stellar labs 108-12 Flex User manual

108-12 Flex Hooklift
Owner’s Manual
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Subject to Change without Notification.
© 2021 Stellar Industries, Inc.
Rev 1
PN 34624
Installation • Assembly Drawings • Parts

Page ii | Stellar®108-12 Flex Owner’s Manual
The serial tag should be located on the right side (passenger side) of the base assembly:
FOR SERVICE ON THIS EQUIPMENT
CONTACT:
STELLAR INDUSTRIES, INC.
190 STATE STREET,GARNER, IA 50438
641-923-3741
800-321-3741
4214
35234
Proudly Designed
and Manufactured
in the USA by
DANGER
Electrocution Hazard
Death or serious injury will result from
inadequate clearance 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.
55832 - RevA
MODELNO.SERIALNO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENTINFORMAT ION
http://www.stellarindustries.com/ip
WARNING
25627 - Rev B
Moving parts can crush
and cut.
Keep hands and arms
clear when operating
equipment.
Crush Hazard
Serial Tag Location
MODEL NO. SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENT INFORMATION
http://www.stellarindustries.com/ip

Stellar®108-12 Flex Owner’s Manual | Page iii
Table of Contents
Serial Tag Location .....................................................................................................................................................................................ii
Introduction iv
Hooklift Nomenclature.............................................................................................................................................................................. v
Chapter 1 - Specifications..............................................................................................................................................................................1
Model 108-12 Flex Specifications............................................................................................................................................................. 1
Acceptable Subframe Dimensions - Model 108-12 Flex....................................................................................................................... 2
Flex36 Grease Zerk Locations................................................................................................................................................................... 2
Chapter 2 - Installation ...................................................................................................................................................................................3
General Installation................................................................................................................................................................................... 3
Installer Notice ....................................................................................................................................................................................... 3
Torque Data Chart ................................................................................................................................................................................ 4
Installation Note..................................................................................................................................................................................... 5
Step 1: Set the hooklift onto the truck frame. ........................................................................................................................................ 5
Step 2A (Non-F550/RAM5500): Bolt tie-down castings to mounting plates........................................................................................ 6
Step 3A (Non-F550/RAM5500): Drill mounting holes into frame rail. .................................................................................................... 7
Step 4A (Non-F550/RAM5500): Bolt tie-down castings to truck frame................................................................................................ 7
Step 2B (F550): Bolt tie-down castings to mounting plates. ................................................................................................................. 9
Step 3B (F550): Drill mounting holes into frame rail.............................................................................................................................. 10
Step 4B (F550): Bolt tie-down castings to truck frame......................................................................................................................... 10
Step 2C (RAM5500): Bolt tie-down castings to mounting plates. ...................................................................................................... 12
Step 3C (RAM5500): Drill mounting holes into frame rail..................................................................................................................... 13
Step 4C (RAM5500): Bolt tie-down castings to truck frame. .............................................................................................................. 13
Step 5: Install bumper.............................................................................................................................................................................. 15
Step 6: Install tarper tower (If applicable)............................................................................................................................................ 15
Step 7: Install hydraulic reservoir and valve bank. .............................................................................................................................. 15
Reservoir Assembly (Cable Controls) - PN 87080 ............................................................................................................................. 16
Reservoir Assembly (Air Controls) - PN 87083.................................................................................................................................... 17
Reservoir Assembly (Electric Controls) - PN 97093 ........................................................................................................................... 18
Reservoir Subassembly - PN 86117..................................................................................................................................................... 19
Side Mount Reservoir Subassembly - PN 88147 ................................................................................................................................ 20
Valve Bank Parts Drawing................................................................................................................................................................... 21
Step 8: Install PTO and pump................................................................................................................................................................. 22
Face Seal/O-Ring Size Chart.................................................................................................................................................................. 23
Step 9: Route hydraulic hoses................................................................................................................................................................ 23
Hose Kit - PN 72355 .............................................................................................................................................................................. 24
Power Beyond VDM8 Valve ............................................................................................................................................................... 25
Step 10: Route Electrical Components................................................................................................................................................. 26
Step 11: Install cab and PTO controls. .................................................................................................................................................. 27
Cable Controls..................................................................................................................................................................................... 27
2 Section 120 in Loader w/Ram Mount - Ford F550 ......................................................................................................................... 28
Ram Mount Adjustment Instructions - Ford F550.............................................................................................................................. 29
2 Section 120 in Loader w/Ram Mount - RAM 5500 ........................................................................................................................ 30
Ram Mount Adjustment Instructions - RAM 5500 ............................................................................................................................. 31
Air Controls ........................................................................................................................................................................................... 32
Electric Controls................................................................................................................................................................................... 33
Step 12: Install Hoist Up Light Sensor - PN 83115................................................................................................................................... 34
Step 13: Install mud flaps and fenders. ................................................................................................................................................. 35
Poly Fender Assembly - PN 15681 ...................................................................................................................................................... 35
Steel Fender Assembly - PN 89528..................................................................................................................................................... 35
Step 14A: Apply Hooklift Assembly Decals........................................................................................................................................... 36
Step 14B: Apply Chassis Decals ............................................................................................................................................................. 37
Step 15: Fill reservoir and activate hydraulic flow. .............................................................................................................................. 38
Step 16: Operate hooklift. ...................................................................................................................................................................... 38
Pressure vs. Capacity.......................................................................................................................................................................... 38
Set System Relief Pressure ................................................................................................................................................................... 39
Chapter 3 - Assembly Drawings ..................................................................................................................................................................41
Base Assembly - PN 41827 ...................................................................................................................................................................... 41
Dump Assembly - PN 34247.................................................................................................................................................................... 42
Secondary Assembly - PN 34249 ........................................................................................................................................................... 43
Main Cylinder Assembly - PN 33462 ...................................................................................................................................................... 46
Tilt Cylinder - PN 35169 ............................................................................................................................................................................ 46
Bumper Assembly - PN 81300................................................................................................................................................................. 47
Optional Gladhand Assembly - PN 81908 ............................................................................................................................................ 47
Optional Tab Alarm Kit - PN 43120......................................................................................................................................................... 48
Optional Tab Alarm Wire Harness - PN 26291....................................................................................................................................... 49
Optional Proximity Switch Wire Harness - PN 26416............................................................................................................................. 50

Page iv | Stellar®108-12 Flex Owner’s Manual
Introduction
A copy of this manual is provided with every hooklift and can be found in the hard plastic
manual case that is installed on the chassis. A copy of this manual shall remain with the
hooklift at all times.
Throughout the manual, three signal words will be used to bring attention to important
items:
A NOTICE signal word indicates a practice not related to physical injury.
A WARNING signal word indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
A DANGER signal word indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Information contained within this manual does not cover operation, maintenance, or trou-
bleshooting. Please refer to the General 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 necessary for product improve-
ment or commercial/production purposes. This right is kept with no requirement or obliga-
tion 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 Depart-
ment by phone at 800-321-3741 or email at [email protected].
WARNING
NOTICE
DANGER
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 [email protected]
Order Parts [email protected]
Warranty Information [email protected]

Stellar®108-12 Flex Owner’s Manual | Page v
Hooklift Nomenclature
The Stellar®Shuttle is a hydraulic, body-loading device when mounted on a truck chassis. It
can 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 familiarize yourself with the various components. Knowing the proper ter-
minology is necessary to get the full benefit of this manual.
HOOKLIFT
BASE
DUMP
SECONDARY
TILT

Page vi | Stellar®108-12 Flex Owner’s Manual
This page intentionally left blank.

Stellar®108-12 Flex Owner’s Manual | Page 1
A
G
E
I
D
H
C
L
J
B
K
Chapter 1 - Specifications
Model 108-12 Flex Specifications
Model 108-12 Flex
Lifting/Dumping Capacity Up to 16,000 lbs (7,257 kg)
ADump Angle 54°
BLowest hook Height 27" (69 cm)
CEffective Length 142" (361 cm)
DTruck Frame Height 36" (92 cm)
EHooklift Height 41.5" (106 cm)
GHooklift Length 154" (391 cm)
HHooklift Center of Gravity 68" (173 cm)
IChassis Cab to Axle 108" to 120" (2,743 to 3,048 cm)
JMax Height When Loading 135" (343 cm)
KLongest Body to Dump 180" (457 cm)
LMax Height when Dumping 185" (470 cm)
Operating Pressure Variable - See Install Chapter
Hydraulic Flow Not to exceed 16 GPM
Shipping Weight 1,615 lbs (733 kg)
Hook Height 35.63" (90.5 cm)
Shipping Dimensions (LxHxW) 154" x 49" x 47"
Minimum Truck GVWR 16,000
RBM 510,000

Page 2 | Stellar®108-12 Flex Owner’s Manual
Acceptable Subframe Dimensions - Model 108-12 Flex
QTY. 1 BASE END OF TILT CYL
QTY. 1 BASE END OF LIFT CYL
QTY. 2
QTY. 1
QTY. 2
QTY. 2
QTY. 2
Note: Grease After Every 100 Cycles.
Flex36 Grease Zerk Locations

Stellar®108-12 Flex Owner’s Manual | Page 3
Chapter 2 - Installation
Installer Notice
According to Federal Law (49 cfr part 571), each final-stage manufacturer shall complete the vehi-
cle in such a manner that it conforms to the standards in effect on the date of manufacture of the
incomplete vehicle, the date of final completion, or a date between those two dates. This require-
ment 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, 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.
Please reference the Code of Federal Regulations, title 49 - Transportation, Volume 5 (400-999), for
further information, or visit http://www.gpoaccess.gov/nara/index.html for the full text of Code of
Federal Regulations.
General Installation
This chapter is designed to serve as a general guide for the installation of a Stellar®Flex
108-12 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, please contact Stellar Customer Service at [phone].
PTO and Pump installation instructions are provided by the corresponding manufacturers.
For more information on which PTO and Pump fit your application, please contact your
local Stellar Distributor or Stellar Customer Service.
Do not install this hooklift on a chassis not capable of handling the loads
imposed on it. Failure to do so may result in serious injury or death.
Do not weld or drill holes into the side wall of the base tubes.
Hooklift Mounting and Assembly
Study names and locations of the parts and familiarize yourself with the hooklift before
starting the assembly . Reading the step-by-step instructions that follow will be helpful.
Assembly
Select an area for assembly that will be large enough to accommodate the completed
unit. The surface of the work area should be as level as possible. Use the proper hand
tools to ensure proper bolt tightness. Refer to the torque data chart in this chapter for the
recommended torque values for different sizes of bolts.
Model Number
Know the model number of the Stellar®Hooklift being mounted. Use this model number
whenever referring to the assembly or parts listing pages. The number is stamped on the
name plate which is located on the front frame member.
WARNING
NOTICE

Page 4 | Stellar®108-12 Flex Owner’s Manual
When using the torque data in the
chart, the following rules should be
observed:
• Bolt manufacturer’s particular
specifications should be consulted
when provided.
• Flat washers of equal strength
must be used.
• All torque measurements are giv-
en in foot-pounds. To convert to
inch-pounds, multiply by 12.
• Torque values specified are for
bolts with residual oils or no special
lubricants applied. If special lubri-
cants of high stress ability, such as
Never-Seez compound graphite
and oil, molybdenum disulphite,
colloidal copper or white lead are applied, multiply the torque values in the charts by the
factor .90. The use of Loctite does not affect the torque values listed above.
• Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
• Do not use these values if a different torque value or tightening procedure is given for
a specific application. Torque values listed are for general use only. Check tightness of
fasteners periodically.
• Sheer bolts are designed to fail under predetermined loads. 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 original.
• Tighten plastic insert or crimped steel-type lock nuts to approximately 110 percent of the
dry torque values shown in the chart below, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full torque value. Note: “Lubricated”
means coated with a lubricant such as engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without lubrication. Tighten lubricated bolts
to approximately 80% of dry bolts.
Size Bolt DIA Plain Plated Plain Plated Plated
(DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb)
5/16-18 0.3125 17 13 25 18 22
3/8-16 0.3750 31 23 44 33 39
7/16-14 0.4375 49 37 70 52 63
1/2-13 0.5000 75 57 105 80 96
9/16-12 0.5625 110 82 155 115 139
5/8-11 0.6250 150 115 220 160 192
3/4-10 0.7500 265 200 375 280 340
7/8-9 0.8750 395 295 605 455 549
1-8 1.000 590 445 910 680 823
1 1/8-7 1.1250 795 595 1290 965 1167
1 1/4-7 1.2500 1120 840 1815 1360 1646
1 3/8-6 1.3750 1470 1100 2380 1780 2158
1 1/2-6 1.500 1950 1460 3160 2370 2865
GRADE 5 GRADE 8 GRADE 9
Torque Data Chart

Stellar®108-12 Flex Owner’s Manual | Page 5
Step 1: Set the hooklift onto the truck frame.
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.
Installation Note
• Visually inspect the truck for any potential issues. For example: Clearance problem, cross
members extending too high, insufficient room in front of the hooklift for tarpers, exhaust
manifolds, etc., or insufficient room in the rear to allow for bumper selection. Note: The
main lift cylinder and counter balance valve manifold hang slightly below the bottom of
the hooklift, see drawing below. Note: Stellar Industries recommends allowing 12” behind
the start of clear truck frame for installation of a tarper 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.
1.32 23.41
2.50

Page 6 | Stellar®108-12 Flex Owner’s Manual
Bolt each tie-down casting to the underside of each mounting plate located on the out-
side of the main rails of the base (both sides):
Note: The mounting plates are designed with multiple slots to offer more flexibility in
mounting locations. Additional holes may not be added.
Step 2A (Non-F550/RAM5500): Bolt tie-down castings to mounting plates.
ITEM PART DESCRIPTION QTY.
3 D0143 TIE DOWN CHANNEL 6
2
C1026 CAP SCR 0.63-11X2.50 HHGR8 12
1
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 24
424868
NUT 0.63-11 HHGR8 NYLOCK ZY 12
11
2
11
3
4
1
3
4
1
2
1
3
4
1
2
1
1

Stellar®108-12 Flex Owner’s Manual | Page 7
Using the holes in the tie-down castings as guides, drill 11/16” mounting holes
through the truck frame as shown (Both Sides):
Step 3A (Non-F550/RAM5500): Drill mounting holes into frame rail.
11/16"
11/16"
Bolt each tie-down angle to the truck frame (both sides):
Step 4A (Non-F550/RAM5500): Bolt tie-down castings to truck frame.
ITEM PART DESCRIPTION QTY.
3 C1026 CAP SCR 0.63-11X2.50 HHGR8 6
4
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 12
5 24868
NUT 0.63-11 HHGR8 NYLOCK ZY 6
4
3
5
4
4
3
5
4
4
3
5
4
Note: See torque chart at beginning of chapter
for proper bolt tightness.

Page 8 | Stellar®108-12 Flex Owner’s Manual
Non-F550/RAM5500 Mounting Kit - PN 23700
PN 23700
ITEM PART DESCRIPTION QTY.
1 D0143 TIE DOWN CHANNEL 6
2
C1026 CAP SCR 0.63-11X2.50 HHGR8 12
3
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 24
4 24868
NUT 0.63-11 HHGR8 NYLOCK ZY 12
3
3
2
2
1
3
4
4
3
3
2
2
1
3 4
4
3
3
2
2
1
3 4
4
3

Stellar®108-12 Flex Owner’s Manual | Page 9
Bolt each tie-down casting to the underside of each mounting plate located on the
outside of the main rails of the base (both sides).
Note: Trim chassis frame stud bolts flush with truck frame if the interfere with mounts.
Note: The mounting plates are designed with multiple slots to offer more flexibility in
mounting locations. Additional holes may not be added.
Note: Tack spacer (PN 91312) to bottom of base.
Note: Use 2 sets of hardware in order to attach spacer (PN’s 91311 & 91313) to the hooklift
base
Step 2B (F550): Bolt tie-down castings to mounting plates.
4
5
6
7
5
9
5
6
8
5
6
6
5
4
5
6
7
5
9
5
6
7
5
7
5
5
6
7
5
5
6
8
5
6
7
5
5
6
7
5
ITEM PART DESCRIPTION QTY.
494991 ANGLE 4.00X3.00X0.50WX7.00 W/SLOTS 2
5
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 36
624868
NUT 0.63-11 HHGR8 NYLOC 18
7
C1026 CAP SCR 0.63-11X2.50 HHGR8 18
8
D0143 TIE DOWN CHANNEL 2
997423
ANGLE FORMED FLEX BASE MNT SS 1
PN 91310
2
NOTE: TACK SPACER (PN 91312) TO BOTTOM OF BASE
.13
TYP 4

Page 10 | Stellar®108-12 Flex Owner’s Manual
Bolt each tie-down angle to the truck frame (both sides):
Step 4B (F550): Bolt tie-down castings to truck frame.
ITEM PART DESCRIPTION QTY.
3 C1026 CAP SCR 0.63-11X2.50 HHGR8 6
4
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 12
5 24868
NUT 0.63-11 HHGR8 NYLOCK ZY 6
4
3
5
4
4
3
5
4
4
3
5
4
Note: See torque chart at beginning of chapter
for proper bolt tightness.
Using the holes in the tie-down castings as guides, drill 11/16” mounting holes
through the truck frame as shown (Both Sides):
Step 3B (F550): Drill mounting holes into frame rail.
RE
CO
MMENDED M
O
UNTIN
G
CO
NFI
G
URATI
O
N F
O
R
20
17-1
8
F55
0
C
HA
SS
I
S
4
9
3
2
N
OTE: USE 2 SETS OF HARDWARE IN ORDER TO ATTACH
S
PACERS (PN'S 91311 & 91313) TO THE HOOKLIFT BASE
8
3
NO
TE: TRIM
S
TUD B
O
LT
S
FLU
S
H
WITH TR
UC
K FRAME IF THEY
I
NTERFERER WITH M
O
UNT
RECOMMENDED MOUNTING CONFIGURATION FOR 2017-18 F550 CHASSIS
4
9
3 2
1
NOTE: USE 2 SETS OF HARDWARE IN ORDER TO ATTACH
SPACERS (PN'S 91311 & 91313) TO THE HOOKLIFT BASE
83
NOTE: TRIM STUD BOLTS FLUSH
WITH TRUCK FRAME IF THEY
INTERFERER WITH MOUNT
ITEM PART DESCRIPTION QTY.
191311 PLATE 0.75X5.63X8.50 SLOTS W/ PAINT 2
291312
FLAT 0.75X2.00X10.00 CR W/HOLE PAINT 2
391313
PLATE 0.50X5.00X14.00 SLOTS W/PAINT 4
494991
ANGLE 4.00X3.00X0.50WX7.00 W/SLOTS 2
8
D0143 TIE DOWN CHANNEL 2
997423
ANGLE FORMED FLEX BASE MNT SS 1
PN 91310
A
.69 1.19
DETAIL A
SCALE 1 : 4
NOTE: DRILL 11/16" HOLE THROUGH TRUCK
FRAME HERE FOR FRONT MOUNTING ANGLE

Stellar®108-12 Flex Owner’s Manual | Page 11
Ford 550 Mounting Kit - PN 91310
3
4
4
8
2
2
1
8
10
1
13
13
12
4
3
2
0
3
3
2
3
3
3
3
4
4
8
2
2
1
8
10
9
1
11
14
13
13 12
4
3
2
1
38
ITEM PART DESCRIPTION
QTY.
191311 PLATE 0.75X5.63X8.50 SLOTS W/ PAINT 2
291312
FLAT 0.75X2.00X10.00 CR W/HOLE PAINT 2
391313
PLATE 0.50X5.00X14.00 SLOTS W/PAINT 4
494991
ANGLE 4.00X3.00X0.50WX7.00 W/SLOTS 2
5
C5902WASHER 0.63 SAE FLAT YELLOW GR8 36
624868
NUT 0.63-11 HHGR8 NYLOC 18
7
C1026 CAP SCR 0.63-11X2.50 HHGR8 18
8
D0143 TIE DOWN CHANNEL 2
997423
ANGLE FORMED FLEX BASE MNT SS 1
10 97424
ANGLE FORMED ECCR BASE MNT CS 1
11 62177
BRKT FUEL FILL 1
12 13576
CAP SCR 0.38-16X1.25 HHGR8 2
13
C6353WASHER 0.38 SAE FLAT YELLOW GR8 4
14 56673
NUT 0.38-16 HHGR8 NYLOC 2
PN 91310
NOTE: (PN 97701) IS NOT USED WITH GAS ENGINE OPTION
NOTE ITEMS NOT SHOWN:
66520 - DECAL DEF FILL WARNING X 1
97701 - EXHAUST PIPE FORD 6.4L ELBOW 3.00” X 1
102204 - INSTRUCTIONS F550 DIESEL EXHAUST MODIFICATION X 1

Page 12 | Stellar®108-12 Flex Owner’s Manual
Bolt each tie-down casting to the underside of each mounting plate located on the
outside of the main rails of the base (both sides).
Note: The mounting plates are designed with multiple slots to offer more flexibility in
mounting locations. Additional holes may not be added.
Note: Tack spacer (PN 96261) to bottom of base.
Note: Use 2 sets of hardware in order to attach spacer (PN’s 96259 & 96260) to the hooklift
base
Step 2C (RAM5500): Bolt tie-down castings to mounting plates.
6
6
7
4
7
6
6
7
5
5
5
4
6
7
6
7
6
7
4
7
6
6
7
46
7
5
66
5
6
5
5
6
6
5
5
6
ITEM PART DESCRIPTION QTY.
4 D0143 TIE DOWN CHANNEL 6
5
C1026 CAP SCR 0.63-11X2.50 HHGR8 18
6
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 36
724868
NUT 0.63-11 HHGR8 NYLOC 18
PN 96258
3
NOTE: TACK SPACER (PN 96261) TO BOTTOM OF BASE
.13
TYP 4

Stellar®108-12 Flex Owner’s Manual | Page 13
Bolt each tie-down angle to the truck frame (both sides):
Step 4C (RAM5500): Bolt tie-down castings to truck frame.
ITEM PART DESCRIPTION QTY.
3 C1026 CAP SCR 0.63-11X2.50 HHGR8 6
4
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 12
5 24868
NUT 0.63-11 HHGR8 NYLOCK ZY 6
4
3
5
4
4
3
5
4
4
3
5
4
Note: See torque chart at beginning of chapter
for proper bolt tightness.
Using the holes in the tie-down castings as guides, drill 11/16” mounting holes
through the truck frame as shown (Both Sides):
Step 3C (RAM5500): Drill mounting holes into frame rail.
R
E
CO
MMENDED M
O
UNTIN
G
CO
NFI
G
URATI
O
N F
O
R RAM 55
00
C
HA
SS
I
S
N
OTE: USE 2 SETS OF HARDWARE IN ORDER TO ATTACH
E
SPACERS
(
PN'S 96259 & 96260
)
TO THE HOOKLIFT BASE
1
4
1
4
3
4
2
RECOMMENDED MOUNTING CONFIGURATION FOR RAM 5500 CHASSIS
NOTE: USE 2 SETS OF HARDWARE IN ORDER TO ATTACHE
SPACERS (PN'S 96259 & 96260) TO THE HOOKLIFT BASE
1
41
434
2
ITEM PART DESCRIPTION QTY.
196259 PLATE 0.19X5.00X14.00 SLOTS W/PAINT 4
296260
PLATE 0.19X5.00X8.50 SLOTS W/ PAINT 2
396261
FLAT 0.19X2.00X10.00 CR W/HOLE PAINT 2
4
D0143 TIE DOWN CHANNEL 6
PN 96258

Page 14 | Stellar®108-12 Flex Owner’s Manual
RAM5500 Mounting Kit - PN 96258
4
1
3
4
2
4
3
4
1
1
3
4
2
4
1
1
3
242
4
3
1
4
1
1
4
1
4
3
4
2
NOTE ITEMS NOT SHOWN:
62177 - BRKT FUEL FILL X 1
ITEM PART DESCRIPTION QTY.
196259 PLATE 0.19X5.00X14.00 SLOTS W/PAINT 4
296260
PLATE 0.19X5.00X8.50 SLOTS W/ PAINT 2
396261
FLAT 0.19X2.00X10.00 CR W/HOLE PAINT 2
4
D0143 TIE DOWN CHANNEL 6
5
C1026 CAP SCR 0.63-11X2.50 HHGR8 18
6
C5902 WASHER 0.63 SAE FLAT YELLOW GR8 36
724868
NUT 0.63-11 HHGR8 NYLOC 18
PN 96258