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Models
TMAX16K
TMAX30K
TMAX1
TMAX2
TMAX3
TMAXLP
Subject to Change without Notification.
© 2023 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 TMAX16K
- Page 1 TMAX Series Service Body Owner’s Manual Operation • Maintenance • Installation • Parts Models TMAX16K TMAX30K TMAX1 TMAX2 TMAX3 TMAXLP Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 Subject to Change without Notification.
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Page 2: P65 Warning & Cold Weather Notice
P65 Warning & Cold Weather Notice NOTICE Although clear data on cold weather performance from every steel manufacturer is not available for all types and thicknesses of steel, Stellar Industries is confident that the weldments on our products will operate to 100% of their intended purpose to temperatures down to -40°... -
Page 3: Table Of Contents
Table of Contents P65 Warning & Cold Weather Notice .................................ii 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 ...................................... -
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 1st Vertical 1st Vertical Rear Compartment Compartment Compartment Rear of Divider Front of Divider (SS Rear) (SS1VR) (SS1VF) -
Page 6: Tmax Service Body Specifications
TMAX Service Body Specifications TMAX™16K-9 TMAX™16K-11 19.5" Dual Rear Wheels on 19.5" Dual Rear Wheels on Applicable Chassis Applicable Chassis 14,000 – 22,900 GVWR 14,000 – 22,900 GVWR Clear Cab to Axle 60” (152.4 cm) Clear Cab to Axle 84” (213.36 cm) Body Length 109”... -
Page 7: Tmax Service Body Specifications (Cont.)
TMAX Service Body Specifications (cont.) TMAX™1-13 19.5" Dual Rear Wheels on Applicable Chassis 22,000 – 22,900 GVWR Clear Cab to Axle 108” (274.32 cm) Body Length 157” (398.78 cm) All Raised 52" (132.08 cm) with Body Height (Aluminum) 8" (20.32 cm) drop well in CS1V Body Width 94”... - 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: Washing The Tmax Body
Washing the TMAX body: New Paint Care and Cleaning Procedures during Initial Ownership and Beyond 0 to 30 days past manu- 30 to 60 days past manu- After 60 days past manu- Any day paint surface is facturing date facturing date facturing date hot due to exposure to daylight... -
Page 13: Torque Data Chart
Torque Data Chart When using the torque data in the chart, the following rules should be GRADE 5 GRADE 8 GRADE 9 observed: • Bolt manufacturer’s particular specifications should be consulted Size Bolt DIA Plain Plated Plain Plated Plated when provided. (DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) 5/16-18... -
Page 14: 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 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: Tmax1/30K/16K-9 Mounting Kit - Dodge - Pn 96076
TMAX1/30K/16K-9 Mounting Kit - Dodge - PN 96076 BODY MOUNT ON FRONT OF SUBFRAME BODY MOUNT ON REAR OF SUBFRAME. 17.13 CENTER OF AXLE TO REAR OF FRONT MOUNT EXISTING HOLES IN CHASSIS. PN 96076 ITEM PART No. DESCRIPTION QTY. 24046 BRKT BODY MNT 60 CA T1 9 LF FRT PC BLACK 24047... -
Page 17: Tmax1/30K/16K-9 Mounting Kit - Chevy - Pn 101362
TMAX1/30K/16K-9 Mounting Kit - Chevy - PN 101362 BODY MOUNT ON FRONT OF SUBFRAME BODY MOUNT ON REAR OF SUBFRAME 17.13 CENTER OF AXLE TO REAR OF FRONT MOUNT PN 101362 ITEM PART No. DESCRIPTION QTY. C1025 CAP SCR 0.63-11X2.00 HHGR8 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 24868... -
Page 18: Tmax1-13 & Tmax1/30K/16K-11 Mounting Kit - Ford - Pn 13258
TMAX1-13 & TMAX1/30K/16K-11 Mounting Kit - Ford - PN 13258 BODY MOUNT ON FRONT OF SUBFRAME BODY MOUNT ON REAR OF SUBFRAME. 41.13 CENTER OF AXLE TO REAR OF FRONT MOUNT EXISTING HOLES IN FORD CHASSIS. PN 13258 ITEM PART No. DESCRIPTION QTY. -
Page 19: Tmax1-13 & Tmax1/30K/16K-11 Mounting Kit - Dodge - Pn 57645
TMAX1-13 & TMAX1/30K/16K-11 Mounting Kit - Dodge - PN 57645 BODY SUBFRAME NOTE: FRAME AND SUBFRAME WELDMENT ARE SHOWN FOR REFERENCE ONLY. 41.13 BODY MOUNT ON REAR OF SUBFRAME. CENTER OF AXLE TO REAR OF FRONT MOUNT NOTE: AFTER LOCATING THE PART IT CAN BE TACK WELDED IN PLACE FOR EASE OF INSTALLATION. -
Page 20: Tmax1-13 & Tmax1/30K/16K-11 Mounting Kit - Chevy - Pn 101361
TMAX1-13 & TMAX1/30K/16K-11 Mounting Kit - Chevy - PN 101361 BODY MOUNT ON FRONT OF SUBFRAME CENTER OF AXLE TO REAR OF FRONT MOUNT BODY MOUNT ON REAR OF SUBFRAME 41.13 RETAIN CHASSIS BOLTS FOR BODY INSTALLATION TYP 4 PN 101361 ITEM PART No. -
Page 21: Tmax Lp Mounting Kit - Ford - Pn 79837
TMAX LP Mounting Kit - Ford - PN 79837 BODY MOUNT ON FRONT OF SUBFRAME DRILL EXISTING HOLES TO FIT 5/8 BOLT FORD MOUNTING HOLES. BODY MOUNT ON REAR OF SUBFRAME. 41.13 (12') 65.13 (14') CENTER OF AXLE TO REAR OF FRONT MOUNT PN 79837 ITEM PART No. -
Page 22: Tmax Lp Mounting Kit - Dodge - Pn 79838
TMAX LP Mounting Kit - Dodge - PN 79838 BODY SUBFRAME NOTE: FRAME AND SUBFRAME WELDMENT ARE SHOWN FOR REFERENCE ONLY. BODY SUBFRAME 41.13 (12') 65.13 (14') CENTER OF AXLE TO REAR OF FRONT MOUNT NOTE: AFTER LOCATING THE PART IT CAN BE TACK WELDED IN PLACE FOR EASE OF INSTALLATION. -
Page 23: Tmax Lp Mounting Kit - Chevy - Pn 101363
TMAX LP Mounting Kit - Chevy - PN 101363 BODY MOUNT ON FRONT OF SUBFRAME BODY MOUNT ON REAR OF SUBFRAME. 41.13 (12') 65.13 (14') CENTER OF AXLE TO REAR OF FRONT MOUNT PN 101363 ITEM PART No. DESCRIPTION QTY. 13251 BRKT BODY MNT FRONT RF PC BLACK 13254... -
Page 24: Tmax2 Mounting Kit - Pn 52043
TMAX2 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 25: 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 26: 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 27: Upfitter Sw Small Lp Or Mech W/O Cprs - 75749
Upfitter SW Small LP or Mech W/O CPRS - 75749 Stellar TMAX™ Owner’s Manual | Page 19 ®... -
Page 28: Ctrl Pkg Mech Upfitter Sw W/Cprs - 93210
Ctrl Pkg Mech Upfitter SW W/Cprs - 93210 Page 20 | Stellar TMAX™ Owner’s Manual ®... -
Page 29: Ctrl Pkg E-Link 2.0 Conn Diagram - 85450
Ctrl Pkg E-Link 2.0 Conn Diagram - 85450 Stellar TMAX™ Owner’s Manual | Page 21 ®... -
Page 30: Ctrl Pkg Vec Front Switch Panel - 34535
Ctrl Pkg VEC Front Switch Panel - 34535 Page 22 | Stellar TMAX™ Owner’s Manual ®... -
Page 31: Light Package 16K Mech Fmvss Only - 120581
Light Package 16K Mech FMVSS Only - 120581 Stellar TMAX™ Owner’s Manual | Page 23 ®... -
Page 32: Light Pkg 16K-9 Mech Body Fmvss & Compt - 120580
Light Pkg 16K-9 Mech Body FMVSS & Compt - 120580 Page 24 | Stellar TMAX™ Owner’s Manual ®... -
Page 33: Light Pkg 16K-11 Mech Body Fmvss & Compt - 120579
Light Pkg 16K-11 Mech Body FMVSS & Compt - 120579 Stellar TMAX™ Owner’s Manual | Page 25 ®... -
Page 34: Light Kit Compt Tmax1 & 30K-9 - 93687
Light Kit Compt TMAX1 & 30K-9 - 93687 Page 26 | Stellar TMAX™ Owner’s Manual ®... -
Page 35: Light Kit Compt Tmax1,2 & 30K-11 - 75739
Light Kit Compt TMAX1,2 & 30K-11 - 75739 Stellar TMAX™ Owner’s Manual | Page 27 ®... -
Page 36: Light Kit Compt 13' & 14' Tmax - 75744
Light Kit Compt 13' & 14' TMAX - 75744 Page 28 | Stellar TMAX™ Owner’s Manual ®... -
Page 37: Light Kit Compt Tmax3 Tandem - 75753
Light Kit Compt TMAX3 Tandem - 75753 Stellar TMAX™ Owner’s Manual | Page 29 ®... -
Page 38: Light Kit Compt V2 Tmax Lp-12 - 75747
Light Kit Compt V2 TMAX LP-12 - 75747 Page 30 | Stellar TMAX™ Owner’s Manual ®... -
Page 39: Light Kit Compt Kit V2 Tmax Lp-14 - 75748
Light Kit Compt Kit V2 TMAX LP-14 - 75748 Stellar TMAX™ Owner’s Manual | Page 31 ®... -
Page 40: Wiring Harness: Side Pack (Both Sides) - Pn 74722
Wiring Harness: Side Pack (Both Sides) - PN 74722 PN 74722 Page 32 | Stellar TMAX™ Owner’s Manual ®... -
Page 41: Side Pack Harness To Rear Harness Connector - Pn 75721
Side Pack Harness to Rear Harness Connector - PN 75721 PN 75721 Side Pack to Rear Connector Wiring Harness T3 Side Pack Extension - PN 75722 PN 75722 Wire Harness T3 Side Pack Extension Stellar TMAX™ Owner’s Manual | Page 33 ®... -
Page 42: Wiring Harness: Rear - Pn 75538
Wiring Harness: Rear - PN 75538 PN 75538 Page 34 | Stellar TMAX™ Owner’s Manual ®... -
Page 43: Signal Light Harness - Pn 85371
Signal Light Harness - PN 85371 PN 85371 Stellar TMAX™ Owner’s Manual | Page 35 ®... -
Page 44: 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 45: Chapter 4 - Assembly Drawings
Chapter 4 - Assembly Drawings 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 37 ®... -
Page 46: 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 47: 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 48: 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 49: 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 41 ®... -
Page 50: 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 42 | Stellar TMAX™... -
Page 51: 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 52: 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 44 | Stellar TMAX™ Owner’s Manual ®... -
Page 53: 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 56 Subject to Change without Notification. © 2023 Stellar Industries, Inc.
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