TireMan 16160

TireMan 16160Owner’s Manual

Stellar Industries, Inc.190 State Street

PO Box 169Garner, IA 50438

800-321-3741 Fax: 641-923-2811

www.stellarindustries.comSubject to Change without Notification.© 2020 Stellar Industries, Inc.

Rev 2PN 90384

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® TM16160 TireMan Owner’s Manual

Model TM16160 Manual RevisionsDate of Revision Section Revised Description of Revision

Rev 212/22/20

Dimensional layoutHydraulic KitAssembly

Updated drawingUpdated drawingUpdated drawing and BOM

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® TM16160 TireMan Owner’s Manual | Page iii

Table of ContentsIntroduction .............................................................................................................................. ivModel TM16160 Specifications ................................................................................................ 1TM16160 Dimensional Layout .................................................................................................. 2General Installation .................................................................................................................. 3

Installer Notice ........................................................................................................................ 3Torque Data Chart ................................................................................................................. 4

Hydraulic Installation ................................................................................................................ 5Hydraulic Pressure Settings ...................................................................................................... 6Face Seal/O-Ring Size Chart ................................................................................................... 6Hydraulic Kit - PN 105060 .......................................................................................................... 7TM16160 Breakdown - PN 109359 ........................................................................................... 8TM16160 Bill - PN 109359 ........................................................................................................... 9Decal Placement - PN 37845 ................................................................................................ 10

Page iv | Stellar® TM16160 TireMan Owner’s Manual

IntroductionA 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

800-321-3741Hours: 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® TM16160 TireMan Owner’s Manual | Page 1

Model TM16160 Specifications

Capacity: 16,500 lbs @15 ft (7,484 kg @ 4.57m)

Clamping Span: 40” to 158” (102 cm to 401 cm)

Tilt Cylinder: Provided by crane extension boom

Body Rotation: 315º power

Rotation System: Worm gear

Clamping Pad Rotation: Continuous 360º power

TireMan Tilt: +80º to -20º

Hydraulic Controls: Incorporated with the crane controls

Approximate Shipping Weight: 6,000 lbs (2,722 kg)

Capacity: 16,500 lbs @15 ft (7,484 kg @ 4.57m)Clamping Span: 40” to 158” (102 cm to 401 cm)Clamp Cylinders: 4.50” (11.43 cm) bore with pilot operated check valvesTilt Cylinder: Provided by crane extension boomBody Rotation: 315º powerRotation System: Worm gearClamping Pad Rotation: Continuous 360º powerTireMan Tilt: +80º to -20ºHydraulic Controls: Incorporated with the crane controlsApproximate Shipping Weight: 6,000 lbs (2,722 kg)

15’(4.57m)16500lbs(7484kg)

ROTATION

17’(5.18m)14000lbs(6350kg)

20’(6.10m)12000lbs(5443kg)

MAXIMUM RATED LOAD

16500 LBSEXCEEDING MAXIMUM RATED LOAD WILL

DAMAGE EQUIPMENT AND VOID WARRANTY37847

7484 KG

| Stellar® TM16160 TireMan Owner’s Manual

158

40

TM16160 Dimensional Layout


Installer NoticeAccording 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 InstallationThis chapter is designed to serve as a general guide for the installation of a Stellar TM16160 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


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 18 223/8-16 0.3750 31 23 44 33 397/16-14 0.4375 49 37 70 52 631/2-13 0.5000 75 57 105 80 969/16-12 0.5625 110 82 155 115 1395/8-11 0.6250 150 115 220 160 1923/4-10 0.7500 265 200 375 280 3407/8-9 0.8750 395 295 605 455 5491-8 1.000 590 445 910 680 823

1 1/8-7 1.1250 795 595 1290 965 11671 1/4-7 1.2500 1120 840 1815 1360 16461 3/8-6 1.3750 1470 1100 2380 1780 21581 1/2-6 1.500 1950 1460 3160 2370 2865

GRADE 5 GRADE 8 GRADE 9

Torque Data Chart

NOTICE


Hydraulic InstallationNever 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


Hydraulic Pressure Settings

Main Relief 4600 psiPressure (psi)

Function Flow (gpm) Extend RetractInner 10.6 4400 2200Outer 10.6 4400 2200Extension 10.6 4400 4400Rotation 10.6 2200 2200TM Rot 6.6 2200 2200TM Pad Rot 6.6 2500 2500TM Clamp 6.6 4200 4200

Face Seal (A)Stellar® PN

HoseSize

FittingSize 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


Hyd

raul

ic K

it -

PN 1

0506

0

PN 1

0506

0

110

5061

1H

OSE

KIT

, TM

1215

4 V

3 C

ON

T R

P (in

cl:

2-8)

471

050

4re

fH

OSE

-HYD

, 0.3

8 X

60

371

052

2re

fH

OSE

-HYD

, 0.3

8 X

81

271

051

2re

fH

OSE

-HYD

, 0.3

8 X

76

585

509

1re

fH

OSE

-HYD

, 0.3

8 X

248

610

5064

1re

fH

OSE

-HYD

, 0.3

8 X

153

710

5348

2re

fH

OSE

-HYD

, 0.3

8 X

153

810

5347

1re

fH

OSE

-HYD

, 0.3

8 X

95

1010

5063

1V

AV

LE S

OLN

D 2

PO

S 3

WA

Y SV

10-3

4-8T

-N-1

2DR

935

111

1V

ALV

E C

OM

B D

IV F

D50

-44-

6T-N

-44

11D

1302

2FT

G 6

-10

MFS

-MA

OR

B 90

12C

0338

1FT

G 6

-6 M

FS-M

AO

RB

9013

0279

11FT

G 6

-6 M

FS-M

OR

B ST

RA

IGH

T14

1355

42

QU

ICK

CPL

R F

FH04

-38-

SAE-

F15

1355

52

QU

ICK

CPL

R F

FH04

-38-

SAE-

M

18D

1193

4FT

G 6

-6 M

FS-M

OA

RB

4517

1355

71

QU

ICK

CPL

R F

FH06

-12S

AE-

M16

1355

61

QU

ICK

CPL

R F

FH06

-12S

AE-

F

19C

2248

1FT

G 6

-6 M

FS-F

FSS

9020

1217

12

FTG

6-6

MFS

-MFS

SW

IVEL

STR

AIG

HT

2133

743

1FT

G 6

-6 F

FSS-

MO

RB

STR

AIG

HT

2253

479

4LO

OM

1.0

0 SP

IRA

L W

RA

P PO

LYET

HYL

ENE

24D

0107

1FT

G 6

-6-6

MFS

-MFS

-FFS

S BR

AN

CH

TEE

23C

1111

4FT

G 1

0-6

MO

RB-

FOR

B ST

RA

IGH

T R

EDU

CER

25C

1854

2FT

G 6

-8 M

FS-M

OR

B ST

RA

IGH

T26

C23

451

FTG

6-6

-6 M

FS-M

FS-M

AO

RB

TEE

ITEM

PART

No

.Q

TY.

DES

CRI

PTIO

N


TM16

160

Bre

akd

ow

n -

PN 1

0935

9

42

23

5029

28

7

31

10

1335

12

8

36

2931

22

20

CY

LIN

DE

R B

USH

ING

S 06

35

3437

9

30

21

14

25

3

30

1

26

41

6

33

48

4816

17

24

1819

29

25

29

43

2537

44

25

26

24

24 45

2529

37 2527

29 25 14

37

4

29

28

40

LIN

K W

ITH

HO

SE C

LA

MP

19

BL

OC

K 3

" FR

OM

EN

D O

F L

INK

5

39

15

TO

WA

RD

S T

HE

TM

AR

M.

27

38

27

2

32

BU

SHIN

GS

INC

LU

DE

D IN

678

62

GE

AR

BO

X R

EPL

AC

EM

EN

T K

IT 3

9969

26

27

TO

TH

E O

UT

SID

E.

CL

AM

P

46 47

2731

11

C-B

AL

AN

CE

VA

LV

E C

6184

CY

LIN

DE

R S

EA

L K

IT 3

5648

4149

VA

LV

ES

SHO

WN

FO

R R

EFE

RE

NC

ER

OU

TE

HA

RN

ESS

WIT

H H

OSE

TH

RU

SPI

RA

L W

RA

P


TM16

160

Bill

- PN

109

359

.YTQ

NOITPI

RCSE

DT

RAP

METI2

2V 06161

MT D

AP01207

11

3V 06161

MT YD

OB263901

22

EDIS

NI 2V 06161

MT KNIL

901763

22

V 06161MT

MR

A64876

4 569

742

BEA

RIN

G S

WIN

G D

RIV

E 14

IN E

NC

LOSE

D

KIN

EMA

TIC

S2

622

275

MO

TOR

HYD

EA

TON

101

-345

42 2

52.81X05.4

RED

NILYC

268767 8

2225

8TU

RN

TABL

E BE

AR

ING

450

-051

10-1

1 12

V 06161MT ES

AB04486

9 1022

268

GEA

R G

UA

RD

TM

1416

0B P

C B

LAC

K1

1122

272

GU

AR

D T

TB T

M14

160B

PC

BLA

CK

1 11-02100-510

XOB

RAE

G7356

21 1353

11M

OTO

R H

YD R

OSS

MG

1406

11A

AA

B1

1415

625C

RPI

N T

EAR

DR

OP

2.50

X18

.38

ZC8

1578

431

LIG

HT

FLO

OD

LED

3.2

X2.

9 85

0LM

16W

10-

30V

2

16C

2239

FTG

2-2

MP-

FP S

TREE

T EL

BOW

90

2

17C

2250

FTG

2-2

X1.

50 M

P-M

P N

IPPL

E ST

RA

IGH

T BL

K 2 2

31.0 EPIP RLP

C GTF

6522C

814

TH

GIA

RTS TPN 8/1 K

REZ2951

c91 20

1577

0PI

N T

EAR

DR

OP

3.00

X10

.38

SS1

2122

273

TEA

R D

RO

P PI

N 3

.00X

16.6

3 SS

2 12

V 06161MT K

NIL93427

22 2354

319

BUSH

ING

CO

MPO

SITE

2.5

0X1.

5032

2422

27BU

SHIN

G B

PC48

DX

R48

3.0

0X3.

004

25D

0790

WA

SHER

0.5

0 SA

E FL

AT

YELL

OW

GR

821

2617

150

WA

SHER

0.7

5 SA

E FL

AT

YELL

OW

GR

950 81

TALF SS

U 13.0 RE

HSA

W3430

72 28C

5902

WA

SHER

0.6

3 SA

E FL

AT

YELL

OW

GR

884

2910

172

CA

P SC

R 0

.50-

13X

1.00

HH

GR

821

3017

149

CA

P SC

R 0

.75-

10X

4.50

HH

GR

9 46

3104

20C

AP

SCR

0.3

1-18

X0.

75 H

HG

R5

1232

D13

12C

AP

SCR

0.6

3-11

X3.

50 H

HG

R8

48

3372

435

CA

P SC

R 0

.63-

11X

5.00

HH

GR

8 R

ED P

ATC

H36

34C

0929

CA

P SC

R 0

.31-

18X

2.75

HH

GR

54 2

HS 52.1X31-05.0

RCS P

AC

7031D

534

HS 05.3X01-57.0

RCS P

AC

8921163

1152.

X05.3X65.0 P

AC

NIP7738

73 3810

1592

PLA

TE C

OV

ER B

OD

Y TM

1215

4 V

41 2

EDIST

UO 2

V 06161MT K

NIL63427

9321

REBBU

R 00.1 PM

ALC

326704

02T

ALF SSU 52.0

REHS

AW

043014 42

0478

CA

P SC

R 0

.25-

20X

0.50

HH

GR

512 4

HS M

M04X

MM21

RCS P

AC

4842634 44

7096

4C

LAM

P 3

HO

SE 0

.38

HYD

280

0 04 2

GED 09 TP

N 8/1 KREZ

7951C

54

NO

T S

HO

WN

:1

- 105

060

- HY

D K

IT T

M12

154

V4

CO

NT

RO

T P

AD

S1

- 214

09 -

WIR

E H

AR

NE

SS F

LO

OD

LIG

HT

TM

1416

01

- 106

349

- WIR

E H

RN

S E

XT

7FT

2P

WP

TO

DT

1 - 3

7845

- D

EC

AL

KIT

TM

1616

01

- D02

40 -

FTG

4-2

CPR

SN-M

P 90

0.67

FT -

D18

10 -

TB

E A

IR S

AE

J844

TY

PE A

.25

(RM

)1

- D13

45 -

FTG

4-2

CPR

SN-M

P ST

RA

IGH

T1

- 221

61 -

FTG

2-2

FP-

FP C

OU

PLE

R S

TR

AIG

HT

BR

ASS

1 - 5

6589

- Z

ER

K 1

/8 N

PT S

TR

AIG

HT

LO

NG

TH

RE

AD

2 - 9

752

- CO

NN

EC

T 2

PIN

SH

RO

UD

PA

CK

AR

D4

- 975

6 - C

ON

TA

CT

M T

ER

M S

HR

OU

D 1

8-20

4 - 8

384

- CA

BL

E S

EA

L 1

8-20

PA

CK

AR

D1

- 390

001

- 903

84 -

MA

NU

AL

TM

1616

0

4604

81C

AP

SCR

0.2

5-20

X2.

00 H

HG

R5

4 4C

OLYN 5

RG

HH 02-52.0 T

UN

333074 48

2115

1G

ASK

ET M

OTO

R 0

08-1

0056

-13

4910

5063

VA

LVE

SOLN

D 2

PO

S 3

WA

Y SV

10-3

4-6T

-N-

12D

R1

5035

111

VA

LVE

CO

MB

DIV

FD

50-4

4-6T

-N-4

41


Decal Placement - PN 37845

2

2

04 22618 DECAL- GREASE WEEKLY

DESCRIPTIONPART No.ITEM

05 37847

DECAL - STELLAR LOGO 6.00X16.5052681

DECAL- RATED LOAD

QTY

2

DECAL- TM 16160 IDENTIFICATION

DECAL- ROATATION BEARING

01 54854

03 22617

02

2

1

06

38976 DECAL- RATED LOAD 2

PN 37845

Rev Level: DDate: Change: Removed PN 54589. Updated artwork to reflect engineering changes.

Last Revision

MAXIMUM RATED LOAD



7484 KG

MAXIMUM RATED LOAD



7484 KG

Grease Weekly

22618

Grease bearing with EP2(Extreme Pressure Grease)while rotating the bearing.

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

Grease Weekly

22618

Grease bearing with EP2(Extreme Pressure Grease)while rotating the bearing.

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

STELLAR TM1616038976

CAPACITYCHART

15’(4.57m)16500lbs(7484kg)

ROTATION

17’(5.18m)14000lbs(6350kg)

20’(6.10m)12000lbs(5443kg)

TireMan 16160

Documents

Transcript of TireMan 16160