stellar labs TireMan 12154 User manual

TireMan Package
12154
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.
© 2019 Stellar Industries, Inc.
Rev 1
PN 103380
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®TMP12154 Owner’s Manual
Model TM12154 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®TMP12154 Owner’s Manual | Page iii
Table of Contents
Introduction.............................................................................................................................................................iv
Chapter 1 - Specifications.......................................................................................................................................... 1
Model TM12154 Capacity ..................................................................................................................................... 1
Model TM12154 Specifications.............................................................................................................................. 2
TM12154 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 69197.............................................................................................................................. 10
TireMan RP Hydraulic Kit - PN 78017 ................................................................................................................... 11
TireMan CRP Hydraulic Kit - PN 78015 ................................................................................................................ 12
Control Kit - PN 92667 ........................................................................................................................................... 13
Grease Kit - PN 68798 ........................................................................................................................................... 14
Main Decal Placement - PN 98664 (MODIFIED)................................................................................................ 15
Tire Manipulator Decal Placement - PN 71047 ................................................................................................. 16
Chapter 3 - Assembly Drawings .............................................................................................................................. 17
Base Assembly - PN 47880 ................................................................................................................................... 17
Optional Load Sensor Base - PN 67062 .............................................................................................................. 18
Stabilizer Assembly - PN 48689............................................................................................................................. 19
Bearing Assembly - PN 18471 .............................................................................................................................. 20
Gearbox - PN 60505 ............................................................................................................................................. 21
Valve Bank - PN 42802.......................................................................................................................................... 22
Mast Assembly - PN 18073 ................................................................................................................................... 23
Main Boom Assembly - PN 68021........................................................................................................................ 24
Main Cylinder Assembly - PN 20694.................................................................................................................... 25
Outer Cylinder Assembly - PN 50628 .................................................................................................................. 26
Extension Boom Assembly - PN 70661 ................................................................................................................ 27
TireMan Assembly - PN 103143............................................................................................................................ 28
TireMan Assembly (cont.) - PN 103143 ............................................................................................................... 29
Stabilizer Cylinder Assembly - PN 48383 ............................................................................................................. 30
Reservoir Assembly - PN 86356 ............................................................................................................................ 31
Optional 15 Ton Hook Kit - PN 55138................................................................................................................... 32
Radio Transmitter - PN 89149/93084.................................................................................................................... 33
Chapter 4 - Replacement Parts ............................................................................................................................... 35

Page iv | Stellar®TMP12154 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®TMP12154 Owner’s Manual | Page 1
Chapter 1 - Specifications
Model TM12154 Capacity

Page 2 | Stellar®TMP12154 Owner’s Manual
Model TM12154 Specifications
Tire Manipulator Rating: 280,000 ft-lbs (38.71 ton meters)
Tire Manipulator Capacity: 13,000 lbs @ 19 ft (5,896 kg @ 5.79 m)
Standard Length: 13’ 2” (4.01 m) from CL of TM main rotation
Main Extension: Hydraulic 37” (94.0 cm)
Clamping Span:
Rotating Pads - 42.6" to 152.7" (108 cm to 388
cm)
C. Rotating Pads - 42.8" to 152.9" (109 cm to
388 cm)
Maximum Horizontal Reach: 22’ 8” (6.91 m) from CL of TM main rotation
(with TM clamp open)
Cylinder Specifications:
Inner Lift Cylinder: 9” (22.9 cm) bore with
integral pilot operated counterbalance
valves
Outer Lift Cylinder: 7” (17.8 cm) bore with
integral pilot operated counterbalance
valves
Extension Cylinder: 6” (15.2 cm) bore with
integral pilot operated counterbalance
valves
Main Rotation: 315 degree power
Main Rotation System: Planetary Gear w/ Pinion
TireMan Rotation: 315 degree power
TireMan Rotation System: Worm gear
Clamping Pad Rotation: Continuous 360 degree power
TireMan Tilt: +80 degree to -20 degree
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): 114” (289.6 cm)
Mounting Space Required: 48" (121.9 cm)
Chassis RBM (Recommended): 3,360,000 in-lb
Approximate Shipping Weight: 19,000 lbs (8617 kg)

Stellar®TMP12154 Owner’s Manual | Page 3
TM12154 Dimensional Layout
43” - Continuous Rotating Pads
153” - Continuous Rotating Pads
43” - Rotating Pads
153” - Rotating Pads

Page 4 | Stellar®TMP12154 Owner’s Manual
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Stellar®TMP12154 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 TM12154
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®TMP12154 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