stellar labs TireMan Package 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 Notification.
© 2021 Stellar Industries, Inc.
Rev 1
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
Model TM6116 Manual Revisions
Date of Revision Section Revised Description of Revision
MODELNO.SERIAL NO.
DATE
MADE IN 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

Stellar®TMP6116 Owner’s Manual | Page iii
Table of Contents
Introduction.............................................................................................................................. iv
Chapter 1 - Specifications........................................................................................................... 1
Model TM6116 Capacity ......................................................................................................... 1
Model TM6116 Specifications.................................................................................................. 2
TM6116 Dimensional Layout .................................................................................................... 3
Chapter 2 - Installation ................................................................................................................ 5
General Installation .................................................................................................................. 5
Installer Notice........................................................................................................................ 5
Torque Data Chart................................................................................................................. 6
Installation Overview ............................................................................................................. 7
Mounting Kit Drawing ............................................................................................................ 7
Hydraulic Installation ................................................................................................................ 8
Hydraulic Pressure Settings ...................................................................................................... 9
Face Seal/O-Ring Size Chart ................................................................................................... 9
Main Hydraulic Kit - PN 97591................................................................................................ 10
TireMan Hydraulic Kit - PN 73108........................................................................................... 13
Control Kit - PN 92663 ............................................................................................................. 15
Grease Kit - PN 97668 ............................................................................................................. 16
Main Decal Placement - PN 98661....................................................................................... 17
TireMan Decal Placement - PN 73107.................................................................................. 18
Chapter 3 - Assembly Drawings ............................................................................................... 19
Base Assembly - PN 72144 ..................................................................................................... 19
Stabilizer Assembly - PN 75925............................................................................................... 20
Gear Bearing - PN 72187........................................................................................................ 21
Valve Bank - PN 76181............................................................................................................ 22
Stabilizer Valve Bank - PN 61642............................................................................................ 23
Valve Assembly - PN 66286 .................................................................................................... 24
Mast Assembly - PN 96545 ..................................................................................................... 25
Main Cylinder Assembly - PN 73497...................................................................................... 26
Main Boom Assembly - PN 96550.......................................................................................... 27
Outer Cylinder Assembly - PN 73498 .................................................................................... 28
Extension Boom Assembly - PN 72199 .................................................................................. 29
Extension Cylinder Assembly - PN 73499 .............................................................................. 30
TireMan Assembly - PN 72047................................................................................................ 31
TireMan Assembly (cont.) - PN 72047 ................................................................................... 32
TireMan w/Rotation Pads Assembly - PN 73106 .................................................................. 33
TireMan w/Rotation Pads Assembly (cont.) - PN 73106 ..................................................... 34
Optional Pad Extensions - PN 35434 ..................................................................................... 35
Optional Pad Extensions - PN 58288 ..................................................................................... 36
Optional Pad Extensions - PN 81015 ..................................................................................... 37
Reservoir Assembly - PN 85788 .............................................................................................. 38
Optional 15 Ton Hook Kit - PN 54768..................................................................................... 39
Radio Transmitter - PN 89149/93084...................................................................................... 40
Chapter 4 - Replacement Parts ................................................................................................ 41

Page iv | Stellar®TMP6116 Owner’s Manual
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]

Stellar®TMP6116 Owner’s Manual | Page 1
Chapter 1 - Specifications
Model TM6116 Capacity
STELLAR TM6116
72077 - Rev A
CAPACITY
CHART
19' (5.79m)
6000 lb (2721kg)
0'
ROTATION
C
L

Page 2 | Stellar®TMP6116 Owner’s Manual
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 - 53.5” to 116” (135.9 cm to 294.6 cm)
Rotating Pads - 52" to 114.5" (132.1 cm to 290.8 cm)
Optional Pad Extension: 34.5” (87.6 cm) arms closed
Maximum Horizontal Reach: 20’ 0” (6.10 m) from CL of TM main rotation (with TM clamp open)
Cylinder Specifications:
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” (8.89 cm) bore with integral pilot operated counterbalance valves TireMan Cylinders: 2.5” (6.35 cm) bore with pilot operated check 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: 8,500 lbs (3855 kg) Standard
8,700 lbs (3946 kg) With 90 degree Rotating Pad

Stellar®TMP6116 Owner’s Manual | Page 3
49"
53.5" - Fixed Pads
52" - Rotating Pads
41"
116" - Fixed Pads
114.5” - Rotating Pads
TM6116 Dimensional Layout

Page 4 | Stellar®TMP6116 Owner’s Manual
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Stellar®TMP6116 Owner’s Manual | Page 5
Installer Notice
According to Federal Law (49 cfr part 571), each final-stage manufacturer shall complete
the vehicle 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 requirement 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®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 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.
Chapter 2 - Installation
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

Page 6 | Stellar®TMP6116 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
given 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.
• 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.
• 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
Torque Data Chart
NOTICE

Stellar®TMP6116 Owner’s Manual | Page 7
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 fit 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 flanges 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 fill 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

Page 8 | Stellar®TMP6116 Owner’s Manual
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 nonflammable cleaning fluid. Then lubricate all components to
aid in assembly.
Hydraulic fluid 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 fluid to support the boom or tire manipulator
(TM). If hydraulic fluid 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 affect 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, flush the system.
When installing metal hydraulic tubes, tighten all fittings finger tight. Then , in order, tighten
the fittings 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 fittings finger tight.
Position the hose so it does not rub the machine or another hose and has a minimum of
bending and twisting. Tighten fittings in both couplings.
Due to manufacturing methods, there is a natural curvature to a hydralic hose. The hose
should be installed so any bend is with this curvature.
WARNING
WARNING
WARNING
NOTICE

Stellar®TMP6116 Owner’s Manual | Page 9
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

Page 10 | Stellar®TMP6116 Owner’s Manual
Main 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 21,2221,22 21,2221,22
03
03
06
06
12
12
13
13
10
10
10
10
11
11
05
05
47 42,38
PN 97591
16
16
16
16
16 16

Stellar®TMP6116 Owner’s Manual | Page 11
Main Hydraulic Kit - PN 97591 (cont.)
PN 97591

Page 12 | Stellar®TMP6116 Owner’s Manual
Main Hydraulic Kit - PN 97591 (cont.)
TOP VIEW OF MAST
BULKHEAD PLATE
TOP VIEW OF MAIN
BOOM PORT TUBES
EXT CYL EXTEND
EXT CYL RETRACT
TM PAD ROT CW
TM PAD ROT CCW
TM CLAMP CLOSE
TM CLAMP OPEN
TM ROT CW TM ROT CCW
4
2
24
24
17 12
17 18
24
17 18
17 12
24
24
EXT CYL EXTEND
EXT CYL RETRACT
TM PAD ROT CCW
TM PAD ROT CW
TM CLAMP CLOSE
TM CLAMP OPEN
TM ROT CW
TM ROT CCW
OUTER CYL RETRACT
OUTER CYL EXTEND
HOSES FROM VALVE BANK TO BULKHEAD
TO TM COUPLERS/EXT CYL
10 10
11
11
13 13
10
10
USE SPIRAL HOSE WRAP OVER HOSES
FROM BULKHEAD PLATE TO PORT TUBES
AND FROM PORT TUBES TO FUNCTIONS.
(APPROX. 2 FT LENGTHS, GROUPED AS
SHOWN)

Stellar®TMP6116 Owner’s Manual | Page 13
TireMan Hydraulic Kit - PN 73108
PN 73108

Page 14 | Stellar®TMP6116 Owner’s Manual
TireMan Hydraulic Kit/w Rotating Pads - PN 73110
PN 73110

Stellar®TMP6116 Owner’s Manual | Page 15
PN 92663
Control Kit - PN 92663

Page 16 | Stellar®TMP6116 Owner’s Manual
Grease Kit - PN 97668
PN 97668