stellar labs 96-10-24, Owner'S Manual

Page 1: ...lar 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 2017 Stellar Industries Inc Last Revision...

Page 2: ...Page ii Stellar 96 10 24 Shuttle Owner s Manual Model 96 10 24 Manual Revisions Date of Revsion Section Revised Description of Revision...

Page 3: ...rols PN 87078 9 Reservoir Assembly Air Controls PN 87081 10 Valve Bank Parts Drawing 11 Step 8 Install PTO and pump 12 Face Seal O Ring Size Chart 13 Step 9 Route hydraulic hoses 13 Hose Kit PN 81916...

Page 4: ...al 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 nec...

Page 5: ...andle 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 fam...

Page 6: ...49 389 6 558 104 5 427 495 5 108 247 6 065 942 5 082 417 CANADIAN PATENTS 6 749 389 5 108 247 WARNING 25627 Rev B Moving parts can crush and cut Keep hands and arms clear when operating equipment Crus...

Page 7: ...Cab to Axle 84 to 102 231 to 259 cm J Max Height When Loading 134 340 cm K Longest Body to Dump 174 442 cm L Max Height when Dumping 183 465 cm Operating Pressure 4200 psi Hydraulic Flow Not to exceed...

Page 8: ...Page 2 Stellar 96 10 24 Shuttle Owner s Manual Acceptable Subframe Dimensions Model 96 10 24 PN 3123...

Page 9: ...24 Hooklift Each installation is considered unique so certain portions of this chapter may or may not apply to your direct application If a question should arise during the in stallation process plea...

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: ...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 Step 1 Set the hooklift onto the truck frame...

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: ...k 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 c...

Page 14: ...gulations 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 dr...

Page 15: ...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 1 14...

Page 16: ...49 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 STRA...

Page 17: ...anual Page 11 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 18: ...ied 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 19: ...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 20: ...Page 14 Stellar 96 10 24 Shuttle Owner s Manual PRESSURE FROM PUMP RETURN TO TANK Hose Kit PN 81916...

Page 21: ...ortion 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 s...

Page 22: ...r source when wiring BLOCK COLORED WHITE REARCLEARANCE BROWN WHITE BACK UPALARM WHITE BLACK REDCLEARANCE WHITE BROWN REDCLEARANCE WHITE BROWN TAGLIGHT BROWN TAGLIGHT BROWN TAGLIGHT BROWN LHTURN STOP R...

Page 23: ...CTRL CONSOLE 3LEVER RVC 3 Section 1 2 37475 CTRL CNTR LOCK LEFT BEND 1 3 37476 CTRL CNTR LOCK NO BEND 1 4 37474 CTRL CNTR LOCK RIGHT BEND 1 5 25933 BRKT CONTROLLER DECAL 1 6 37469 CABLE CONN KIT FOR...

Page 24: ...1 9 87688 LID CONTROL TOWER 2 SECT HOOKLIFT 1 10 16948 GROMMET 2 50ODX0 125X0 25ID 1 11 35211 PTO AIR REGULATOR 378414 1 12 45333 FTG 4 2 PC DOT MP STRAIGHT 4 13 C5934 FTG 4 4XCLOSE MP MP NIPPLE STRAI...

Page 25: ...R5 NYLOC 2 7 CLAMP CLAMP 2 00 BLK VINYL 1 8 BRACKET BRKT 10GAX2 00X24 00 1 Note The bracket can be bent cut trimmed etc to allow fastening to the structure under the passenger seat If the chassis floo...

Page 26: ...CRIPTION 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 BOLT 0 38X4 00X4 00 ZP 8 5 0347 NUT 0 38 16 HHGR5...

Page 27: ...09 TERML 12 10X 31 RING X 1 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 NOTE BRACKET SHOWN AS...

Page 28: ...nds and arms clear when operating equipment Crush Hazard 26134 Rev A Operating hooklift when dump tabs are not properly fastened can result in death or serious injury Inspect tabs daily Immediately re...

Page 29: ...il 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 rel...

Page 30: ...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 31: ...6 9 0220 CAP SCR 0 25 20X1 50 HHGR5 3 10 0340 WASHER 0 25 USS FLAT 3 11 0521 WASHER 0 25 LOCK 3 12 0532 CAP SCR 0 38 16X3 75 HHGR5 2 13 0347 NUT 0 38 16 HHGR5 NYLOC 2 14 58052 SET SCREW 0 50 13X0 50 1...

Page 32: ...GARLOCK 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 23930 COLLAR 2 51X3 50X1 00 2 14 32086 CAP SCR 0 38 16X4 25 HHGR5 4 15 0347 NUT 0 38 16...

Page 33: ...81870 SECONDARY 108 11 20K GEN2 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 21880 CYLINDER ASM 5 00X40 25 1 6 2257 SNAP RING INSIDE 2...

Page 34: ...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 35: ...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 36: ...L Y C 3 4 2 5 2 1 2 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 4 3 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 4 5 C4961 PLUG STR HOLLOW HEX 0 38 6 HP5ON 2 1 6 5 7 2 X 8...

Page 37: ...ner s Manual Page 31 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 38: ...Subject to Change without Notification 2017 Stellar Industries Inc...