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