stellar labs TireMan 4110 User manual

TireMan Package
4110
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 98580
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®TMP4110 Owner’s Manual
Model TM4110 Manual Revisions
Date of Revision Section Revised Description of Revision
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.
WARNING

Stellar®TMP4110 Owner’s Manual | Page iii
Table of Contents
Introduction ............................................................................................................................................iv
Chapter 1 - Specifications......................................................................................................................... 1
Model TM4110 Capacity ....................................................................................................................... 1
Model TM4110 Specifications ............................................................................................................... 1
TM4110 Dimensional Layout.................................................................................................................. 2
Chapter 2 - Installation .............................................................................................................................. 3
General Installation................................................................................................................................ 3
Installer Notice ..................................................................................................................................... 3
Torque Data Chart .............................................................................................................................. 4
Installation Overview .......................................................................................................................... 5
Mounting Kit Drawing ......................................................................................................................... 5
Hydraulic Installation.............................................................................................................................. 6
Hydraulic Pressure Settings.................................................................................................................... 7
Face Seal/O-Ring Size Chart................................................................................................................. 7
Main Hydraulic Kit - PN 61547 ............................................................................................................... 8
TireMan Hydraulic Kit - PN 67411 ........................................................................................................ 10
Control Kit - PN 92663........................................................................................................................... 12
Grease Kit - PN 61641........................................................................................................................... 13
Main Decal Placement - PN 98660 .................................................................................................... 14
TireMan Decal Placement - PN 35432 ............................................................................................... 15
Chapter 3 - Assembly Drawings ............................................................................................................. 17
Base Assembly - PN 94131 ................................................................................................................... 17
Base Assembly Rear Mount Australia Stop - PN 94132..................................................................... 18
Stabilizer Assembly - PN 61089 ............................................................................................................ 19
Gear Bearing - PN 63815 ..................................................................................................................... 20
Valve Bank - PN 51658 ......................................................................................................................... 21
Outrigger Valve Bank - PN 61642........................................................................................................ 22
Valve Assembly - PN 66286.................................................................................................................. 23
Mast Assembly - PN 29350................................................................................................................... 24
Main Cylinder Assembly - PN 29352 ................................................................................................... 25
Main Boom Assembly - PN 29354 ....................................................................................................... 26
Outer Cylinder Assembly - PN 29356.................................................................................................. 27
Extension Boom Assembly - PN 61204................................................................................................ 28
Extension Cylinder Assembly - PN 73499............................................................................................ 29
TireMan Assembly - PN 61223 ............................................................................................................. 30
TireMan Assembly (cont.) - PN 61223................................................................................................. 31
TireMan w/Rotation Pads Assembly - PN 61386................................................................................ 32
TireMan w/Rotation Pads Assembly (cont.) - PN 61386................................................................... 33
Mounting Kit - PN 61401....................................................................................................................... 34
Optional Pad Extensions - PN 35434................................................................................................... 35
Optional Pad Extensions - PN 58288................................................................................................... 36
Optional Pad Extensions - PN 81015................................................................................................... 37
Reservoir Assembly - PN 100786.......................................................................................................... 38
Compressor Mounting - PN 64165 ...................................................................................................... 39
Reservoir Assembly - PN 86510............................................................................................................ 40
Radio Transmitter - PN 89149/93084 ................................................................................................... 41
Chapter 4 - Replacement Parts .............................................................................................................. 43

Page iv | Stellar®TMP4110 Owner’s Manual
Introduction
A copy of this manual is provided with every tire manipulator 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 tire manipulator 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 Owner’s 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®TMP4110 Owner’s Manual | Page 1
19’(5.79m)
4600lbs(2086kg)
ROTATION
Model TM4110 Capacity
Chapter 1 - Specifications
Tire Manipulator Rating 90,000 ft-lbs (12.44 ton meters)
Tire Manipulator Capacity 4,600 lbs @19 ft (2,086 kg @ 5.79m)
Standard Length 13’ 1” (3.99 m) from CL of TM main rotation
Main Extension Hydraulic 41" (104 cm)
Clamping Span Fixed Pads - 48” to 110” (121.92 cm to 279.4 cm)
Rotating Pads - 47" to 109" (119.38 cm to 276.86 cm)
Optional Pad Extension 29” (73.66 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 290 degree power
Main Rotation System Worm Gear Drive
TireMan Rotation 285 degree power
TireMan Rotation System Rotation bearing and worm-driven gear box
TireMan Tilt +85 degrees to -37 degrees
Power Supply Required PTO & Pump - 12 gpm @3,000 psi (45.4 lpm @ 206 bar)
Controls Fully Proportional Paddle Controls for all functions.
Stowed Height (Above Truck Frame) 84” (213 cm)
Mounting Space Required 42” (107 cm)
Chassis RBM (Recommended) 1,080,000 in-lb
Approximate Shipping Weight 6,350 lbs (2878 kg) Standard
6,625 lbs (3002 kg) With 90 degree Rotating Pad
Model TM4110 Specifications

Page 2 | Stellar®TMP4110 Owner’s Manual
48” - Fixed Pads
47” - Rotating Pads
110” - Fixed Pads
109” - Rotating Pads
TM4110 Dimensional Layout

Stellar®TMP4110 Owner’s Manual | Page 3
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 TM4110
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
capacity 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 4 | Stellar®TMP4110 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®TMP4110 Owner’s Manual | Page 5
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 375-400 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
8
6
5
4
2
3
6
7
7
PN 102554
160517 1BASE 9000 FOLD OVER STABILIZER
48202 4FRAME SUPPORT 15000 PC BLACK
358660 4PLATE MOUNTING 1.00 IN RODS PC BLACK
2102555 8TIE DOWN ROD 1.00-8X40.00
558658 4MTG BLOCK HIAB 122 PC BLACK
66538 16WASHER 1.00 SAE FLAT YELLOW GR8
761558 16NUT 1.00-8 HHGR8
861559 8NUT 1.00-8 HHGR8 TOP LOCKING
10 94742 1MTG BLOCK 9000 SPECIAL
ITEM PART No. QTY.DESCRIPTION

Page 6 | Stellar®TMP4110 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 hydraulic hose. The hose
should be installed so any bend is with this curvature.
WARNING
WARNING
WARNING
NOTICE