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Models
TMAX1
TMAX1AL
TMAX2
TMAX2AL
TMAX3
TMAX30K
TMAX30KAL
Subject to Change without Notification.
© 2018 Stellar Industries, Inc.
Operation • Maintenance • Installation • Parts
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
TMAX Series
Service Body
Owner's Manual
Rev 1
PN 89683
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Summary of Contents for stellar labs TMAX Series
- Page 1 TMAX Series Service Body Owner’s Manual Operation • Maintenance • Installation • Parts Models TMAX1 TMAX1AL TMAX2 TMAX2AL TMAX3 TMAX30K TMAX30KAL Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 Subject to Change without Notification.
- Page 2 TMAX Manual Revisions Date of Revsion Section Revised Description of Revision WARNING 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).
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Page 3: Table Of Contents
Table of Contents Introduction ....................iv TMAX Service Body Terminology ...............v TMAX Service Body Specifications ............vi TMAX Service Body Specifications (cont.) ..........vii Chapter 1 - Operation .................. 1 Masterlock Operation ................1 Air Drain Operation..................1 Stabilizer Operation ..................1 Tailgate Operation ..................2 Door Latch Operation ................2 Sliding Top Operation .................2 Crane Drain Pan Operation ..............2... -
Page 4: Introduction
Introduction A copy of this manual is provided with every body 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 body at all times. Throughout the manual, three signal words will be used to bring attention to important items: NOTICE... -
Page 5: Tmax Service Body Terminology
TMAX Service Body Terminology Streetside Compartment Master Locking Arm Curbside Compartment Master Locking Arm Streetside View Streetside Horizontal Compartment Streetside Compartment Streetside Streetside Master Locking Arm Streetside 2nd Vertical 1st Vertical 3rd Vertical Compartment Compartment Compartment (SS2V) (SS1V) (SS3V) Work Bench Bumper Curbside View Curbside 1st Vertical... -
Page 6: Tmax Service Body Specifications
TMAX Service Body Specifications TMAX™30K-9 TMAX™30K-11 Applicable Chassis14,000 – 19,500 GVWR Applicable Chassis14,000 – 19,500 GVWR Cab to Axle60” (152.4 cm) Cab to Axle84” (213.36 cm) Body Length109” (276.9 cm) Body Length133” (337.82 cm) Body Height (Steel)44”/60” (111.76/152.4 cm) Body Height (Steel)44”/60"... -
Page 7: Tmax Service Body Specifications (Cont.)
TMAX Service Body Specifications (cont.) TMAX™3S TMAX™3T Applicable Chassis33,000 GVWR and up Applicable Chassis46,000 GVWR and up Cab to Axle120" (304.8 cm) Cab to Trunnion138" (350.58 cm) Body Length169" (429.26 cm) Body Length210" (533.40 cm) Body Height60" (152.4 cm) Body Height60"... - Page 8 This page intentionally left blank. Page viii | Stellar TMAX™ Owner’s Manual ®...
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Page 9: Chapter 1 - Operation
Chapter 1 - Operation This chapter contains information regarding the operation of Stellar manufactured service bodies. Please study the following pages to ensure your familiarity with the operation process. This understanding is vital to the safe and efficient operation of the service body. Masterlock Operation Step 1: Close all doors. -
Page 10: Tailgate Operation
Tailgate Operation Lowering the tailgate Step 1: Pull upward on the red post/bar attached to the right side linkage of the tailgate. Step 2: Now pull downward on the tailgate. Closing/Stowing the tailgate Step 1: Pull upward on the red post/bar attached to the right side linkage. Step 2: Push the tailgate upward until it stops. -
Page 11: Chapter 2 - Maintenance
Chapter 2 - Maintenance Maintenace Item Action Note Interval Door Latch Inspect and Lubricate with EP2 grease or light-weight Monthly Assembly Lubricate lithium spray grease. Inspect and Lubricate with EP2 grease or light-weight Door Rod Guides Monthly Lubricate lithium spray grease. Inspect and Lubricate with EP2 grease or light-weight Door Spring Rod... -
Page 12: A Note About Washing The Tmax Body
A note about washing the TMAX body: The body should be washed at least once per week to prevent damage to the paint, wiring or rubber material from any type of corrosive substances collected from roads or job sites. When washing the body, avoid direct water spray toward electrical components such as floodlights, radio remote receivers, the VEC center, and areas of the body which may have rock chips. -
Page 13: Replacement Parts
Replacement Parts Description 71479 Door Latch 71480 Door Latch 29446 Key Lock Cylinder & Key 71476 Hinge 19321 Door Bumper (clear w/adhesive) D0202 Fender Rubber 14000 Push-in Fastener (Fender Rubber) 16909PC Vise Mount Bracket 9263 Quick Release Pin (Vise mount bracket) 63894 Weatherstrip 63895... - Page 14 This page intentionally left blank. Page 6 | Stellar TMAX™ Owner’s Manual ®...
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Page 15: Chapter 3 - Installation
Chapter 3 - Installation TMAX Installation Notes • Before performing any tasks that involve welding to the chassis, refer to the specific chassis manufacturer’s recommendations. • When lifting and placing the body, use the D-Ring tiedown locations and always lift vertically. -
Page 16: Tmax1/Al/30K Mounting Kit - Dodge - Pn 57645
TMAX1/AL/30K Mounting Kit - Dodge - PN 57645 BODY SUBFRAME 40.94 MEASUREMENT FROM CENTER OF AXLE TO REAR OF FRONT MOUNT NOTE: AFTER LOCATING THE PART, IT CAN BE TACK WELDED IN PLACE FOR EASE OF INSTALLATION PN 57645 ITEM PART DESCRIPTION 13253... -
Page 17: Tmax2/Al Mounting Kit - Pn 52043
TMAX2/AL Mounting Kit - PN 52043 NOTE: FOR BODIES LONGER THAN 11 FEET, ADD DIFFERENCE IN LENGTH TO MEASUREMENTS MEASUREMENT FROM CENTER OF AXLE TO FRONT MOUNTING HOLE 74.28 MEASUREMENT FROM CENTER OF AXLE TO REAR MOUNTING HOLE 41.28 IMPORTANT NOTE: DO NOT OVER SIZE MOUNTING HOLES IN CHASSIS FRAME. -
Page 18: Tmax3 Mounting Kit - Single Axle - Pn 27936
TMAX3 Mounting Kit - Single Axle - PN 27936 MEASUREMENT FROM CENTER OF AXLE TO FRONT MOUNTING HOLE MEASUREMENT FROM CENTER OF AXLE TO REAR MOUNTING HOLE 109.28 BODY SUBFRAME USE PN 15853 .38 X 2.50 FLAT AS SPACER ON CHASSIS WITH DOUBLE FRAME RAILS THAT DO NOT EXTEND TO REAR. -
Page 19: Tmax3 Mounting Kit - Tandem Axle - Pn 31143
TMAX3 Mounting Kit - Tandem Axle - PN 31143 MEASUREMENT FROM CENTER OF AXLE TO FRONT MOUNTING HOLE MEASUREMENT FROM CENTER OF AXLE TO REAR MOUNTING HOLE 133.69 88.69 USE PN 15853 .38 X 2.50 FLAT AS SPACER ON CHASSIS WITH DOUBLE FRAME RAILS THAT DO NOT EXTEND TO REAR. - Page 20 Page 12 | Stellar TMAX™ Owner’s Manual ®...
- Page 21 Stellar TMAX™ Owner’s Manual | Page 13 ®...
- Page 22 Page 14 | Stellar TMAX™ Owner’s Manual ®...
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Page 23: Welder Installation
Welder Installation When installing welders on Stellar® Mechanic body packages it is highly recommended that you install an electrical surge protector to the chassis battery. If the electrical surge protector is not installed on to the battery, your customer could experience failures to the Chassis wiring circuit and also to the Stellar Mechanic body package wiring circuits. -
Page 24: Chapter 4 - Assembly Drawings
Chapter 4 - Assembly Drawings Steel Tailgate Assembly - PN 21401 PN 21401 21322PC TAILGATE WLDMT MCH 21322 POWDERCOAT 15851 PLUG PLASTIC 1.50 HOLE 85985K29 16094 DECAL STELLAR LOGO6.00X14.25REFLECT 75917 BRKT ASM RH TAILGATE MECH Page 16 | Stellar TMAX™ Owner’s Manual ®... -
Page 25: Aluminum Tailgate Assembly - Pn 86100
Aluminum Tailgate Assembly - PN 86100 PN 86100 86101 TAILGATE 12.00X52.00 MECH AL 15851 PLUG PLASTIC 1.50 HOLE 85985K29 16094 DECAL STELLAR LOGO6.00X14.25REFLECT 75917 BRKT ASM RH TAILGATE MECH Stellar TMAX™ Owner’s Manual | Page 17 ®... -
Page 26: Right Tailgate Arm Assembly - Pn 75917
Right Tailgate Arm Assembly - PN 75917 PN 75917 0333 NUT 0.25-20 HHGR5 NYLOC 15846 BRKT TAILGATE STOP FOLD DOWN 15849 BRKT TAILGATE WLDMT STOP 22165 NUT 0.50-13 HH JAM NYLOC SS 22169 STUD .50-13X4.00X1.75THRD 22170 CAP SCR 0.50-13X1.50 HHGR5 SS 41047 WASHER 0.25 BONDED SEALING NEO BACK 66182... -
Page 27: Left Tailgate Arm Assembly - Pn 75918
Left Tailgate Arm Assembly - PN 75918 PN 75918 15846 BRKT TAILGATE STOP FOLD DOWN 22170 CAP SCR 0.50-13X1.50 HHGR5 SS 41047 WASHER 0.25 BONDED SEALING NEO BACK 66182 WASHER 0.38 BONDED SEALING NEO BACK C4516 WASHER 0.56IDX1.50ODX0.13 THK NYLON C4726 BUMPER RUBBER 1.00 W/WASHER 0.531H C6022... -
Page 28: Light Box/Reflector Assembly
Light Box/Reflector Assembly PART ITEM NO. DESCRIPTION QTY. NUMBER 19338 BOX LIGHT ASM MOUNT LH PAINTED BLK 19337 BOX LIGHT ASM MOUNT RH PAINTED BLK 10334 GROMMET 4.00 ROUND LAMP (PETERSON) 13143 LIGHT STOP/TURN/TAIL 4 RND LED 13145 LIGHT CLEARANCE RED RND 2 LED C4862 GROMMET FOR 2 CLEARANCE 30700 2320... -
Page 29: Grab Handle Assembly - Pn 54547
Grab Handle Assembly - PN 54547 PN 54547 ITEM PART DESCRIPTION QTY. 13489 GRAB HANDLE 11 BLACK AH4303 C6022 CAP SCR 0.25-20X1.00 BTNHD SS 41047 WASHER 0.25 BONDED SEALING NEO BACK 0333 NUT 0.25-20 HHGR5 NYLOC Stellar TMAX™ Owner’s Manual | Page 21 ®... -
Page 30: Mud Flap Assembly - Pn 19494
Mud Flap Assembly - PN 19494 PN 19494 ITEM PART DESCRIPTION QTY. C4821 MUD FLAP 24.00X24.00 STELLAR 0485 CAP SCR 0.31-18X1.25 HHGR5 0342 NUT 0.31-18 HH NYLOC D0607 WASHER 0.31 BONDED C2225 WASHER 0.31 FENDER 1.25OD Page 22 | Stellar TMAX™... -
Page 31: Harness Guard Kit Assembly - Pn 54549
Harness Guard Kit Assembly - PN 54549 PN 54549 ITEM PART DESCRIPTION QTY. 16727 CHANNEL HARNESS GUARD LH 16728 CHANNEL HARNESS GUARD RH C6022 CAP SCR 0.25-20X1.00 BTNHD SS 30659 NUT 0.25-20 HH NYLOC SS 41047 WASHER 0.25 BONDED SEALING NEO BACK Stellar TMAX™... -
Page 32: Ford Fuel Fill Assembly (Tmax1) - Pn 54715
Ford Fuel Fill Assembly (TMAX1) - PN 54715 PN 54715 ITEM NO. PART NUMBER DESCRIPTION QTY. C4884 FUEL FILL FORD PLASTIC 11754 RIVET SS 0.19X0.063-0.437 MGLP-U6-E 12 Page 24 | Stellar TMAX™ Owner’s Manual ®... -
Page 33: License Plate Hardware Assembly - Pn 54548
License Plate Hardware Assembly - PN 54548 Compartment wall between these washers. PN 54548 ITEM PART DESCRIPTION QTY. 0654 NUT 0.25-20 WING 41047 WASHER 0.25 BONDED SEALING NEO BACK 0340 WASHER 0.25 USS FLAT ZINC 0437 CAP SCR 0.25-20X1.25 HHGR5 0333 NUT 0.25-20 HHGR5 NYLOC 0521... - Page 34 Subject to Change without Notification. © 2018 Stellar Industries, Inc.
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