Stellar labs SHUTTLE 84-12-13 G Guida all'installazione

STELLAR SHUTTLE

MODEL 84-12-13 G

ASSEMBLY

AND

INSTALLATION

MANUAL

Updated 3/12/98

Manual, 8-12-13 G 1

Table of Contents

Hydraulic Hook Lift Specifications............................................................................2

Base Assembly..........................................................................................................3

Secondary Assembly..................................................................................................4

Tilt Assembly............................................................................................................5

Installation Instructions..............................................................................................6

Mounting Kit.............................................................................................................7

Safety Valve Installation............................................................................................8

7 Gallon Tank Assembly............................................................................................9

Mounting Kit, 7 Gallon Tank...................................................................................10

Hydraullic Assembly...............................................................................................11

Controller Assembly................................................................................................12

Subframe.................................................................................................................13

Warranty..................................................................................................................14

Manual, 8-12-13 G 2

Hydraulic Hook Lift Specifications

Lifting Capacity: 13,000 pounds gross weight evenly distributed in, or on, body.

Container Length: 10-foot through 13-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 body-mounted

or extendable truck-mounted bumper to meet the Office of Motor Carrier Safety

(OMCS) Rear End Protection regulation 393.86)

Maximum Dump Angle: 43°with a 10-foot body and 38° with a 13-foot body

Operating Pressure: 4200 PSI maximum

Weight of Loader: Loader weight not to exceed 1,500 pounds

Height of Loader: Loader height not to exceed 5 1/2” as measured from top of truck frame to top of

loader rollers

Hook Height: 35.63-inches from bottom of skid rails to bottom of hook bar. Loader must be able to

pick up 10-inches below grade when mounted on a truck with 36” 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 3-inch bore with 1-1/2-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.

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 prevent cylinder

collapse in case of hose failure.

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.

Pins & Bushings All pins to be hardened chrome steel. All bushings to be of the permanently lubricated

variety. No grease zerks allowed.

Hoses & Hydraulic All hoses and fittings are to be SAE: metrics not allowed. O-ring face seal

Fittings: fittings to be utilized wherever possible.

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

Manual, 8-12-13 G 3

Base Assembly

ITEM P/N DESCRIPTION QTY ITEM P/N DESCRIPTION QTY

1 5697 Base Weldment 1 7 4915 Pin, 2.00 x 15.44 2

2 0057 Cylinder, 5.00 x 40.38 1 8 0013 Roller Steel, 2.1877 2

3 0066 Bushing, GS-3235-32 8 9 0015 Collar, 2.01 x 3.50 x 2.88 2

4 0065 Pin, 2.00 x 9.00 1 10 0507 Cap Screw, 1/2-13 x 4.50 2

5 0108 Snap Ring, 2.00" 2 11 0505 Cap Screw, 1/2-13 x 3.50 2

6 1546 Thrust Washer, 2.01" Dia 4 12 0360 Nut, 1/2-13 Nylock 4

Manual, 8-12-13 G 4

Secondary Assembly

ITEM P/N DESCRIPTION QTY ITEM P/N DESCRIPTION QTY

1 5700 Secondary Weldment 1 6 4917 Pin, 2.00 x 8.75 2

2 0108 Snap Ring, 2" 2 7 4914 Pin, 2.00 x 14.50 1

3 0066 Bushing, GS-3235-32 2 8 0067 Bushing, GS-2426-24 4

4 0505 Cap Screw, 1/2-13 x 3.50 2 9 5145 Plate, 3.00" Hole 2

5 0360 Nut,1/2-13 Nylock 2 10 0359 Cap Screw, 1/2-13 x 1.50 2

Manual, 8-12-13 G 5

Tilt Assembly

ITEM P/N DESCRIPTION QTY ITEM P/N DESCRIPTION QTY

1 5694 Tilt, 120-15-13 1 8 0068 Bushing, GS-1618-24 2

2 0058 Cylinder, 3.00 x 14.50 1 9 0110 Snap Ring, 1.00 4

3 4919 Pin, Tear Drop, 1.50 x 3.50 2 10 0295 Latch, 12,000# 1

4 C0990 Cap Screw, 1/2-13 x 0.75 2 11 0298 Snap Ring, 0.75 1

5 0069 Bushing, GS-1618-16 1 12 5145 Plate, 3.00" Hole 4

6 0064 Pin, 1.00 Clevis 1 13 0359 Cap Screw, 1/2-13 x 1.50 4

7 4913 Pin, 1.00 x 7.50 1

Manual, 8-12-13 G 6

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 5/8” BOLTS, WASHERS, AND NUTS ATTACH THE 4 MOUNTING CHANNELS TO

THE 6 MOUNTS ON THE LOADER, AS SHOWN IN THE INSTALLATION DRAWING ON

PAGE 7

USING THE MOUNTING CHANNELS AS A GUIDE DRILL (6) 11/16” HOLES THROUGH

THE TRUCK FRAME

USING 5/8” BOLTS , 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, 8-12-13 G 7

Mounting Kit

ITEM P/N DESCRIPTION QTY

1 7053 Tie Down, 120-15-9 2

2 0358 Washer, 5/8 Flat 14

3 0526 Washer, 5/8 Lock 14

4 0399 Cap Screw, 5/8-11x2.00 14

5 0357 Nut, 5/8 14

6 7049 Tie Down, 120-15-9 4

Manual, 8-12-13 G 8

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 non-

standard 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, 8-12-13 G 9

7 Gallon Tank Assembly

ITEM P/N DESCRIPTION QTY ITEM P/N DESCRIPTION QTY

1 3503 Tank 7 Gal 1 13 C1180 Fitg, Adapter 8-12 F5OLO-S 2

2 C4825 Fitg, Bush Blk 2.50x.75 1 14 0521 Washer, .25 Lock 3

3 C2126 Plug, Magnet .75 1 15 0339 Cap Screw., .25-20x2.50 3

4 C6326 Diffuser, 5-17 Gal 1 16 C1855 Fitg, Adapter 6-10 F5OLO-S 4

5 C2242 St. Elbow .75x90°Blk 2 17 C2248 Fitg, Adapter 6-C6LO-S 4

6 C1054 Nipple, .75x6.00 Blk 1 18 1563 Nipple, Barb 0588-20-20 1

7 C6226 Filter Head ZAF-07-25-1 1 19 C5552 Filter, Strainer TF-1220-0 1

8 C6227 Filter Long, AE-10 1 20 C4955 Sight Gauge, .75 Npt Eye 1

9 C6014 Fitg, Adapter 8-12 FLO-S 1 21 C1053 Nipple, .75x2.50 Blk Pipe 2

10 1559 Fitg, Seal Lok 90 1J943-8-8 2 22 C5930 Coupler, .75 Blk 2

11 C2773 Hose, Hyd .50 381-8 18" 23 C2151 Cap, Filler Breather 2

12 C4944 Valve Bank, V-20 1 24 C4282 Muffler, Load Genie 2

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