STELLAR SHUTTLE MODEL 108-14-40 G ASSEMBLY AND

STELLAR SHUTTLE MODEL 108-14-40 G ASSEMBLY AND
STELLAR SHUTTLE
MODEL 108-14-40 G
ASSEMBLY
AND
INSTALLATION
MANUAL
Updated 11/4/97
Table of Contents
Hydraulic Hook Lift Specifications............................................................................2
Base Assembly ..........................................................................................................3
Dump Assembly ........................................................................................................4
Secondary Assembly..................................................................................................5
Tilt Assembly ............................................................................................................6
Installation Instructions..............................................................................................7
Mounting Kit .............................................................................................................8
Safety Valve Installation............................................................................................9
Rotary Valve Assembly ...........................................................................................10
25 Gallon Tank Assembly........................................................................................11
Hydraullic Assembly ...............................................................................................12
Controller Assembly................................................................................................13
Mounting Kit, 25Gallon...........................................................................................14
Miscellaneous Parts .................................................................................................14
Subframe .................................................................................................................15
Warranty..................................................................................................................16
Manual, 108-14-40 G
1
Hydraulic Hook Lift Specifications
Lifting Capacity:
40,000 pounds gross weight evenly distributed in, or on, body.
Container Length:
12.5-foot through 17-foot from front A-frame to rear of skid rails. Longer bodies may
be accommodated if full dump angle is not required (may require special bodymounted or extendable truck-mounted bumper to meet the Office of Motor Carrier
Safety (OMCS) Rear End Protection regulation 393.86)
Maximum Dump Angle: 55°
Operating Pressure:
4200 PSI maximum
Weight of Loader:
Loader weight not to exceed 4,800 pounds
Height of Loader:
Loader height not to exceed 11” as measured from top of truck frame to top of loader
rollers
Hook Height:
61.75-inches from bottom of skid rails to centerline of hook bar. Loader must be able
to pick up 10-inches below grade when mounted on a truck with 41” frame height.
Hydraulic Pump:
Direct-coupled high-pressure gear pump.
Hydraulic Control Valve: Stack-type valve mounted directed onto the oil reservoir.
Controls:
Dual manual levers with sealed cable actuators mounted in the truck cab to allow full
feathering of all loader functions.
Tilting Hook Assembly:
Loader must have pivoting type front tilt section (jib) to provide a low degree
loading/unloading angle. Hook to include automatic mechanical safety latch, which
disengages only when the container/body is in proper position to be picked up or
dropped off.
Tilt Cylinder:
Single 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.
Tilt Section Operation:
Loader must include a hydraulic lock-out device to prevent operation of the tilt section
while loader is in the dumping mode.
Lift/Dump Cylinder:
Single 7-inch bore with 3-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.
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 with front saddles to provide support for the
container while in the dump mode. These sections form this frame without the use of
mechanical latches, which rely on gravity, springs, or container/body mounted latches.
Rear Body Hold-Downs: Dual fixed-position hold-down devices mounted to the dump frame to secure the body
to the loader through all ranges of the dump mode. This must be accomplished
without the use of steel springs and/or hydraulic/air cylinders.
Rear Dump Hinge Pin:
2-1/2-inch diameter hardened, chrome-plated steel minimum
Pins & Bushings
All pins to be hardened chrome steel. All bushings to be of the permanently lubricated
variety. No grease zerks allowed.
Hoses & Hydraulic
Fittings:
All hoses and fittings are to be SAE: metrics not allowed. O-ring face seal
fittings to be utilized wherever possible.
Origin of Manufacture:
Loader to be designed and manufactured in the United States of America.
Manual, 108-14-40 G
2
Base Assembly
ITEM
1
2
3
4
5
Manual, 108-14-40 G
P/N
D0127
0636
0857
0635
2860
DESCRIPTION
Base Weldment
Snap Ring, 2.50"
Pin, 2.50x12.38
Bushing, 40DXRO32
Cylinder, 7.00x50.50 Mod
3
QTY
1
2
1
6
1
Dump Assembly
ITEM
1
2
3
4
5
P/N
2816
0360
0507
0866
1548
DESCRIPTION
Dump Weldment
Nut, .50-13 Nyloc
Cap Screw, .50-13x4.50
Collar, Roller
Thrust Washer, 3.01 Dia
Manual, 108-14-40 G
QTY
1
2
2
2
4
ITEM
6
7
8
9
10
4
P/N
0865
0813
0859
0636
0858
DESCRIPTION
Bushing, 48DXR32
Roller, 6.00
Pin, 3.00x50.88
Snap Ring, 2.50
Pin, 2.50x35.88
QTY
4
2
1
2
1
Secondary Assembly
ITEM
1
2
3
4
5
6
Manual, 108-14-40 G
P/N
2817
0066
0636
0861
0635
0860
DESCRIPTION
Secondary Weldment
Bushing, GF-3235-32
Snap Ring, 2.50
Pin, 2.50x20.13
Bushing,40DXR32
Pin, 2.50x27.88
5
QTY
1
4
4
1
2
1
Tilt Assembly
ITEM
1
2
3
4
5
P/N
0810
0246
2293
0812
0108
DESCRIPTION
Tilt Weldment
Snap Ring, 1.50
Latch, CS 40,000#
Latch, SS 40,000#
Snap Ring, 2.00
Manual, 108-14-40 G
QTY
1
2
1
1
8
ITEM
6
7
8
9
10
6
P/N
0864
0066
1748
0862
0863
DESCRIPTION
Pin, 2.00x13.00
Bushing, GSI-3235-32
Cylinder, 4.00x24.50
Pin, 2.00x10.50
Pin, 2.00x18.75
QTY
1
3
1
2
1
INSTALLATION INSTRUCTIONS
READ ALL INSTRUCTIONS BEFORE PROCEEDING
MOUNT PTO AND PUMP
MOUNT RESERVOIR VALVE COMBO TO TRUCK FRAME
CONNECT SUCTION AND PRESSURE TO TANK, VALVE BANK, AND PUMP
FILL OIL RESERVOIR TO 3” OF THE TOP (DEXTRON II IS RECOMMENDED)
INSTALL CONTROLLERS AND CABLES IN CAB
SET SHUTTLE ON THE TRUCK SO THAT ITS FRONT PLATE IS AT LEAST 2” BEHIND
THE CAB
SQUARE THE SHUTTLE ON THE TRUCK FRAME
DRILL 2-11/16” DIAMETER HOLES THROUGH THE TRUCK FRAME AT THE BACK
USING THE LOADER’S HOLES AS A GUIDE
USING 5/8” BOLTS, WASHERS AND NUTS, BOLT THE REAR OF THE LOADER TO THE
TRUCK FRAME
SHORTEN THE TRUCK FRAME TO ABOUT 2” FROM THE REAR TO THE LOADER
USING 1” BOLTS (3 ½” LONG), WASHERS, AND NUTS ATTACH THE 4 MOUNTING
CHANNELS TO THE 4 MOUNTS ON THE LOADER, AS SHOWN IN THE INSTALLATION
DRAWING ON PAGE 8
USING THE MOUNTING CHANNELS AS A GUIDE DRILL (4) 1-1/16” HOLES THROUGH
THE TRUCK FRAME
LOCATE (4) 1/2X8X16 PLATES, ITEM 5 ON PAGE 8, AND DRILL (2) 1-1/16” HOLES PER
PLATE THROUGH BOTH THE PLATE AND THE TRUCK FRAME. INSTALL 1” BOLTS
(3” LONG), WASHERS AND NUTS AND SECURE PATES TO THE TRUCK FRAME.
THEN WELD THE PLATES DIRECTLY TO THE BASE SECTION OF THE LOADER
USING 1” BOLTS (3” LONG), WASHERS, AND NUTS SECURE ALL TIE DOWNS TO THE
TRUCK FRAME AND THE LOADER
CONNECT HOSES TO VALVE BANK AS INDICATED IN HYDRAULIC ASSEMBLY
SET THE RELIEF VALVE TO 4200 PSI
OPERATE THE LOADER TO ELIMINATE AIR FROM THE SYSTEM
CHECK THE OIL LEVEL AND ADD OIL IF REQUIRED
Manual, 108-14-40 G
7
Mounting Kit
ITEM
1
2
3
4
5
P/N
2830
1443
1440
2829
3596
DESCRIPTION
Cap Screw, 1.00-8x3.50
Washer, 1.00 Flat
Tie Down, 40,000#
Nut, 1.00-8 Nyloc
Plate, 0.50x8.00x16.00
Manual, 108-14-40 G
QTY
4
32
4
16
4
ITEM
6
7
8
9
8
P/N
2826
0358
0399
1442
DESCRIPTION
Nut, 0.63-11 Nyloc
Washer, .63 SAE
Cap Screw, .63-11x2.00
Cap Screw, 1.00-8x3.00
QTY
2
4
2
12
Safety Valve Installation
Incorporated into the standard Stellar Hooklift is a safety valve designed to protect the dump section tabs from
being damaged by the tilt section.
It is important to locate this valve properly for safe operation of the Stellar Hooklift.
This cartridge is located in the main valve stack and MUST be placed off of the tilt cylinder retract port. The
following illustrations show a standard (driver side) installation and an optional (passenger side) installation.
Passenger side installations are common when mounting to cab-over chassis. All valve stacks are shipped for
standard (driver side) installations. The safety valve must be moved to the tilt cylinder retract port for all nonstandard installations. This valve will be switched with a load check plug when being moved to an alternate
position. A poppet and spring are located behind the safety valve and load check plugs. Care should be taken not
to lose these parts when modifying.
Valve stack for standard installation
Valve stack for non-standard installation
Manual, 108-14-40 G
9
Rotary Valve Installation
ITEM
1
*2
3
4
5
6
7
8
9
P/N
0482
0933
0347
1521
2478
2476
2479
0333
0480
DESCRIPTION
Cap Screw, 0.25-20x3.00
Body, Rotary Valve
Nut, 0.38-16 Nyloc
Rod, Rotary Valve
Nut, 0.31-24
Rod, 0.31-24 Threaded GR7
Clevis, 0.31 Pin
Nut, 0.25-20 Nyloc
Cap Screw, 0.25-20x1.00
QTY
2
1
1
1
2
12”
2
2
1
ITEM
10
*11
*12
13
14
15
16
17
P/N
0353
D0270
0979
3748
C6113
0977
D1638
0877
* Items are part of #17(0877- Rotary Valve Assembly)
Manual, 108-14-40 G
10
DESCRIPTION
Cap Screw, 0.38-16x2.00
Spool, Rotary Valve
Seal, U-Cup
Washer, Rotary Valve
Cotter, 0.094x1.00
O’Ring, 1.00x1.25x0.12
O’Ring, 1.12x1.38x0.12
Rotary Valve Assembly
QTY
1
1
2
1
2
1
1
1
25 Gallon Tank Assembly
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P/N
3501
C4825
C2126
C6328
C4694
D0024
C6228
C6225
C2375
C4952
C4866
C1585
C4944
C2142
0521
DESCRIPTION
Tank 25 Gal
Fitg, Bush Blk 2.50x.75
Plug, Magnet .75
Diffuser, 25-35 Gal
St. Elbow 1.25x90° Blk
Nipple, 1.25x14.00 Blk
Filter Head SF120-25 1.3
Filter Large, SE-10
Fitg, Reducer 0102-20-12
Fitg, Adapter 12 FLO-S
Fitg, Seal Lok 90 1J943-12-12
Hose, Hyd .75 381-12
Valve Bank, V-20
Fitg, Adapter 12-F5OLO-S
Washer, .25 Lock
Manual, 108-14-40 G
QTY
1
1
1
1
2
1
1
1
1
1
2
24"
1
1
3
ITEM
16
17
18
19
20
21
22
23
24
25
26
27
28
29
11
P/N
0339
C2252
C2376
C2248
C1855
1559
1563
C5552
C4955
C1053
C5930
C2151
C4282
C1180
DESCRIPTION
Cap Screw., .25-20x2.50
Fitg, Adapter 8-10 F5OLO-S
Fitg, Adapter 8-C6LO-S
Fitg, Adapter 6-C6LO-S
Fitg, Adapter 6-10 F5OLO-S
Fitg, Hose 1J943-8-8
Nipple, Barb 0588-20-20
Filter, Strainer TF-1220-0
Sight Gauge, .75 Npt Eye
Nipple, .75x2.50 Blk Pipe
Coupler, .75 Blk
Cap, Filler Breather
Muffler, Load Genie
Fitg, Adapter 8-12 F5OLO-S
QTY
3
2
2
2
2
1
1
1
1
2
2
2
2
1
Hydraulic Assembly
Valve Bank
Rotary Valve
Lift Cylinder
Tilt Cylinder
Suction Line
ITEM
1
2
3
4
5
P/N
1558
C0545
0279
C0546
1098
DESCRIPTION
Hose Ftg, 1JS43 8-8
Hose Ftg, 1JS43 6-6
Adapter, 6-F5OLO-S
Hose Ftg, 1J943 6-6
Hose Ftg, 10L 43-8-6
Manual, 108-14-40 G
Standard Pump
QTY
3
4
4
2
2
ITEM
6
7
8
9
10
12
P/N
1559
1554
C1123
D0549
C4747
DESCRIPTION
Hose Ftg, 1J943 8-8
Adapter, 8-F5OLO-S
Hose Clamp, 88 DB-20
Adapter, 16-8 F5OG5-S
Ftg, 4603-20-16
QTY
2
2
2
1
1
Controller Assembly
Controllers
Valve Bank
ITEM
1
2
3
4
5
6
7
P/N
2103
0608
0663
0333
0340
0528
0486
DESCRIPTION
Bracket Controller
Control Lever
Bracket, Decal
Nut, 0.25-20 Nyloc
Washer, 0.25 Flat
Cap Screw, 0.25-20x4.50
Cap Screw, 0.31-18x1.50
Manual, 108-14-40 G
QTY
1
2
1
2
4
2
4
ITEM
8
9
10
11
12
13
13
P/N
0343
0342
0607
0651
1056
0662
DESCRIPTION
Washer, 0.31 Flat
Nut, 0.31-18 Nyloc
Controller Cable
Decal, Operation
Nut, 0.25 Fine Thread
Cable Ends, 0.25
QTY
8
4
2
1
2
2
Mounting Kit,
25 Gallon Tank
ITEM
1
2
3
P/N
0501
0352
0360
DESCRIPTION
Cap Screw, 0.50-13x2.00
Washer, 0.50 Flat
Nut, 0.50-13 Nyloc
QTY
6
6
6
Miscellaneous Parts
P/N
D0045
Manual, 108-14-40 G
DESCRIPTION
Alarm, Backup
14
QTY
1
Subframe
Manual, 108-14-40 G
15
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
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