stellar labs TireMan 7120 User manual

TireMan 7120
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 Notication.
© 2016 Stellar Industries, Inc. Last Revision: 11/28/16
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®TM7120 TireMan Owner’s Manual
Model TM7120 Manual Revisions
Date of Revsion Section Revised Description of Revision

Stellar®TM7120 TireMan Owner’s Manual | Page iii
Table of Contents
Introduction ........................................................................................ iv
Model TM7120 Specications ............................................................1
TM7120 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 (FP Version) - PN 78071 .................................................7
Hydraulic Kit (RP Version) - PN 78019 .................................................8
Hydraulic Kit (CRP Version) - PN 78012 ..............................................9
TM7120 (FP Version) Breakdown - PN 77857 ...................................10
TM7120 (FP Version) Bill - PN 77857 ..................................................11
TM7120 (RP Version) Breakdown - PN 74244 ..................................12
TM7120 (RP Version) Bill - PN 74244 ..................................................13
TM7120 (CRP Version) Breakdown - PN 76339 ................................14
TM7120 (CRP Version) Bill - PN 76339 ...............................................15
Decal Placement - PN 54772 .........................................................16

Page iv | Stellar®TM7120 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®TM7120 TireMan Owner’s Manual | Page 1
Capacity: 7,200 lbs @20 ft (3,265 kg @ 6.10m)
Clamping Span: Fixed Pads - 28" to 125" (71 cm to 318 cm)
Rotating Pads - 28" to 125" (71 cm to 318 cm)
Cont. Rotating Pads - 26" to 123" (65 cm to 311 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: Continuous 360º power
TireMan Tilt: +79º to -43º
Hydraulic Controls: Incorporated with the crane controls
Approximate Shipping Weight: 2,750 lbs (1,247 kg) FP Version
3,300 lbs (1,497 kg) RP Version
3,450 lbs (1,565 kg) CRP Version
Model TM7120 Specications
Capacity: 7,200 lbs @20 ft (3,265 kg @ 6.10m)
Clamping Span: 49” to 124” (124 cm to 314 cm)
Clamp Cylinders: 3.5” (8.9 cm) bore with integral pilot operated
counterbalance valves
Tilt Cylinder: Provided by crane extension boom
Body Rotation: 300º power
Rotation System: Hourglass worm gear
Clamping Pad Rotation: Continuous 360º power
TireMan Tilt: +79º to -43º
Hydraulic Controls: Incorporated with the crane controls
Approximate Shipping Weight: 2,450 lbs (1,110 kg) Standard
2,900 lbs (1,315 kg) With Rotary Pads
ROTAT ION
20’(6.10m)
7200lbs(3265kg)

Page 2 | Stellar®TM7120 TireMan Owner’s Manual
125” - Fixed Pads
125” - Rotating Pads
123” - Continuous Rotating Pads
28” - Fixed Pads
28” - Rotating Pads
26” - Continuous Rotating Pads
TM7120 Dimensional Layout

Stellar®TM7120 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 conicting
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 Trafc 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 TM7120
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®TM7120 TireMan Owner’s Manual
When using the torque data in the
chart, the following rules should be
observed:
• Bolt manufacturer’s particular
specications 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 specied 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 specic 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®TM7120 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 nonammable 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®TM7120 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 2500 2500
TM Clamp 6.6 4200 4200
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