stellar labs TireMan 4110 User manual

Owner’s Manual
Last Revision: 04/08/14
Subject to Change without Notification.
© 2014 Stellar Industries, Inc.
Safety • Assembly • Maintenance • Parts
TireMan 4110
Stellar Industries, Inc.
190 State Street
O Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com

TM4110 Manual Revisions
Date of Revision
July 1st, 2012
Description of Revision
Updated Assembly Drawings to reflect engineering
changes.
Section Revised
Assembly Drawings

Table of Contents i
TM4110
Table of Contents
An Overview about Safety ..................................................................ii
TireMan 4110 Introduction ...................................................................1
TireMan 4110 Specifications ................................................................2
TireMan 4110 Dimensional Layout ......................................................3
TireMan Safety Notes ...........................................................................4
TireMan Safety Notes Continued........................................................5
Stellar Safety Decal - PN 16732 ...........................................................6
TireMan 4110 Decal it.........................................................................7
TireMan 4110 Assembly - PN 61223.....................................................8
TireMan 4110 Mounting it - PN 61401 ...............................................9
TireMan 4110 Assembly w/Rotation Pads - PN 61386.....................10
TireMan 4110 Optional Pad Extensions - PN 35434.........................11
TireMan 4110 Optional Pad Extensions - PN 58288.........................12
TireMan 4110 Optional Pad Extensions - PN 61707.........................13
Lubrication Recommendations ........................................................14
TireMan 4110 Hydraulic it - PN 67411 .............................................15
TireMan 4110 w/Rotating Pads Hydraulic it - PN 63809 ...............16
Replacement Parts.............................................................................17
Troubleshooting...................................................................................18
Troubleshooting Continued... ............................................................19
Troubleshooting Chart........................................................................20
Troubleshooting Chart Continued... .................................................21
6-Function Hetronic Radio Remote Troubleshooting .....................22
Transmitter Troubleshooting ...............................................................23
Receiver Troubleshooting ..................................................................23
Warranty Information .........................................................................24

ii Stellar TM4110 Owner’s Manual
As the owner or employer, it is your responsibility to instruct the operator in the safe opera-
tion of this equipment and to provide the operator with properly maintained equipment.
Failure to read this manual by anyone who will operate, service, or work around this tire
manipulator is a misuse of the equipment. Death or serious injury will result from improper
use or maintenance of this machine.
Occupational safety is a prime concern of Stellar Industries in the design and production
of this tire manipulator. Our goal in writing this manual was the safety of the operator and
others who work around this equipment.
It is your responsibility to know the specific requirements, governmental regulations, pre-
cautions and work hazards that exist in the operation and maintenance of this tire manip-
ulator. You shall make these available and known to all personnel working with and
around the equipment, so that all of you will take the necessary and required safety pre-
cautions.
FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
It is also your responsibility to operate and maintain your tire manipulator with caution, skill,
and good judgment. Following the recognized safety procedures will help you avoid
accidents. Modification to any part of his tire manipulator can create a safety hazard
and therefore shall not be made without the manufacturer’s written approval. Use only
factory approved accessories, options, and parts on this equipment. The rebuilding or
remounting of this equipment requires the mounting procedures and retesting to be in
accordance with factory instructions. Safety covers and devices must remain installed
and maintained in proper working condition. Safety decals must be maintained, be com-
pletely legible, and be properly located. If safety covers, devices, or decals are missing,
they must be replaced with the proper designated Stellar part.
Be capable, careful, and concerned! Make safety your everyday business!
An Overview about Safety
Attention!
According to Federal Law (49 cfr part 571),
each final-stage manufacturer shall com-
plete 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 manu-
factured in two or more stages.
Therefore, the installer of Stellar tire manipu-
lators is considered one of the manufactur-
ers of the vehicle. As such a manufacturer,
the installer is responsible for compliance
with all applicable federal and state regu-
lations. 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
www.gpoaccess.gov/nara/index.html for
the full text of Code of Federal Regulations.

Page 1
TM4110TM4110
For Technical Questions, Information, arts, 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 arts [email protected]
Warranty Information [email protected]
The Stellar TireMan is designed to provide
safe and dependable service. With proper
use and maintenance, these tire manipula-
tors will operate at peak performance for
many years.
To promote this longevity, carefully study
the information contained in this manual
before putting the equipment into service.
Though it is not intended to be a training
manual for beginners, this manual should
provide solid guidelines for the safe and
proper usage of the tire handler.
Once you feel comfortable with the materi-
al contained in this manual, strive to exer-
cise your knowledge as you safely operate
and maintain the tire manipulator. This
process is vital to the proper use of the unit.
A few notes on this manual:
A copy of this manual is provided with
every tire manipulator and shall remain with
the tire manipulator at all times.
Information contained within this manual
does not cover all maintenance, operating,
or repair instructions pertinent to all possible
situations.
Please be aware that some sections of this
manual contain information pertaining to
Stellar manufactured tire manipulators in
general and may or may not apply to your
specific model.
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 require-
ment or obligation for immediate mandato-
ry 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].
ATTENTION
Failure to adhere to the instructions could result in property damage or
even serious bodily injury to the operator or others close to the tire
manipulator.
TireMan 4110 Introduction

2Stellar TM4110 Owner’s Manual
TireMan 4110 Specifications
Capacity: 4,600 lbs @16 ft (2,086 kg @ 4.87m)
Clamping Span: 48” to 110” (121.92 cm to 279.4 cm)
Optional Pad Extension: 29” (73.66 cm) arms closed
Clamp Cylinders: 2.5” (6.35 cm) bore with pilot operated check valves
Tilt Cylinder: Provided by crane extension boom
Body Rotation: 285º power
Rotation System: Rotation bearing and worm-driven gear box
Clamping Pad Rotation: Optional: 90º Rotating Pads
TireMan Tilt: +85º to -37º
Hydraulic Controls: Incorporated with the crane controls
Approximate Shipping Weight: Standard: 1,550 lbs (703 kg)
16’(4.87m)
4600lbs(2086kg)
ROTATION
90º Rotating Pad: 1,825 lbs (827 kg)

Page 3
TM4110TM4110
TireMan 4110 Dimensional Layout
48” 110”

4Stellar TM4110 Owner’s Manual
TireMan Safety Notes
General
It is the responsibility of the owner to instruct
the operator in the safe operation of your
equipment and to provide the operator
with properly maintained equipment.
Trainees or untrained persons shall be under
the direct supervision of qualified persons.
Do not operate equipment under the
adverse influence of alcohol, drugs, or
medication.
ersonal Safety
eep clear of all moving parts.
Always wear the prescribed personal safety
devices.
Always wear approved accident-preven-
tion clothing such as: protective helmets,
anti-slip shoes with steel toes, protective
gloves, anti-noise headphones, protective
glasses, and reflective jackets with breath-
ing apparatus. Consult your employer
regarding current safety regulations and
accident-prevention equipment.
Do not wear rings, wristwatch, jewelry,
loose-fitting or hanging clothing such as
ties, torn garments, scarves, unbuttoned
jackets or unzipped overalls, which could
get caught up in the moving parts of the
tire manipulator.
eep a first-aid box and a fire extinguisher
readily available on the truck. Regularly
check to make sure the fire extinguisher is
fully charged and the first-aid kit is stocked.
Do not use controls and hoses as hand-
holds. These parts move and cannot pro-
vide stable support.
Never allow anyone to ride the tire manipu-
lator arms or load.
Maintenance Safety
Never modify or alter any of the equip-
ment, whether mechanical, electrical, or
hydraulic, without explicit approval from
Stellar Industries.
Do not perform any maintenance or repair
work on the tire manipulator unless author-
ized and trained to do so.
Release system pressure before attempting
to make any adjustments or repairs.
Do not attempt service or repair when the
PTO is engaged.
Decals are considered safety equipment.
They must be maintained, as would other
safety devices. Do not remove any Decals.
Replace any Decals that are missing, dam-
aged, or not legible.
The safety instruction plates, notices, load
charts and any other sticker applied to the
tire manipulator, crane or service body must
be kept legible and in good condition. If
necessary, replace them.
Stability
now the tire manipulator components and
their capabilities and limitations.
Overloading the tire manipulator may result
in serious injury to self and others, and dam-
age to the equipment and immediate sur-
roundings.
Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s
hydraulic, mechanical, and structural
design rather than stability.
The supporting surface under the service
truck must be able to support the weight of
the machine and its load. Use outrigger
pads if necessary.

Page 5
TM4110TM4110
TireMan Safety Notes Continued...
Park the vehicle on level ground and
extend the outriggers fully out and then
down.
eep feet and legs clear when lowering
outrigger jacks.
Never operate the tire manipulator without
making sure the outriggers are positioned
on stable, flat ground.
Set the parking brake and disengage the
drive axle before attempting a lift.
Load Safety
Operate the tire manipulator in compliance
with the load capacity chart at all times.
now the weight of the load being lifted.
Do not rely on the overload device to
determine maximum rated loads.
Never use a sling bar or anything larger
than the hook throat that could prevent the
hook latch from closing. This would negate
the safety feature.
Do not apply side loads to the booms.
Do not leave a tire manipulator load sus-
pended or unattended.
Do not walk under suspended loads.
Do not position any load over a person nor
should any person be permitted to place
him or herself under a load.
Do not use the boom or the winch to drag
a load.
Do not use the tire manipulator arms to
push downward onto anything.
Electrocution
Allow extra space for swaying power lines in
windy conditions.
eep a minimum of ten feet between any
portion of the tire manipulator and an elec-
trical line. Add an additional 12” for every
additional 30,000 Volts or less.
Remember - Death or serious injury can
occur when working near power lines or
during electrical storms.
Use a signal person when operating near
electrical sources.
Environment
Do not operate the tire manipulator during
electrical storms.
In extreme cold, allow adequate time to
warm the truck before engaging the PTO.
Do not rev the truck engine and over
speed the hydraulic pumps as permanent
damage to the pumps may occur. Follow
the vehicle owner’s manual regarding
operating the vehicle in such adverse con-
ditions.
In dusty work areas, every effort must be
taken to keep dust and sand out of the
moving parts of the machinery.
In high humidity work areas, keep parts as
dry as possible and well lubricated.
ATTENTION
Stellar Industries, Inc. is not liable for accidents incurred by the tire
manipulator because of the operator’s non-fulfillment of current rules, laws
and regulations.

6Stellar TM4110 Owner’s Manual
Stellar Safety Decal - N 16732
DANGER
NEVER handle tires filled with ballast.
Instability and structural failure will result.
NEVER operate the unit while persons not
required for operation are in the work area.
NEVER drag the tire - the unit is designed
to lift and position.
NEVER clamp an uninflated tire and then
inflate - Damage or injury will result.
NEVER use the outer cylinder to push objects with the
TireMan - Damage to the equipment will result.
NEVER use the unit for any jacking, pulling, or dragging
operation involving an object or another vehicle.
Damage to the equipment will result.
16732
NEVER use one arm of the TireMan to break beads.
Damage to the equipment will result.
NEVER use one arm of the TireMan to sling a load.
Damage to the equipment will result.
FAILURE TO OBEY THE FOLLOWING WILL RESULT IN
DEATH OR SERIOUS INJURY
INSTABILITY OR EQUIPMENT DAMAGE.
IMPROPER OPERATION WILL VOID WARRANTY

Page 7
TM4110TM4110
TireMan 4110 Decal Kit
03
04
02
01
35114
54598
35113
PART No.ITEM
DECAL TM4110 RATED LOAD
DECAL IDENTIFICATION TM4110
DECAL TM4110 TIREMAN ROATATION
DESCRIPTION
2
2
53850 DECAL STELLAR LOGO 4.00X11.5 2
1
QTY
2
5
3
3
05
38664 DECAL CAPACITY TM4110 2
4
1
PN 35432

8Stellar TM4110 Owner’s Manual
TireMan 4110 Assembly - N 61223
PN 61223
MOTOR HYD EATON 158-1035
9 64305
1
13 C2491 LIGHT DOCKING 07-0780-32 REF. ONLY 1
14 C5902WASHER 0.63 SAE FLAT YELLOW GR834
15 C1025 CAP SCR 0.63-11X2.00 HHGR8 ZY34
891.0X05.2X44.0PACNIP304761
88RGTALF83.0REHSAW3536C71
18 0351 CAP SCR 0.38-16X1.00 HHGR58
19 C6219 WASHER 0.75 SAE FLAT YELLOW GR84
20 35097 CAP SCR 0.75-10X3.00 SHGR8 ZINC4
21 21151GASKETMOTOR 008-10056-11
22 D1307 CAP SCR 0.50-13X1.25 SH2
23 0343 WASHER 0.31 USS FLAT ZINC8
24 0420 CAP SCR 0.31-18X0.75 HHGR56
29727PC8
1GEAR GUARD TM411035002PC7
2ARM TM4110 V2612246
2CYLINDER 2.50X31.25350015
1BODY TM4110
1C0216MTDRAUGRAEG
34572
3230812
2PIN 1.25X7.00 D&T3509211
2PIN 1.25X8.00 D&T740210
4
W/COUNTERSINKS
WEAR PAD TM4110 0.38X1.75X17.00
.YTQNOITPIRCSEDTRAPMETI
12V0114MTESAB722161
2 33944 GEARBOX 010(EAR 02356)1
3 33945 TURNTABLE BEARING 450-05110-11
4
.YTQNOITPIRCSEDTRAPMETI
25 0352 WASHER 0.50 USS FLAT ZINC16
26 C6106 NUT 0.50-13 HHGR5 NYLOC 8
27 D0894 SCREW #10-24X0.75 BTN HD SS 2
30 D1315 CAP SCR 0.25-20X1.00 FHSH CAP16
22TALF52.0REHSAW043013
32 0333 NUT 0.25-20 HHGR5 NYLOC 20
33 35111VALVE COMB DIV FD10-44-6T-N-441
34 0332 CAP SCR 0.31-18X1.75 HHGR52
35 8621 CLAMP HOSE/TUBE AG-32
36 0486 CAP SCR 0.31-18X1.50 HHGR52
37 39540PC GUARD FLOOD LIGHT TM41101
38 D0561 CAP SCR 0.25-20X0.50 BTNHD SS4
39 39545 WEAR PAD TM4110 BACK 2
40 28034 ANGLE WLDMT BUMPER TM61202
41 27989 FLAT BELTED RUBBERTM6120 BUMPER8
42 0359 CAP SCR 0.50-13X1.50 HHGR54
43 C1000 CAP SCR 0.50-13X5.00 HHGR54
44 41687 CAP SCR 0.25-20X1.25 FHSH CAP4
4
6
18
17
16
10
16
17
18
5
20
21
22
12
2
1
43 25
41
25
26
40
42 25
38 27
13
33
31
34
37
18
17
16 11 16
17 18
15
14
24
23
87
3
24 23
36
35 23
44
31
32
9
39
30
31
32
14
15
19

Page 9
TM4110TM4110
TireMan 4110 Mounting Kit - N 61401
PN 61401
.YTQNOITPIRCSEDTRAPMETI
12V0114MTKNIL283161
2 35102ZP PIN TEAR DROP 1.50X9.061
3 0067BUSHING BPC24DXR24 1.50X1.50 6
452.X05.3X65.0PACNIP30474
5C6353 WASHER 0.38 SAE FLAT YELLOW GR84
6 13573 CAP SCR 0.38-16X1.00 HHGR84
7 8621 CLAMP HOSE/TUBE AG-36
8 0343 WASHER 0.31 USS FLAT ZINC2
2COLYNHH81-13.0TUN24309
6THGIARTSTPN8/1KREZ2951c01
11 61404ZP PIN TEAR DROP 1.50X11.06 1
12 16067BUSHING BPC24DXR16 1.50X1.002
1T&D00.01X05.1NIPPZ3783131
14 D0790 WASHER 0.50 SAE FLAT YELLOW GR82
15 10666 CAP SCR 0.50-13X1.25 HHGR81
16 10172 CAP SCR 0.50-13X1.00 HHGR81
5
6
5
4
3
12
13
11
14
15
10
3
3
1
9
10
3
8
3
54
10
6
16
14
2
4
6
5
4
7
6

10 Stellar TM4110 Owner’s Manual
TireMan 4110 Assembly w/Rotation ads - N 61386
PN 61386
18
44
51
48
18
19 45
23
46
47
18
52
11
17
18 59 7
5
20
21
2
15
16
22
13
23
24
1
3
8
26 25
49
34 42 29
37
30
31
10 30
31
27
39
53
40
28
28
38
27
41
32
30
33
56
14
35
36
19
18
17 12
43
6
4
16
15
26
25
9
50
54
25
34
25 55
57 58
27
18
16
8
29 CAP SCR 0.25-20X1.00 FHSH CAPD1315
.YTQNOITPIRCSEDTRAPMETI
12V0114MTESAB722161
2 33944 GEARBOX 010(EAR 02356)1
3 33945 TURNTABLE BEARING 450-05110-11
4 51650 BODY TM4110 ROT PADS 1
252.13X05.2REDNILYC100535
6 61387 ARM TM4110 ROT PADS SS V2 1
7 61388 ARM TM4110 ROT PADS CS V2 1
10114MTDRAUGRAEGCP200538
1C0216MTDRAUGRAEGCP727929
10 64305 WEAR PAD TM4110 0.38X1.75X17.00
W/COUNTERSINKS 4
2T&D00.8X52.1NIP204711
2T&D00.7X52.1NIP2905321
13 32308 MOTOR HYD EATON 158-10351
14 C2491 LIGHT DOCKING 07-0780-32 REF. ONLY 1
15 C5902WASHER 0.63 SAE FLAT YELLOW GR834
16 C1025 CAP SCR 0.63-11X2.00 HHGR8 ZY34
891.0X05.2X44.0PACNIP304771
618RGTALF83.0REHSAW3536C81
19 0351 CAP SCR 0.38-16X1.00 HHGR58
20 C6219 WASHER 0.75 SAE FLAT YELLOW GR84
21 35097 CAP SCR 0.75-10X3.00 SHGR8 ZINC4
22 21151GASKETMOTOR 008-10056-11
48RGTALF05.0REHSAW0970D32
24 D1307 CAP SCR 0.50-13X1.25 SH2
25 0343 WASHER 0.31 USS FLAT ZINC12
26 0420 CAP SCR 0.31-18X0.75 HHGR56
27 0352 WASHER 0.50 USS FLAT ZINC16
28 C6106 NUT 0.50-13 HHGR5 NYLOC
.YTQNOITPIRCSEDTRAPMETI
42TALF52.0REHSAW043003
31 0333 NUT 0.25-20 HHGR5 NYLOC 20
32 35111VALVE COMB DIV FD10-44-6T-N-442
33 0332 CAP SCR 0.25-20X1.75 HHGR54
34 8621 CLAMP HOSE/TUBE AG-36
35 39540PC GUARD FLOOD LIGHT TM41101
36 D0561 CAP SCR 0.25-20X0.50 BTNHD SS4
37 39545 WEAR PAD TM4110 BACK 2
38 28034 ANGLE WLDMT BUMPER TM61202
39 27989 FLAT BELTED RUBBERTM6120 BUMPER8
40 0359 CAP SCR 0.50-13X1.50 HHGR54
41 C1000 CAP SCR 0.50-13X5.00 HHGR54
42 41687 CAP SCR 0.25-20X1.25 FHSH CAP4
43 61391 PAD TM4110 ROT PAD SS V21
44 61394 PAD TM4110 ROT PAD CS V2 1
291.0X05.3X65.0PACNIP773854
46 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY2
47 51652ZP PIN TEAR DROP 1.50X2.312
48 9320 PIN CAP 0.44X1.75X0.19 SS2
49 0489 CAP SCR 0.31-18X2.50 HHGR52
1SS57.9X00.2REDNILYC4431505
1SC57.9X00.2REDNILYC9181515
52 0492 CAP SCR 0.38-16X0.75 HHGR52
53 51445 BUSHING COMPOSITE MRP 2.00X2.504
54 0488 CAP SCR 0.31-18X2.00 HHGR52
2COLYNHH81-13.0TUN243055
56 D0894 SCREW #10-24X0.75 BTN HD SS2
283.1PMALC6855C75
58 16962 CAP SCR 0.38-16X1.50 HHGR82
59 56673 NUT 0.38-16 HHGR8 NYLOC 2

Page 11
TM4110
TireMan 4110 Optional ad Extensions - N 35434
PN 35434
1
2
ITEM PART DESCRIPTION QTY.
134942 PAD EXTENSION TM4110 20" 1
254922 PIN HITCH 0.63X6.50 W/LYNCH PIN 1

12 Stellar TM4110 Owner’s Manual
TireMan 4110 Optional ad Extensions - N 58288
.YTQNOITPIRCSEDTRAPMETI
1 57921 PAD EXTENSION TM4110 TEAR DROP2
2 54922 PIN HITCH 0.63X6.50 W/LYNCH PIN2
PN 58288
2
1

Page 13
TM4110
TireMan 4110 Optional ad Extensions - N 61707
.YTQNOITPIRCSEDTRAPMETI
1 61702 PAD EXT TM4110 ROT PAD V2 2
2 54922 PIN HITCH 0.63X6.50 W/LYNCH PIN 2
3 71894 HAIR PIN CLIP 0.19 x 3.75 2
PN 61707
2
1
3
Remove the lynch pin that comes
with the hitch pin

14 Stellar TM4110 Owner’s Manual
TM4110
Lubrication Recommendations
Component Location Recommendation
Engine Crankcase Apply Manufacturerer’s
Recommendations
Hydraulic System
Below –5*F
-5*F to 90*F
Above 90*F
Reservoir
Petro-Canada Arctic MV 15 (ISO 22)
Petro-Canada HYDREX 32 (ISO 32)
Petro-Canada HYDREX 46 (ISO 46)
Open Gears Hand Precision XL3 Moly EP 2
(NLGI 2 grease with moly)
Bearings, grease
(including turntable bearing
inner race)
Gun Precision XL EP 2 (NLGI 2)
Worm Drive Gearbox Gearbox Precision Synthetic EP 00 (NLGI 00)
Planetary Gearbox
(including winch)
Gearbox Traxon Synthetic 75W-90 (API GL-5)
Wear Pad Lubrication Spray Gearshield NC
Compressor Fluids
Reciprocating Single Stage
Reciprocating Double Stage
Crankcase
Crankcase
Compro 100 (ISO 100)
Compro 100 (ISO 100)
Screw
-15˚F to 86˚F
-23˚F to 100˚F
32˚F to 113˚F
Crankcase
Compro XL-S 32 (ISO 32)
Compro XL-S 46 (ISO46)
Compro XL-S 68 (ISO68)

Page 15
TM4110
TireMan 4110 Hydraulic Kit - N 67411
PN 67411

16 Stellar TM4110 Owner’s Manual
TireMan 4110 w/Rotating ads Hydraulic Kit - N 63809
PN 63809