stellar labs 120-16-20, Owner'S Manual

Page 1: ...Stellar Industries Inc 190 State Street PO Box 169 Garner IA 50438 800 321 3741 Fax 641 923 2811 www stellarindustries com Subject to Change without Notification 2021 Stellar Industries Inc Rev 1 PN 2...

Page 2: ...Page ii Stellar 120 16 20 Shuttle Owner s Manual Model 120 16 20 Manual Revisions Date of Revision Section Revised Description of Revision...

Page 3: ...ank Parts Drawing 13 Step 8 Install PTO and pump 14 Face Seal O Ring Size Chart 15 Step 9 Route hydraulic hoses 15 Hose Kit PN 81682 16 Power Beyond VDM8 Valve 17 Step 10 Route Electrical Components 1...

Page 4: ...ral Shuttle Hooklift Manual for details on these items 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 ne...

Page 5: ...handle a multitude of bodies ranging from flatbeds to recycling containers and dump bodies The Shuttle consists of four basic parts the base dump secondary and tilt sections Please take the time to fa...

Page 6: ...ce if hooklift load or vehicle becomes electrically charged Maintain safe clearance from high voltage power sources Never approach vehicle or load if equipment is near a high voltage power source 5583...

Page 7: ...s Cab to Axle 114 to 130 290 to 330 cm J Max Height When Loading 143 363 cm K Longest Body to Dump 204 518 cm L Max Height when Dumping 204 518 cm Operating Pressure 4200 psi Hydraulic Flow Not to exc...

Page 8: ...Page 2 Stellar 120 16 20 Shuttle Owner s Manual Acceptable Subframe Dimensions Model 120 16 20...

Page 9: ...6 20 Hooklift Each installation is considered unique so certain portions of this chap ter may or may not apply to your direct application If a question should arise during the installation process ple...

Page 10: ...oads Always replace shear bolts with identical grade Fasteners should be replaced with the same or higher grade If higher grade fasteners are used these should only be tightened to the strength of the...

Page 11: ...ng system Be sure to square the hooklift on the truck frame to allow for proper measurement The front of the hooklift needs to be at least 2 50 behind the cab or any equipment mount ed behind the cab...

Page 12: ...Note The mounting plates are designed with multiple slots to offer more flexibility in mount ing locations Additional holes may not be added Step 2 Bolt tie down castings to mounting plates ITEM PART...

Page 13: ...ck frame ITEM PART DESCRIPTION QTY 1 24868 NUT 0 63 11 HHGR8 NYLOCK ZY 8 2 C5902 WASHER 0 63 SAE FLAT YELLOW GR8 16 3 C1026 CAP SCR 0 63 11X2 50 HHGR8 ZY 8 2 2 1 3 2 2 Using the holes in the tie down...

Page 14: ...egulations for acceptable placement Modify the truck frame as necessary so that it ends 2 from the rear of the hooklift Step 5 Install bumper 2 00 See brand specific installation instructions Before d...

Page 15: ...G 16 8 MORB FORB STRAIGHT REDUCER 1 9 17767 HOSE SUCT 1 25 10FT 1 10 C0075 HOSE CLAMP HC125 2 11 C4747 FTG 20 16 HB MAORB 45 1 12 10094 GAUGE OIL LF 2 5 0 5000 BM 1 13 25630 FTG 10 4 MORB FP STRAIGHT...

Page 16: ...8 D0549 FTG 16 8 MORB FORB STRAIGHT REDUCER 1 9 17767 HOSE SUCT 1 25 10FT 1 10 C0075 HOSE CLAMP HC125 2 11 C4747 FTG 20 16 HB MAORB 45 1 12 10094 GAUGE OIL LF 2 5 0 5000 BM 1 13 25630 FTG 10 4 MORB FP...

Page 17: ...13002 DECAL HYD OIL SPECIFICATION MOBIL 1 5 86118 RSRVR 10GAL K MODEL W TANK TOP FILTER 1 6 86123 FILTER TANK TOP SFM 12 SAE 1 7 5591 WASHER 0 31 SAE FLAT YELLOW GR8 2 8 0420 CAP SCR 0 31 18X0 75 HHG...

Page 18: ...ORT RELIEF HERE WHEN PN S FROM THE FOLLOWING LIST ARE USED TILT ASM S PN 83048 USES PORT RELIEF PN 69172 PORT RELIEF VDM8 3600 PSI PN 85778 USES PORT RELIEF PN 26184 PORT RELIEF VDM8 3300 PSI NOTE INS...

Page 19: ...anual Page 13 Valve Bank Parts Drawing SPOOL SPRING KIT WITH COVER PN 43776 AIR ACTUATOR PN 26566 HANDLE ASM OUTSIDE CTRLS WITH HANDLE PN 30381 SPOOL RETAINER PN 61522 MAIN RELIEF VALVE PN 28510 HANDL...

Page 20: ...fied by looking from the front of the truck to the rear of the truck Use the brand specific PTO Pump installation instructions If the directions are not quite clear contact Stellar Customer Service or...

Page 21: ...e Power Beyond feature for additional function see Power Beyond VDM8 Valve later in this chapter for further details Notes on hose line routing Protect these lines with hose wrap when necessary Keep t...

Page 22: ...Page 16 Stellar 120 16 20 Shuttle Owner s Manual PRESSURE FROM PUMP RETURN TO TANK Hose Kit PN 81682...

Page 23: ...portion of cavity to activate the power beyond fea ture Use thread sealer tape sealers not recommended 3 The Power Beyond feature is now activated and will divert oil to alternate system via the port...

Page 24: ...ARANCE WHITE BROWN TAGLIGHT BROWN TAGLIGHT BROWN TAGLIGHT BROWN LHTURN STOP REDLIGHT WHITE BROWN YELLOW RHTURN STOP REDLIGHT WHITE BROWN YELLOW RHTURN STOP REDLIGHT WHITE BROWN YELLOW BACKUP WHITELIGH...

Page 25: ...NTROL CABLES TO VALVE BANK 3 4 2 1 8 7 6 8 9 10 11 8 8 9 5 At Valve Installation ITEM PART DESCRIPTION QTY 1 38351 VALVE CTRL CONSOLE 3LEVER RVC 1 2 37475 CTRL CNTR LOCK LEFT BEND 1 3 37476 CTRL CNTR...

Page 26: ...8 GROMMET 2 50ODX0 125X0 25ID 1 9 35211 PTO AIR REGULATOR 378414 1 10 45333 FTG 4 2 PC DOT MP STRAIGHT 4 11 C5934 FTG 4 4XCLOSE MP MP NIPPLE STRAIGHT BLK 1 12 C1065 BUSHING 0 50X0 25 BLK 1 13 86116 PL...

Page 27: ...DUMP UP LIGHT WIRE ITEM PART DESCRIPTION QTY 1 45907 SWITCH REMOTE KP60 1 2 30472 CAP SCR 10 24X1 25 BTNHD SS 3 3 D0178 WASHER 10 SAE FLAT 6 4 26034 NUT 10 24 HH NYLOC 3 ITEMS NOT SHOWN C0073 TERML 16...

Page 28: ...HE PACKAGED INSTALLATION INSTRUCTIONS ITEM PART DESCRIPTION QTY 1 4467 FENDER SINGLE 2 TON PLASTIC W 7633 2 2 86004 FLAT 0 75X3 00X5 38 CR W HOLES 4 3 5733 MTG KIT OFFSET POLY FENDER FLEET 2 4 80044 U...

Page 29: ...GO 6 00X16 50 06 55832 2 DECAL DANGER ELECTROCUTION HOOK 07 68024 1 DECAL WARNING UNTRAINED OPERATOR ITEM PART No QTY DESCRIPTION Rev Level O Date 08 16 21 Changes Separate chassis decals from hooklif...

Page 30: ...79983 1 DECAL DANGER ELECTROCUTION 10 91219 1 DECAL HITCH CAPACITY 30K 09 91220 1 DECAL HITCH CAPACITY 16K 11 68222 1 DECAL HITCH CAPACITY 90K 12 45697 1 ENGINE SPEED PTO CAUTION 13 69463 1 DECAL BACK...

Page 31: ...oil level and add oil if needed When checking hydraulic oil level make certain that all system cylinders are fully retracted Calibrate dump light system Be sure to check all clearances Be sure that re...

Page 32: ...d release the jam nut using a 13 mm wrench 4 Adjust the system relief pressure using 4 mm allen wrench See chart on previous page Clockwise increases pressure counter clockwise decreases pressure 5 On...

Page 33: ...70294 COLLAR 0 28X0 75X0 38 UHMW 2 10 77784 PLATE MNT BRKT STOP SYSTEM CS HOLES 1 11 70293 LEVER PLUNGER VALVE FINGER 1 12 77785 CAP SCR 0 25 20X1 75 FHSH 6 13 53853 VALVE PLUNGER VILLA HYD NORMALLY...

Page 34: ...K 4 10 22227CR PIN 2 00X25 25 1 11 31091CR PIN 2 50X16 625 2 12 1547 THRUST WASHER 2 51DIA UHMW 12THK 6 13 c1592 ZERK 1 8 NPT STRAIGHT 4 14 44508 COLLAR 2 51X3 50X2 56 2 15 23930 COLLAR 2 51X3 50X1 00...

Page 35: ...1 19026 CYLINDER ASM 5 X 52 38 1 2 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 14 3 22286CR PIN 2 00X16 00 1 4 24610CR PIN 2 00X16 88 SR D T 1 5 0377 MACHY WASHER 2 00ID 14GA 2 6 81462 SECONDARY 120 16 20K...

Page 36: ...2 00X0 63 YZ 1 4 0427 MACHY WASHER 2 00ID 10GA 6 5 0108 SNAP RING 2 00 7200 200 2 6 24249CR PIN 2 00X15 88 SR 1 7 C0953 CAP SCR 0 38 16X4 00 HHGR5 2 8 0347 NUT 0 38 16 HH NYLOC 2 9 24250CR PIN WLDMT 2...

Page 37: ...6 3 4380 BUSHING 32DXR24 2 00X1 50 GARLOCK 2 4 24610CR PIN 2 00X16 88 SR D T 1 5 28766 LATCH CS 40000K 1 6 8457 CAP SCR 0 50 13X1 00 SS 1 7 8818 PIN CAP 0 55X2 00X0 63 YZ 1 8 24250CR PIN WLDMT 2 00X1...

Page 38: ...C S E D O N T R A P O N 1 15822 MANIFOLD DOUBLE T11A 5000 PSI 1 6 S O L O 5 F 6 T P A D A G T F 9 7 2 0 2 2 5 2 3 2 X 8 3 0 M S A E B U T 7 2 0 9 1 3 1 8 3 2 5 X 0 0 5 R E D N I L Y C 9 7 0 0 4 5 1870...

Page 39: ...ner s Manual Page 33 Tilt Cylinder PN 23159 2 2 1 3 BUSHINGS SHOWN AS REFERENCE ITEM NO QTY PART NO DESCRIPTION 1 1 0907 CYLINDER 4 00X14 50 2 3 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 3 2 0279 FTG 6 6...

Page 40: ...OWERS BRACKET PN 26293 IS NOT USED B C COMPONENTS ARE TO BE INSTALLED IN TOWER ASSEMBLY ITEM PART DESCRIPTION QTY 1 26293 PLATE TAB ALARM MNT 1 2 0491 CAP SCR 0 31 18X4 00 HHGR5 2 3 0343 WASHER 0 31 U...

Page 41: ...RE THE HARNESS RUNS TO THE FRONT OF THE TRUCK ATTACHING TO THE BASE OR INBETWEEN THE TRUCK FRAME RAILS TO BE CONNECTED TO WIRE HARNESS PN 26291 DETAIL A SCALE 1 4 1 TO SET TAB ALARM ADJUST TO BE JUST...

Page 42: ...Page 36 Stellar 120 16 20 Shuttle Owner s Manual Optional Tab Alarm Wire Harness PN 26291...

Page 43: ...Stellar 120 16 20 Shuttle Owner s Manual Page 37 Optional Proximity Switch Wire Harness PN 26416...

Page 44: ...Subject to Change without Notification 2021 Stellar Industries Inc...