owner’s Manual - PN 43301

1

7

3

8

3

2

4

4

3

9

6

5

6

3

5

NOTE: BUSHINGS ARE SHOWN FOR REFERENCE

.YTQNOITPIRCSEDTRAPMETI

15

2.36X00.

5 REDNIL

YC

602

11
215822 MANIFOLD DOUBLE T11A 5000 PSI 1
3 0279 FTG ADAPT 6-F5OLO-S 6
4C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2
5 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4
618701 CLAMP PORT TUBE ZR518 2
719369 HOSE CLAMP 4.13-7.00 5416K38 2
821881 TUBE ASM 0.38 X 27.56 1
923095 TUBE ASM 0.38 X 33.59 1

PN 21882

Main Cylinder (138-18-20) - PN 21882

Assembly Drawings 77

8

3

7

2

4

4

3

3

6

6

1

5

8

3

5

NOTE: BUSHINGS ARE SHOWN FOR REFERENCE

.

YTQ

NOITPIRCSEDTRAPMETI
11894 CYLINDER 5.00X71.00 W/2.50 ROD 1
215822 MANIFOLD DOUBLE T11A 5000 PSI 1
30279 FTG ADAPT 6-F5OLO-S 6
4C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2
54381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4
618701 CLAMP PORT TUBE ZR518 2
719369 HOSE CLAMP 4.13-7.00 5416K38 2
821885 TUBE ASM 0.38 X 34.46 2

PN 21884

Main Cylinder (168-20-20) - PN 21884

77

Manual PN 43301

78 Shuttle Owner’s Manual - PN 43301

8

3

7

2

4

4

3

3

6

6

1

5

8

3

5

NOTE: BUSHINGS ARE SHOWN FOR REFERENCE

.

YTQ

NOITPIRCSEDTRAPMETI

11894 CYLINDER 5.00X71.00 W/2.50 ROD 1
215822 MANIFOLD DOUBLE T11A 5000 PSI 1
30279 FTG ADAPT 6-F5OLO-S 6
4C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2
54381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4
618701 CLAMP PORT TUBE ZR518 2
719369 HOSE CLAMP 4.13-7.00 5416K38 2
821885 TUBE ASM 0.38 X 34.46 2

PN 21884

Main Cylinder (190-24-20) - PN 21884

Assembly Drawings 79

9

5

5

3

4

6

7

4

8

10

2

4

1

7

NOTE: BUSHINGS ARE SHOWN FOR REFERENCE.

4

2

10

.

YTQNOITPIRCSE

DT

RAPME

TI

183.04X05.5 REDNILYC342521

24381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4

315822 MANIFOLD DOUBLE T11A 5000 PSI 1

6S-OLO5F-6 TPADA GTF97204

5 C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2

165.72 X 83.0 MSA EBUT188126

2815RZ EBUT TR

OP P

MALC107817

819369 HOSE CLAMP 4.13-7.00 5416K38 2

915888 TUBE ASM 0.38X7.22 TM14160 1

2THGIARTS TPN 8/1 KREZ2951c01

PN 25244

79

Main Cylinder (96-10-24) - PN 25244

Manual PN 43301

80 Shuttle Owner’s Manual - PN 43301

Chapter 8 - Troubleshooting

Troubleshooting 81

81

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 43301

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