stellar labs TireMan 6116 User manual

TireMan 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 99433
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®TM6116 TireMan Owner’s Manual
Model TM6116 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®TM6116 TireMan Owner’s Manual | Page iii
Table of Contents
Introduction.............................................................................................................................. iv
Model TM6116 Specifications.................................................................................................. 1
TM6116 Dimensional Layout .................................................................................................... 2
General Installation .................................................................................................................. 3
Installer Notice........................................................................................................................ 3
Torque Data Chart................................................................................................................. 4
Hydraulic Installation ................................................................................................................ 5
Hydraulic Pressure Settings ...................................................................................................... 6
Face Seal/O-Ring Size Chart ................................................................................................... 6
Hydraulic Kit - PN 99146............................................................................................................ 7
Decal Placement - PN 73107 .................................................................................................. 9
TM6116 Standard Assembly - PN 99145................................................................................ 10
TM6116 w/Rotation Pads Assembly - PN 99143 ................................................................... 11
TM6116 w/Rotation Pads Bill - PN 99143 ............................................................................... 12

Page iv | Stellar®TM6116 TireMan 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 Crane 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®TM6116 TireMan Owner’s Manual | Page 1
Capacity: 6,000 lbs @ 19' (2,721 kg @ 5.79m)
Clamping Span: Fixed Pads - 19” to 116” (48.3 cm to 294.6 cm)
Rotating Pads - 17" to 114" (43.2 cm to 289.6 cm)
Clamp Cylinders: 3.5” (8.9 cm) bore with integral pilot operated
counter balance valves
Tilt Cylinder: Provided by crane extension boom
Body Rotation: 300º power
Rotation System: Hourglass worm gear
Clamping Pad Rotation: Optional: 90º Rotating Pads
TireMan Tilt: +79º to -43º
Hydraulic Controls: Incorporated with the crane controls
Approximate Shipping Weight: 2,375 lbs (1077 kg) Standard
2,650 lbs (1202 kg) With 90º Rotating Pad
Model TM6116 Specifications
STELLAR TM6116
72077 - Rev A
CAPACITY
CHART
19' (5.79m)
6000 lb (2721kg)
0'
ROTATION
C
L

Page 2 | Stellar®TM6116 TireMan Owner’s Manual
17" Rotating Pads
19" Fixed Pads
116" Fixed Pads
114" Rotating Pads
TM6116 Dimensional Layout

Stellar®TM6116 TireMan 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®Cranes 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.
General Installation
This chapter is designed to serve as a general guide for the installation of a Stellar TM6116
on a Stellar Service Crane. 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 crane is designed for use with a Stellar Service Crane installed on a vehicle that meets
the minimum chassis requirements of the crane. It is the installer’s responsibility to assure
that the unit is mounted on a platform that will support the maximum crane rating of this
crane.
Do not install this crane/manipulator on a body not capable of handling
the loads imposed on it. Failure to do so may result in serious injury or death.
WARNING

Page 4 | Stellar®TM6116 TireMan 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®TM6116 TireMan Owner’s Manual | Page 5
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 crane. If
hydraulic fluid escapes, the boom or crane 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

Page 6 | Stellar®TM6116 TireMan Owner’s Manual
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®TM6116 TireMan Owner’s Manual | Page 7
Hydraulic Kit - PN 99146
PN 99146

Page 8 | Stellar®TM6116 TireMan Owner’s Manual
Hydraulic Kit/w Rotating Pads - PN 99136
PN 99136

Stellar®TM6116 TireMan Owner’s Manual | Page 9
Decal Placement - PN 73107
MAXIMUM RATED LOAD
6000 LBS
EXCEEDING MAXIMUM RATEDLOAD WILL
DAMAGE EQUIPMENT AND VOID WARRANTY
72239
2720 KG
03
04
02
01
72239
72238
22617
PART No.ITEM
DECAL TM6116 RATED LOAD
DECAL IDENTIFICATION TM6116
DECAL ROTATION BEARING
DESCRIPTION
2
2
53850 DECAL STELLAR LOGO 4.00X11.5 2
1
QTY
05
72077 DECAL CAPACITY TM6116 2
PN 73107 - Rev A
STELLAR TM6116
72077
CAPACITY
CHART
17'6" (5.33m)
6000lb (2721kg)
0'
ROTATION
C
L
MAXIMUM RATED LOAD
6000 LBS
EXCEEDING MAXIMUM RATEDLOAD WILL
DAMAGE EQUIPMENT AND VOID WARRANTY
72239
2720 KG
01
02
03
03
04
05
1.)Lubricate bearing and pinion teeth with Molub-Alloy 936SF.
2.)Lubricate inner race and pin with EP2 (extreme pressure grease).
3.)Check gearbox oil level monthly (Traxon 80W-90).
4.)Visually inspect bolts for tightness. Check torque if necessary.
Bolts on inner and outer race should be torqued to 340 ft-lbs.
Inspect Rotation Bearing Monthly
22617
05
04
(HIDDEN)

Page 10 | Stellar®TM6116 TireMan Owner’s Manual
TM6116 Standard Assembly - PN 99145
.YTQNOITPIRCSEDTRAPMETI
12V6116MTYDOB952491
42V6116MTKNIL333492 22V6116MTMRA633493
252.31X05.3REDNILYC153474
535111 VALVE COMB DIV FD10-44-6T-N-4
41
678431 LIGHT FLOOD LED 3.2X2.9 850LM 16W 10-
30V 2
75145PIN CAP 0.56X3.00X0.19 YZ 24
21THGIARTSTPN8/1KREZ2951c8
910172 CAP SCR 0.50-13X1.00 HHGR
83
0
10 0339CAP SCR 0.25-20X2.50 HHGR5 2 11 22278CAP SCR 0.75-10X3.50 HHGR9 12 12 0420CAP SCR 0.31-18X0.75 HHGR5 12 13 D0790 WASHER 0.50 SAE FLAT YELLOW GR830
4TALFSSU52.0REHSAW043041
15 17150WASHER 0.75 SAE FLAT YELLOW GR926
41TALFSSU13.0REHSAW343061
17 0333 NUT 0.25-20 HHGR5 NYLOC 2
8CZT&D57.41X00.2NIPRC5137181
4T&D36.01X00.2NIPRC0564791
20 4380BUSHING BPC32DXR24 2.00X1.5
01
6
21 4381BUSHING BPC32DXR32 2.00X2.0
02
0
22 4379BUSHING BPC32DXR40 2.00X2.50 8 23 90767 COVER BODY FRONT TM6116 V2 1
16116MTESAB5523742
16116MTKNIL6023752
26 29723 GEARBOX 010(EAR 02356) 1 27 29722 TURNTABLE BEARING 450-05110-
11
28 D1453MOTOR HYD EATON 101-2493 1 29 21151GASKET MOTOR 008-10056-1 1 30 8377 PIN CAP 0.56X3.50X0.19 YZ 3
31 73400CRPIN TEAR DROP 2.00X11.31 ZC 3 32 D1307 CAP SCR 0.50-13X1.25 SHGR8 W/ RED
PATCH2
4HS05.2X9-88.0RCSPAC5940333
34 17148CAP SCR 0.75-10X3.00 HHGR9 14
35 0485CAP SCR 0.31-18X1.25 HHGR5 2 36 29725PCGUARD TTB TM6120C PC BLAC
K1
37 29727GUARD TTB TM6120C PC BLAC
K1
38 18042 HOSE CLAMP TM14160 PC WHIT
E2
PN 99145

Stellar®TM6116 TireMan Owner’s Manual | Page 11
TM6116 w/Rotation Pads Assembly - PN 99143
1
27 22 5 22 15
33 29
10 21 13
35
30
10
21 13
17
25
7
28
25
34
14 21
8
21
26
21
10
29
33
19 24 31
39
18
24
11
13
21
9
32
12
32
36
38
2
12
12
37
6
4
40
20
25
41
23
16
3
43
53
25
56
13
21
49
34
12 34 48
21 13
50 46 47 51
44
52
23
12
48
21
13
42
45
20
25 54
20
25
55
CHECK OIL LEVEL IN GEARBOX
GEAR BOX REPLACEMENT KIT 39965 OUTPUT SHAFT ONLY 68662 OUTPUT SHAFT KIT 68667 OUTPUT SHAFT SEAL KIT 68663
C-BALANCE VALVE C6184 CYLINDER SEAL KIT 80989 CYLINDER BUSHINGS 4381 BUSHINGS INCLUDED IN 74351
C-BALANCE VALVE 9803 CYLINDER SEAL KIT 1099 CYLINDER BUSHING 16067 BUSHINGS INCLUDED IN 51344/51819

Page 12 | Stellar®TM6116 TireMan Owner’s Manual
TM6116 w/Rotation Pads Bill - PN 99143
.YTQNOITPIRCSEDTRAPMETI
12V6116MTYDOB952491
42V6116MTKNIL333492
394264 ARM TM6116 SS PAD ROT V2 1
252.31X05.3REDNILYC153474
535111VALVE COMB DIV FD10-44-6T-N-442 678431 LIGHT FLOOD LED 3.2X2.9 850LM 16W 10-
30V 2
8LYNIVKLB57.0PMALC2800C7
283.1PMALC6855C8
913315PIN CAP 0.56X4.00X0.19 YZ 2
10 5145PIN CAP 0.56X3.00X0.19 YZ 24 11 9320 PIN CAP 0.44X1.75X0.19 YZ 2
41THGIARTSTPN8/1KREZ2951c21
13 10172 CAP SCR 0.50-13X1.00 HHGR8 30 14 8833CAP SCR 0.50-13X2.00 HHGR8 2 15 0339 CAP SCR 0.25-20X2.50 HHGR5 4 16 22278 CAP SCR 0.75-10X3.50 HHGR9 12 17 0486CAP SCR 0.31-18X1.50 HHGR5 4 18 0351 CAP SCR 0.38-16X1.00 HHGR5 2 19 0492 CAP SCR 0.38-16X0.75 HHGR5 2 20 0420CAP SCR 0.31-18X0.75 HHGR5 12
21 D0790 WASHER 0.50 SAE FLAT YELLOW GR836
8TALFSSU52.0REHSAW043022
23 17150WASHER 0.75 SAE FLAT YELLOW GR9 26
24 C6353 WASHER 0.38 SAE FLAT YELLOW GR8 4
22TALFSSU13.0REHSAW343052
26 5468NUT 0.50-13 HHGR8 NYLOC2 27 0333NUT 0.25-20 HHGR5 NYLOC4 28 0342NUT 0.31-18 HHGR5 NYLOC4
8CZT&D57.41X00.2NIPRC5137192
4T&D36.01X00.2NIPRC0564703
31 51652CRPIN TEAR DROP 1.50X2.31 ZC 2 32 0865 BUSHING BPC48DXR32 3.00X2.004 33 4380 BUSHING BPC32DXR24 2.00X1.5016
34 4381 BUSHING BPC32DXR32 2.00X2.0020 35 4379 BUSHING BPC32DXR40 2.00X2.508 36 94880PAD TM6116 V2 ROT PAD SS 1 37 94375PAD TM6116 V2 ROT PAD CS 1
38 94879 ARM TM6116 CS PAD ROT V2 1
1SS57.9X00.2REDNILYC4431593 1SC57.9X00.2REDNILYC9181504
41 90767 COVER BODY FRONT TM6116 V2 1
16116MTESAB5523724
.YTQNOITPIRCSEDTRAPMETI
16116MTKNIL6023734
44 29723 GEARBOX 010(EAR 02356) 1 45 29722 TURNTABLE BEARING 450-05110-11 46 D1453MOTOR HYD EATON 101-24931
47 21151 GASKET MOTOR 008-10056-11 48 8377 PIN CAP 0.56X3.50X0.19 YZ 3 49 73400CRPIN TEAR DROP 2.00X11.31 ZC 3 50 D1307 CAP SCR 0.50-13X1.25 SHGR8 W/ RED
PATCH2
4HS05.2X9-88.0RCSPAC5940315
52 17148 CAP SCR 0.75-10X3.00 HHGR9 14 53 0485 CAP SCR 0.31-18X1.25 HHGR5 2 54 29725PCGUARD TTB TM6120C PC BLACK1 55 29727 GUARD TTB TM6120C PC BLACK1 56 18042 HOSE CLAMP TM14160 PC WHITE2
NOT SHOWN: 21409 (1) WIRE HARNESS FLOOD LIGHT TM14160 73107 (1) DECAL KIT TM6116 99136 (1) HYD KIT TM6116 V2 ROT PADS D0240 (1) FTG 4-2 CPRSN-MP 90 D1810 (0.67 FT) TBE AIR SAEJ844 TYPE A .25 (RM) D1345 (1) FTG 4-2 CPRSN-MP STRAIGHT 22161 (1) FTG 2-2 FP-FP COUPLER STRAIGHT BRASS 56589 (1) ZERK 1/8 NPT STRAIGHT LONG THREAD 9752 (2) CONNECT 2 PIN SHROUD PACKARD 9756 (4) CONTACT M TERM SHROUD 18-20 8384 (4) CABLE SEAL 18-20 PACKARD 39000 99433 (1) MANUAL TM6116 V2

Stellar®TM6116 TireMan Owner’s Manual | Page 13
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Subject to Change without Notification.
© 2021 Stellar Industries, Inc.