stellar labs TireMan 20165 User manual
TireMan 20165
Owner’s Manual
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
Subject to Change without Notication.
© 2018 Stellar Industries, Inc.
Rev 1
PN 90385
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®TM20165 TireMan Owner’s Manual
Model TM20165 Manual Revisions
Date of Revsion Section Revised Description of Revision
2/17/16 Hydraulics and Assembly Updated Hydraulic and Assembly
Drawings
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®TM20165 TireMan Owner’s Manual | Page iii
Table of Contents
Introduction .........................................................................................................iv
Model TM20165 Specications ...........................................................................1
TM20165 Dimensional Layout .............................................................................2
General Installation .............................................................................................3
Installer Notice ...................................................................................................3
Torque Data Chart ............................................................................................4
Hydraulic Installation ...........................................................................................5
Face Seal/O-Ring Size Chart ..............................................................................6
Hydraulic Kit - PN 81761 Part 1 ...........................................................................7
Hydraulic Kit - PN 81761 Part 2 ...........................................................................8
Hydraulic Kit - PN 81761 Part 3 ...........................................................................9
Hydraulic Installation Drawing - PN 82658 ......................................................10
Hydraulic Schematic - PN 81761 ......................................................................11
TireMan Hydraulic Kit - PN 65365 ......................................................................12
Cooler Wiring .....................................................................................................13
PTO Schematic ..................................................................................................14
24V Converter Wiring ........................................................................................15
Decal Placement - PN 77565 ...........................................................................16
TM20165 Assembly Standard - PN 63528 ........................................................17
TM20165 Assembly w/Fallback Protection - PN 76685 ..................................18
Crane Assembly - PN 81760 Part 1 ...................................................................19
Crane Assembly - PN 81760 Part 2 ...................................................................20
Crane Assembly - PN 81760 Part 3 ...................................................................21
Crane Assembly - PN 81760 Part 4 ...................................................................22
Mounting Kit Subframe Assembly - Part 1 .......................................................23
Mounting Kit Subframe Assembly - Part 2 .......................................................24
Crane Base Stabilizer Assembly - PN 65107 ....................................................25
Crane Base Stabilizer Cylinder Assembly - PN 64367 .....................................26
Non-Crane Base Stabilizer Assembly - PN 64262 ............................................27
Non-Crane Base Stabilizer Extension Cylinder Assembly - PN 64367 ...........28
Reservoir Assembly - PN 86517 .........................................................................29
Page iv | Stellar®TM20165 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:
Order Parts [email protected]
Warranty Information [email protected]
Stellar®TM20165 TireMan Owner’s Manual | Page 1
ROTATION
21’(6.40m)
20,000lbs(9,070kg)
24’(7.31m)
17,000lbs(7,710kg)
Capacity: 20,000 lbs @ 21’ (9,070 kg @ 6.4 m)
Clamping Span: 43” to 164” (110 cm to 417 cm)
Clamp Cylinders: 5” (12.7 cm) bore with pilot operated check valves
Tilt Cylinder: Provided by crane extension boom
Body Rotation: 320º power
Rotation System: Worm gear
Clamping Pad Rotation: Continuous 360º power
TireMan Tilt: +74º to -27.5º
System Pressure: 5000 PSI (350 bar)
Hydraulic Flow: 26-32 GPM (100-120 L/min)
Hydraulic Controls: Incorporated with the crane controls
Approximate Shipping Weight: 10,700 lbs (4,854 kg)
Model TM20165 Specications
Page 2 | Stellar®TM20165 TireMan Owner’s Manual
164
43
TM20165 Dimensional Layout
Stellar®TM20165 TireMan Owner’s Manual | Page 3
Installer Notice
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 effect 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 conicting
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 Trafc 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 TM20165
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 (800) 321 3741.
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®TM20165 TireMan Owner’s Manual
When using the torque data in the
chart, the following rules should be
observed:
• Bolt manufacturer’s particular
specications 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 specied 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 specic 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®TM20165 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 nonammable 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 crane. If
hydraulic uid 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, 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 hydralic hose. The hose
should be installed so any bend is with this curvature.
WARNING
WARNING
WARNING
NOTICE
Page 6 | Stellar®TM20165 TireMan Owner’s Manual
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®TM20165 TireMan Owner’s Manual | Page 7
Hydraulic Kit - PN 81761 Part 1
.YTQNOITPIRCSEDTRAPMETI
1C2142 FTG 12-12 MFS-MORB STRAIGHT 2
2C2269 FTG 12-16 MFS-MORB STRAIGHT 1
359763 FTG 12-16 MFS-MBSPP STRAIGHT 2
431658 FTG 12-12 MFS-MBSPP STRAIGHT 3
109SSFF-SFM21-21GTF3094c5
642053 FTG 12-12 MBSPP W/BS-FORB3
751274 FTG 16-12 MFS-MAORB 90 1
865584 FTG 16-12 MFS-MBSPP 90 3
965580 FTG 16-16 MFS-MBSPP STRAIGHT 1
10 65582 FTG 12-12 MFS-MBSPP 90 1
11 67060 VALVE SHUTTLE VONBERG 65125-6T 1
12 30542 FTG 12-12-12 MAORB-FORB-FORB TEE1
13 C2053 FTG 12-8 MORB-FORB STRAIGHT REDUCER8
14 59959FTG 16-16 MFS-MAORB 90 2
109BROAM-SFM8-6GTF7455C51
16 C4227 FTG 8-12 MFS-MAORB 90 6
609SSFF-SFM8-8GTF6732C71
18 65587FTG 6-6 MFS-MBSPP STRAIGHT 1
109BROAM-SSFF6-6GTF6682191
209BROAM-SFM6-6GTF8330C02
21 65670 FTG 6-4 MFS-MBSPP STRAIGHT1
22 10980 FTG 8-4 MORB-FORB STRAIGHT REDUCER1
23 51817FTG 4-4 MAORB-FORB 90 1
24 1554 FTG 8-8 MFS-MORB STRAIGHT 14
25 C5968FTG 12-12 MFS-MAORB 90 2
26 39780GAUGE OIL LF 2.5 0-6000 CBM SAE1
PN 81761 - Part 1
21
3
3
4
7
4
5
9
10
2
6
11
12
1
1
6
26 23
22
13
6
15 13
17
24
13
16
14
19
18
20 20
8
8
25
24
14
16
25
13
17
Page 8 | Stellar®TM20165 TireMan Owner’s Manual
Hydraulic Kit - PN 81761 Part 2
.YTQNOITPIRCSEDTRAPMETI
165579 FTG 16-12 MFS-MBSPP STRAIGHT 1
231658 FTG 12-12 MFS-MBSPP STRAIGHT 3
331659 FTG 8-12 MFS-MBSPP STRAIGHT 1
1
2
3
PN 81761 - Part 2
Stellar®TM20165 TireMan Owner’s Manual | Page 9
Hydraulic Kit - PN 81761 Part 3
.YTQNOITPIRCSEDTRAPMETI
11554FTG 8-8 MFS-MORB STRAIGHT 14
265663 FTG 8-8 MORB-MFS 90 SWIVEL 4
A
B
C
DETAIL A
SCALE 1 : 10
1
DETAIL B
SCALE 1 : 10
2
DETAIL C
SCALE 1 : 10
1
PN 81761 - Part 3
Page 10 | Stellar®TM20165 TireMan Owner’s Manual
Hydraulic Installation Drawing - PN 82658
PN 82658
Stellar®TM20165 TireMan Owner’s Manual | Page 11
Hydraulic Schematic - PN 81761
AB AB AB AB AB AB
654 21
8113838321
T1
T2
P2
P1
S
T
Ps
P
S
TP
T1
P1
S
SWIVEL
JOINT
10
VARIABLE FLOW
100 - 120 l/m
40 l/m
C1
C2
V1
V2
T
C1
C2
V1
V2
T
3
34
(c)50-50-50-50(c)
04A
(o)0-75-50-0(o)
92B
(d)75-75-75-75(d)
320A
(d)35-35-75-75m(d)
016A
(d)35-35-75-75m(d)
016A
M
12
41
1 Mpa
1 Mpa
12
43
1 Mpa
1 Mpa
T2 T3
P2
To pressure reducer PRF
C3
V2
V1
C1
C2
25
25
2
18
1
18
AB AB
(o)0-50- 50-0(o)
84A
(c)50-50-50-50(c)
04A
(o)0-50-50-0(o)
84A
M2
C1C2
V1
V2
37 21
S
P1
P2
T2
T1
S
P1
P2
T2
T1
Pad
rotation
Body
rotation
Clamp
cylinder
AB
P
P
T
T
AB AB
AB
P
PT
T
AB AB
123
SS Front
In/Out
SS Front
Up/Down
SS Rear
Up/Down
CS Front
In/Out
CS Front
Up/Down
CS Rear
Up/Down
123
A
CB
Page 12 | Stellar®TM20165 TireMan Owner’s Manual
TireMan Hydraulic Kit - PN 65365
PN 65365
Stellar®TM20165 TireMan Owner’s Manual | Page 13
Cooler Wiring
Page 14 | Stellar®TM20165 TireMan Owner’s Manual
PTO Schematic
Stellar®TM20165 TireMan Owner’s Manual | Page 15
24V Converter Wiring
Page 16 | Stellar®TM20165 TireMan Owner’s Manual
Decal Placement - PN 77565
STELLAR TM20165
CAPACITY
CHART
ROTATION
21’(6.40m)
20,000lbs(9,070kg)
24’(7.31m)
17,000lbs(7,710kg)
PN69749
MAXIMUM RATEDLOAD
20000 LBS
EXCEEDINGMAXIMUM RATED LOAD WILL
DAMAGEEQUIPMENT AND VOID WARRANTY
77562
9070 KG
WARNING
CrushHazard
Keepclearof stabilizer legs during
operation.
Failuretokeep clear of moving
stabilizerlegscan result in death or
seriousinjury. C4795
1.)Lubricate bearing and pinion teeth with Molub-Alloy 936SF.
2.)Lubricate inner race and pin with EP2 (extreme pressuregrease).
3.)Check gearbox oil level monthly (Traxon80W-90).
4.)Visually inspect bolts for tightness. Check torque if necessary.
Boltson inner and outer race should be torqued to 340 ft-lbs.
Inspect Rotation Bearing Monthly
22617
GreaseWeekly
22618
GreasebearingwithEP2
(ExtremePressureGrease)
whilerotatingthebearing.
12
4
10
6 8 9 11
12 12
WARNING
CrushHazard
Keepclearof stabilizer legs during
operation.
Failuretokeep clear of moving
stabilizerlegscan result in death or
seriousinjury. C4795
7
3
SSFRONT
STABILIZER
SSFRONT
STABILIZER
IN
OUT
DOWN
UP
SSREAR
STABILIZER
DOWN
UP
PN77563
CSREAR
STABILIZER
CSFRONT
STABILIZER
DOWN
UP
DOWN
UP
CSFRONT
STABILIZER
IN
OUT
PN77564
OPENCLOSE
TireMan
Clamp
TireMan
Rotation
TireMan
PadSpin
PN77569
Donothandletires filled with ballast.
Donotdragthe tire. the unit is designed
toliftandposition.
Donotclampan uninflated tire and then inflate.Do Not use the outer cylinder to push objects.
Donotusethe unit for any jacking, pulling, or
dragginginvolvinganobject or another vehicle.
Donotuseone arm of the to break beads.
Donotuseone arm to sling a load.
54781-RevA
Readandunderstandall manuals and safety
signsbeforeoperatingor servicing this
equipment.
Failureto follow
theseinstructions
canresult in death
orserious injury:
UntrainedOperatorHazard
MisuseHazard
MisuseHazardMisuseHazard
MisuseHazardMisuseHazard
MisuseHazardMisuseHazard
Keepnon-essentialpersonsclear of crane
duringoperation.
CrushHazard
DANGER
Deathorseriousinjury will result from
touchingtetheredremoteif crane, load, or
vehiclebecomeselectricallycharged.
Maintainsafeclearancefrom high voltage
powersources.
ElectrocutionHazardElectrocutionHazard
WARNING
Deathorseriousinjury will result from
inadequateclearanceifcrane, load, or vehicle
becomeselectricallycharged.
•Maintainsafeclearance from high voltage
powersources.
•Neverapproachvehicle or load if equipment
is near a high voltage power source.
5
Not Shown
Front Stabilizers
Rear Stabilizers
PN 77565
(Rev A - 04/12/16)
ITEM PN DESCRIPTION LOCATION QTY
1 22617 DECAL ROTATION BEARING Rotation Bearing Base 1
2 22618 DECAL GREASE WEEKLY Tire Man Arms - Both Sides 2
3 52681 DECAL STELLAR LOGO 6.00X16.50 TIreMan Link - Both Sides 2
4 54589 DECAL STELLAR LOGO 8.00x22.25 Main Boom - Both Sides 2
5 54781 DECAL WARNING PLACARD Front Stabilizer Leg - Both Sides 2
6 69749 DECAL CAPACITY TM20165 On body near control center - Not Shown 2
7 77562 DECAL RATED LOAD TM20165 Tire Man Arms - Both Sides 2
8 77563 DECAL STABILIZERS TM20165 SS Near valve banks - Not Shown 1
9 77564 DECAL STABILIZERS TM20165 CS Near valve banks - Not Shown 1
10 77566 DECAL IDENTIFICATION TM20165 Main Boom - Both Sides 2
11 77569 DECAL VB CONTROL TM20165 Near valve banks - Not Shown 1
12 C4795 DECAL WARNING STABILIZER Front/Rear Stabilizer Legs - Both Sides 4
13 81771 DECAL TM20165 PUSH/PULL Near Selector Valve - Not shown 1
For use
with body:
ITEM PN DESCRIPTION LOCATION QTY
14 C4545 DECAL DANGER ELECTROCUTION Four corners of the body. 4
15 C5910 DECAL STELLAR LOGO 3.75X9.00 Optional 1
16 C5911 DECAL STELLAR LOGO 1.65X4.50 Optional 3
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