stellar labs TireMan 6116 User manual

TireMan Package
6116
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 Notication.
© 2023 Stellar Industries, Inc.
Rev 4
PN 98581
Installation • Assembly Drawings • Parts
Notice: A copy of this manual must remain with the equipment at all times.
For a printable download copy, please visit: www.stellarindustries.com

Page ii | Stellar®TMP6116 Owner’s Manual PN 98581
Serial Tag Location / P65 Warning
WARNING
Operating, maintaining, and servicing a Stellar
product may expose you to chemicals including, but
not limited to, engine exhaust, carbon monoxide,
phthalates, and lead. These chemicals are known
to the State of California to cause cancer and birth
defects (or other reproductive harm). To keep your
exposure to a minimum, be sure to avoid breathing
exhaust and service your Stellar product in a well-
ventilated area while wearing gloves or washing
your hands frequently. For more information, go to
www.P65Warnings.ca.gov/passenger-vehicle. www.p65/warning.ca.gov
MODELNO. SERIALNO.
DATE
MADEIN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PNC5942
®
PATENTINFORMATION
http://www.stellarindustries.com/ip
MODEL NO. SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENT INFORMATION
http://www.stellarindustries.com/ip
Serial Tag
Location
NOTICE
Cold Weather Performance
Although clear data on cold weather performance from every steel
manufacturer is not available for all types and thicknesses of steel, Stellar
Industries is confident that the weldments on our products will operate to
100% of their intended purpose to temperatures down to -40° F / C.
It is recommended it Stellar manufactured equipment needs to be used in
temperatures below -40° F / C, the operator should pull the unit into a
climate-controlled area and allow the weldments to warm up to and then
maintain a temperature above this level.

Stellar®TMP6116 Owner’s Manual PN 98581 | Page iii
Table of Contents
Introduction ...............................................................................................................................................................v
Chapter 1 - Specications ...........................................................................................................................1
Model TM6116 Specications ...................................................................................................................................2
TM6116 Dimensional Layout.....................................................................................................................................3
TM6116 Dimensional Layout (Continued).................................................................................................................4
TM6116 Rotation Stop Locations..............................................................................................................................5
Chapter 2 - Installation.................................................................................................................................7
General Installation ...................................................................................................................................................8
Installer Notice ..........................................................................................................................................................8
Torque Data Chart.....................................................................................................................................................9
Installation Overview............................................................................................................................................10
Mounting Kit Drawing...........................................................................................................................................10
Hydraulic Installation...............................................................................................................................................11
Hydraulic Pressure Settings....................................................................................................................................12
Face Seal/O-Ring Size Chart..................................................................................................................................12
Hydraulic Kit - PN 97591.........................................................................................................................................14
Hydraulic Kit w/Fixed Pads - PN 99146 ..................................................................................................................18
Hydraulic Kit w/Fixed Pads - PN 99146 Parts List ..................................................................................................19
Hydraulic Kit w/Rotating Pads - PN 99136 .............................................................................................................20
Hydraulic Kit w/Rotating Pads - PN 99136 .............................................................................................................21
Hydraulic Backup Valve (Opt.) PN - 103421...........................................................................................................22
Hydraulic Backup Valve (Opt.) PN - 103421 Parts List...........................................................................................23
Hydraulic Backup Valve (Opt.) PN - 103421 (Continued) .......................................................................................24
Hydraulic Backup Valve (Opt.) PN - 103421 (Continued) .......................................................................................25
Hydraulic Backup Valve (Opt.) PN - 103421 (Continued) .......................................................................................26
Valve Mobile Backup - 101759................................................................................................................................27
Control Kit - PN 92663 ............................................................................................................................................28
Control Kit - PN 92663 Parts List ............................................................................................................................29
Grease Kit - PN 97668............................................................................................................................................30
Grease Kit - PN 97668............................................................................................................................................31
Main Decal Placement - PN 98661.........................................................................................................................32
TireMan Decal Placement - PN 73107....................................................................................................................33
Chapter 3 - Assembly Drawings................................................................................................................35
Base Asm 13500 RR MNT RH Drive - PN 130730 .................................................................................................36
Base Asm 13500 RR MNT RH Drive - PN 130730 Parts........................................................................................37
Base Asm 13500 - PN 72144..................................................................................................................................38
Base Asm 13500 - PN 72144..................................................................................................................................39
Stabilizer Assembly - PN 75925..............................................................................................................................40
Stabilizer Assembly - PN 75925 Parts List..............................................................................................................41
Gear Bearing - PN 72187 .......................................................................................................................................42
Gear Bearing - PN 72187 Parts List .......................................................................................................................43
Valve Bank - PN 76181...........................................................................................................................................44
Valve Bank - PN 76181 Parts List...........................................................................................................................45
Stabilizer Valve Bank - PN 61642 ...........................................................................................................................46
Valve Assembly - PN 66286 Parts List....................................................................................................................47
Mast Assembly - PN 96545.....................................................................................................................................48
Mast Assembly - PN 96545 Parts List.....................................................................................................................49
Main Cylinder Assembly - PN 73497 ......................................................................................................................50
Main Cylinder Assembly - PN 73497 Parts List ......................................................................................................51
Main Boom Assembly - PN 96550 ..........................................................................................................................52
Main Boom Assembly - PN 96550 Parts List ..........................................................................................................53
Outer Cylinder Assembly - PN 73498 .....................................................................................................................54
Outer Cylinder Assembly - PN 73498 Parts List .....................................................................................................55
Extension Boom Assembly - PN 72199 ..................................................................................................................56
Extension Boom Assembly - PN 72199 Parts List ..................................................................................................57

Page iv | Stellar®TMP6116 Owner’s Manual PN 98581
Extension Cylinder Assembly - PN 73499 ..............................................................................................................58
Extension Cylinder Assembly - PN 73499 ..............................................................................................................59
TM6116 Standard Assembly - PN 99145................................................................................................................60
TM6116 Standard Assembly - PN 99145 Parts List................................................................................................61
TM6116 Standard Assembly - PN 99145 Parts List................................................................................................62
TM6116 w/Rotation Pads Assembly - PN 99143 ....................................................................................................64
TM6116 w/Rotation Pads Assembly - PN 99143 Parts List ....................................................................................65
TM6116 w/Rotation Pads Assembly - PN 99143 Parts List ....................................................................................66
Reservoir Assembly - PN 128835 ...........................................................................................................................68
Reservoir Assembly - PN 128835 Parts List ...........................................................................................................69
Optional 15 Ton Hook Kit - PN 54768 .....................................................................................................................70
Radio Transmitter - PN 89149/93084 .....................................................................................................................71
Transmitter Docking Station Asm (Opt.) - PN 97334 .............................................................................................72
Transmitter Docking Station (Opt.) - PN 97334 Parts List .....................................................................................73
Wiring Diagram Docking Station - PN 65989..........................................................................................................74
Table of Contents

Page v | Stellar®TMP6116 Owner’s Manual PN 98581
Introduction
A copy of this manual is provided with every tire manipulator (TM) 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 TM
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
troubleshooting. Please refer to the Large OTR Tire Manipulator 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 improvement or commercial/
production purposes. This right is kept with no requirement or obligation 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 Department 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]

Page vi | Stellar®TMP6116 Owner’s Manual PN 98581
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Stellar®TMP6116 Owner’s Manual PN 98581 | Page 1
Chapter 1 - Specifications
CHAPTER CONTENTS
Model TM6116 Specications .................................................................................................... 2
TM6116 Dimensional Layout...................................................................................................... 3
TM6116 Dimensional Layout (Continued).................................................................................. 4
TM6116 Rotation Stop Locations ............................................................................................... 5

Page 2 | Stellar®TMP6116 Owner’s Manual PN 98581
Model TM6116 Specifications
Tire Manipulator Rating: 135,000 ft-lbs (18.6 ton meters)
Tire Manipulator Capacity: 6,000 lbs @ 19' (2,721 kg @ 5.79m)
Standard Length: 13’3” (4.04 m) from CL of TM main rotation
Main Extension: Hydraulic 41.5” (105.4 cm)
Clamping Span: Fixed Pads - 19” to 116” (48.3 cm to 294.6 cm)
Rotating Pads - 19” to 116” (48.3 cm to 294.6 cm)
Maximum Horizontal Reach: 20’ 0” (6.10 m) from CL of TM main rotation (with TM clamp open)
Cylinder Specications: Inner Lift Cylinder: 6” (15.24 cm) bore with integral pilot operated
counterbalance valves
Outer Lift Cylinder: 5” (12.7 cm) bore with integral pilot operated
counterbalance valves
Extension Cylinder: 3.5” (8.9 cm) bore with integral pilot operated
counterbalance valves
TireMan Cylinders: 3.5” (8.9 cm) bore with integral pilot operated
counterbalance valves
Main Rotation: 315 degree power
Main Rotation System: Planetary Gear w/ Pinion
TireMan Rotation: 300 degree power
TireMan Rotation System: Hourglass worm gear
Clamping Pad Rotation: Optional: 90 degree Rotating Pads
TireMan Tilt: +79 degrees to -43 degrees
Power Supply Required: PTO & Pump - 16 gpm @ 4,400 psi (60 lpm @ 304 bar)
Controls: Fully Proportional Paddle Controls for all functions.
Stowed Height (Above Truck Frame): 97” (246.4 cm)
Mounting Space Required: 47” (119.4 cm)
Chassis RBM (Recommended): 1,620,000 in-lb
Approximate Shipping Weight:
8,800 lbs (3990 kg) Standard
9,050 lbs (4105 kg) With 90 degree Rotating Pad

Stellar®TMP6116 Owner’s Manual PN 98581 | Page 3
TM6116 Dimensional Layout
Rotating Pads: 19"
Fixed Pads: 19"
Fixed Pads: 116"
Rotating Pads: 116"

Page 4 | Stellar®TMP6116 Owner’s Manual PN 98581
TM6116 Dimensional Layout (Continued)
TIREMAN TILT
43°
79°

Page 5 | Stellar®TMP6116 Owner’s Manual PN 98581
TM6116 Rotation Stop Locations
23º
23º
44º
TMP6116 Front & Rear Mount LH Drive
Front of Truck
Working Rotation Range
23º
23º
44º
TMP6116 Rear Mount RH Drive
Rear of Truck
Working Rotation Range

Page 6 | Stellar®TMP6116 Owner’s Manual PN 98581
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Stellar®TMP6116 Owner’s Manual PN 98581 | Page 7
Chapter 2 - Installation
CHAPTER CONTENTS
General Installation .................................................................................................................... 8
Installer Notice ........................................................................................................................... 8
Torque Data Chart...................................................................................................................... 9
Hydraulic Installation.................................................................................................................11
Hydraulic Pressure Settings..................................................................................................... 12
Face Seal/O-Ring Size Chart................................................................................................... 12
Hydraulic Kit - PN 97591.......................................................................................................... 14
Hydraulic Kit w/Fixed Pads - PN 99146 ................................................................................... 18
Hydraulic Kit w/Fixed Pads - PN 99146 Parts List ................................................................... 19
Hydraulic Kit w/Rotating Pads - PN 99136............................................................................... 20
Hydraulic Kit w/Rotating Pads - PN 99136............................................................................... 21
Hydraulic Backup Valve (Opt.) PN - 103421 ............................................................................ 22
Hydraulic Backup Valve (Opt.) PN - 103421 Parts List ............................................................ 23
Hydraulic Backup Valve (Opt.) PN - 103421 (Continued) ........................................................ 24
Hydraulic Backup Valve (Opt.) PN - 103421 (Continued) ........................................................ 25
Hydraulic Backup Valve (Opt.) PN - 103421 (Continued) ........................................................ 26
Valve Mobile Backup - 101759................................................................................................. 27
Control Kit - PN 92663 ............................................................................................................. 28
Control Kit - PN 92663 Parts List ............................................................................................. 29
Grease Kit - PN 97668............................................................................................................. 30
Grease Kit - PN 97668............................................................................................................. 31
Main Decal Placement - PN 98661.......................................................................................... 32
TireMan Decal Placement - PN 73107..................................................................................... 33

Page 8 | Stellar®TMP6116 Owner’s Manual PN 98581
According to Federal Law (49 cfr part 571), each nal-stage manufacturer shall complete the
vehicle in such a manner that it conforms to the standards in e󰀨ect on the date of manufacture
of the incomplete vehicle, the date of nal completion, or a date between those two dates. This
requirement shall, however, be superseded by any conicting provisions of a standard that applies
by its terms to vehicles manufactured in two or more stages.
Therefore, the installer of Stellar®Tire Manipulators and Bodies 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 Tra󰀩c and Motor Vehicle Safety Act.
Please reference the Code of Federal Regulations, title 49 - Transportation, Volume 5 (400-999),
for further information, or visit https://www.ecfr.gov/current/title-49 for the full text of Code of Federal
Regulations.
www.ecfr.gov/current/title-49
General Installation
This chapter is designed to serve as a general guide for the installation of a Stellar TM6116 on
a Stellar Service Body. 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 installation
process, please contact Stellar Customer Service at [phone].
This tire manipulator (TM) is designed for use with a Stellar Service Body installed on a vehicle that
meets the minimum chassis requirements of the TM. It is the installer’s responsibility to assure that
the TM is mounted on a platform that will support the maximum rating of this TM.
Do not install this TM on a body not capable of handling the loads imposed on it.
Failure to do so may result in serious injury or death.
When installing welder units to the service bodies, it is highly recommended that
a surge protector is installed on the chassis batteries to protect the TM radio receiver, wiring and
other electronic devices from an unexpected electrical spike or surge. Failure to do so could result
in extensive damage to the service body and TM electrical circuit.
WARNING
NOTICE
Installer Notice

Stellar®TMP6116 Owner’s Manual PN 98581 | Page 9
When using the torque data in the
chart, the following rules should be
observed:
• Bolt manufacturer’s particular
specications should be consulted
when provided.
• Flat washers of equal strength must
be used.
• All torque measurements are given
in foot-pounds. To convert to inch-
pounds, multiply by 12.
• Torque values specied are for
bolts with residual oils or no special
lubricants applied.
• Torque values for socket-head
capscrews are the same as for Grade 8
capscrews.
• Do not use these values if a di󰀨erent torque value or tightening procedure is
given for a specic application. Torque values listed are for general use only. Check tightness of
fasteners periodically.
• Shear 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
NOTICE
Torque Data Chart

Page 10 | Stellar®TMP6116 Owner’s Manual PN 98581
1. Relocate any obstructions on the frame that will be in the way of mounting the tire manipulator (TM).
2. Measure the inside of the frame rails and cut the frame support to this length. Ensure that the frame supports have a
tight t between the frame rails.
3. Set the TM on the chassis and allow a minimum of 3” from the cab.
4. Make certain that the frame supports are installed square, cut to length in such a way as to support the frame anges
with the tie down rods are torqued.
5. Install the TM tie downs. Start at one corner and tighten both tie downs to 200 ft-lbs. Move to the diagonal set and
tighten to 200 ft-lbs. Tighten the remaining 2 corners. Continue this pattern at 200 ft-lb increments until 500-550 ft-
lbs is achieved. Be sure the mounting block stays perpendicular to the frame rail as they are tightened down.
6. Connect the pressure and return lines per the hydraulic kit.
7. Connect the electrical power and ground wires. Ground preferably connected to battery.
8. With the TM and outriggers in the stored position, check the reservoir for oil and ll if necessary.
9. Operate the TM for several cycles. Fully cycle the cylinder in both directions (blow past relief) to remove any air from
the system.
Installation Overview
Mounting Kit Drawing
PN 54420
7
5
5
4
1
2
3
6
7
ITEM PART DESCRIPTION QTY.
18900TIE DOWN ROD 15000 8
28202PC FRAME SUPPORT 15000
38054PCMTG BLOCK 150004
411677PCPLATE MOUNTING 23000 4
58978 NUT 1.25-7 HHGR8 16
68834NUT 1.25-7 HHGR8 TOP LOCKING8
79180WASHER 1.25 SAE FLAT YELLOW GR816
4

Stellar®TMP6116 Owner’s Manual PN 98581 | Page 11
Hydraulic Installation
Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without
Stellar Industries’ approval.
Do not touch or grab any hoses that could be under pressure. Release system
pressure before attempting to make adjustments or repairs.
Do not attempt service or repair when PTO is engaged.
Disassemble and assemble hydraulic components on a clean surface.
Clean all metal parts in a nonammable cleaning uid. Then lubricate all components to aid in
assembly.
Hydraulic uid expands when heated. This raises the pressure in an
unventilated tank. Release the tank pressure before removing the cap completely. Failure to do so
may cause the oil to shoot out of the tank very rapidly and cause severe burns.
Do not rely on the hydraulic uid to support the boom or tire manipulator (TM).
If hydraulic uid escapes, the boom or TM can fall immediately. Make sure the ground or blocking
is supporting the boom before performing any maintenance or repair.
Contaminants in a hydraulic system a󰀨ect operation and will result in serious
damage to the system components. Dirty hydraulic systems are a major cause of component
failures.
If evidence of foreign particles is found in the hydraulic system, ush the system.
When installing metal hydraulic tubes, tighten all ttings nger tight Then, in order, tighten the
ttings at the rigid end, the adjustable end, and the mounting brackets. After tubes are mounted,
install the hoses. Connect both ends of the hose with all ttings nger tight. Position the hose so
it does not rub the machine or another hose and has a minimum of bending and twisting. Tighten
ttings in both couplings.
Due to manufacturing methods, there is a natural curvature to a hydraulic hose. The hose should
be installed so any bend is with this curvature.
WARNING
WARNING
WARNING
NOTICE

Page 12 | Stellar®TMP6116 Owner’s Manual PN 98581
Hydraulic Pressure Settings
Main Relief 4600 psi
Pressure (psi)
Function Flow (gpm) Extend Retract
Inner 10.6 4400 2200
Outer 10.6 4400 2200
Extension 10.6 4400 4400
Rotation 10.6 2200 2200
TM Rot 6.6 2200 2200
TM Pad Rot 6.6 3000 3000
TM Clamp 6.6 3000 3000
Face Seal (A)
Stellar®PN
Hose
Size
Fitting
Size Stellar®PN
O-ring Boss (B)
#4 C2027 D1245
#6 C2028 D1246
#8 C2029 D1247
#10 32223 D1248
#12 D1244 D1249
#161”
3/4”
5/8”
1/2”
3/8”
1/4”
D1250
B
A
Face Seal/O-Ring Size Chart

Stellar®TMP6116 Owner’s Manual PN 98581 | Page 13
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Page 14 | Stellar®TMP6116 Owner’s Manual PN 98581
Hydraulic Kit - PN 97591
3 17
21,22
26,24,
34
19 19
3 17
217 16 2 2
19 19 19 19 19
17 16 222
28
28
21,2221,22 21,2221,2221,22 21,22
03
03
06
06
12
12
13
13
10
10
10
10
11
11
05
05
47 42,38
16
16
16
16
16 16