stellar labs TMAX Series User manual

TMAX Series
Service Body
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.
© 2018 Stellar Industries, Inc.
Rev 1
PN 89683
Operation • Maintenance • Installation • Parts
Models
TMAX1
TMAX1AL
TMAX2
TMAX2AL
TMAX3
TMAX30K
TMAX30KAL

Page ii | Stellar®TMAX™ Owner’s Manual
TMAX Manual Revisions
Date of Revsion Section Revised Description of Revision
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®TMAX™ Owner’s Manual | Page iii
Table of Contents
Introduction ................................................................................................ iv
TMAX Service Body Terminology ...............................................................v
TMAX Service Body Specications ...........................................................vi
TMAX Service Body Specications (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
Chapter 2 - Maintenance............................................................................. 3
A note about washing the TMAX body: ..................................................4
Torque Data Chart ...................................................................................4
Replacement Parts .....................................................................................5
Chapter 3 - Installation ................................................................................. 7
TMAX Installation Notes ..............................................................................7
TMAX1/AL/30K Mounting Kit - Ford - PN 13258 ........................................7
TMAX1/AL/30K Mounting Kit - Dodge - PN 57645 ....................................8
TMAX2/AL Mounting Kit - PN 52043 ...........................................................9
TMAX3 Mounting Kit - Single Axle - PN 27936 .........................................10
TMAX3 Mounting Kit - Tandem Axle - PN 31143 .....................................11
Welder Installation ....................................................................................15
Electrical Circuit Grounding ....................................................................15
Chapter 4 - Assembly Drawings ................................................................ 16
Steel Tailgate Assembly - PN 21401 ........................................................16
Aluminum Tailgate Assembly - PN 86100 ...............................................17
Right Tailgate Arm Assembly - PN 75917 ................................................18
Left Tailgate Arm Assembly - PN 75918 ..................................................19
Light Box/Reector Assembly ..................................................................20
Grab Handle Assembly - PN 54547 .........................................................21
Mud Flap Assembly - PN 19494 ...............................................................22
Harness Guard Kit Assembly - PN 54549 .................................................23
Ford Fuel Fill Assembly (TMAX1) - PN 54715 ............................................24
License Plate Hardware Assembly - PN 54548.......................................25

Page iv | Stellar®TMAX™ Owner’s Manual
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:
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.
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®TMAX™ Owner’s Manual | Page v
TMAX Service Body Terminology
Curbside
Crane
Compartment
Work Bench
Bumper
Work Bench
Bumper
Curbside
2nd Vertical
Compartment
(CS2V)
Streetside
3rd Vertical
Compartment
(SS3V)
Streetside
2nd Vertical
Compartment
(SS2V)
Streetside
1st Vertical
Compartment
(SS1V)
Curbside 1st Vertical
Compartment
(CS1V)
Curbside Horizontal
Compartment
Streetside Horizontal
Compartment
Streetside Compartment
Master Locking Arm
Streetside Compartment
Master Locking Arm
Curbside Compartment
Master Locking Arm
Curbside Compartment
Master Locking Arm
Streetside View
Curbside View

Page vi | Stellar®TMAX™ Owner’s Manual
TMAX Service Body Specications
TMAX™30K-9
Applicable Chassis14,000 – 19,500 GVWR
Cab to Axle60” (152.4 cm)
Body Length109” (276.9 cm)
Body Height (Steel)44”/60” (111.76/152.4 cm)
Body Height (AL)52” (132.08 cm)
Body Width94” (238.76 cm)
Compartment Depth22” (55.88 cm)
Floor Width50” (127 cm)
Net Weight (Steel)2,610 lbs (1184 kg)
Net Weight (AL)2,220 lbs (1007 kg)
Crane ModelsEC3200, EC4000, EC5000
3315, 4421, 5521
TMAX™30K-11
Applicable Chassis14,000 – 19,500 GVWR
Cab to Axle84” (213.36 cm)
Body Length133” (337.82 cm)
Body Height (Steel)44”/60" (111.76/152.4 cm)
Body Height (AL)52" (132.08 cm)
Body Width94” (238.76 cm)
Compartment Depth22” (55.88 cm)
Floor Width50” (127 cm)
Net Weight (Steel)2,710 lbs (1229 kg)
Net Weight (AL)2,250 lbs (1021 kg)
Crane ModelsEC3200, EC4000, EC5000
3315, 4421, 5521
TMAX™1-9
Applicable Chassis16,000 – 19,500 GVWR
Cab to Axle60” (152.4 cm)
Body Length109" (276.86 cm)
Body Height (Steel)44”/60" (111.76/152.4 cm)
Body Height (AL)52" (132.08 cm)
Body Width94” (238.76 cm)
Compartment Depth22” (55.88 cm)
Floor Width50” (127 cm)
Net Weight (Steel)3,285 lbs (1490 kg)
Net Weight (AL)2,750 lbs (1247 kg)
Crane Models3315, 4421, 5521, 7621, 7630
TMAX™1-11
Applicable Chassis16,000 – 19,500 GVWR
Cab to Axle84” (213.36 cm)
Body Length133” (337.82 cm)
Body Height (Steel)44”/60" (111.76/152.4 cm)
Body Height (AL)52" (132.08 cm)
Body Width94” (238.76 cm)
Compartment Depth22” (55.88 cm)
Floor Width50” (127 cm)
Net Weight (Steel)3,740 lbs (1696 kg)
Net Weight (AL)3,050 lbs (1383 kg)
Crane Models3315, 4421, 5521, 7621, 7630
TMAX™2-11
Applicable Chassis19,500 GVWR and up
Cab to Axle84" (213.36 cm)
Body Length133" (337.82 cm)
Body Height60” (152.4 cm)
Body Width94" (238.76 cm)
Compartment Depth22” (55.88 cm)
Floor Width50" (127 cm)
Net Weight (Steel)4,465 lbs (2025 kg)
Net Weight (AL)3,510 lbs (1592 kg)
Crane Models7621, 7630, 9621, 9630,
10621, 10630, 12621, 12630
TMAX™2-14
Applicable Chassis19,500 GVWR and up
Cab to Axle120" (304.8 cm)
Body Length169" (429.26 cm)
Body Height60” (152.4 cm)
Body Width94" (238.76 cm)
Compartment Depth22” (55.88 cm)
Floor Width50" (127 cm)
Net Weight (Steel)4,985 lbs (2261 kg)
Net Weight (AL)3,780 lbs (1715 kg)
Crane Models7621, 7630, 9621, 9630,
10621, 10630, 12621, 12630

Stellar®TMAX™ Owner’s Manual | Page vii
TMAX Service Body Specications (cont.)
TMAX™3S
Applicable Chassis33,000 GVWR and up
Cab to Axle120" (304.8 cm)
Body Length169" (429.26 cm)
Body Height60" (152.4 cm)
Body Width96" (243.84 cm)
Compartment Depth22” (55.88 cm)
Floor Width50"/52" (127/132.1 cm)
Net Weight6,750 lbs (3062 kg)
Crane Models14530
TMAX™3T
Applicable Chassis46,000 GVWR and up
Cab to Trunnion138" (350.58 cm)
Body Length210" (533.40 cm)
Body Height60" (152.4 cm)
Body Width96" (243.84 cm)
Compartment Depth22” (55.88 cm)
Floor Width50"/52" (127/132.1 cm)
Net Weight7,495 lbs (3400 kg)
Crane Models14530
TMAX™LP-12
Applicable Chassis15,000 – 19,500 GVWR
Cab to Axle84” (213.36 cm)
Body Length145" (368.3 cm)
Body Height44” (111.76 cm)
Body Width96" (243.84 cm)
Compartment Depth17” (43.2 cm)
Floor Width75"/78" (190.5/198.1 cm)
Net Weight3,390 lbs (1538 kg)
Crane ModelsEC4000, EC5000, EC6000
4421, 5521, 7621, 7630
TMAX™LP-14
Applicable Chassis15,000 – 19,500 GVWR
Cab to Axle108” (274.32 cm)
Body Length169" (429.26 cm)
Body Height44” (111.76 cm)
Body Width96" (243.84 cm)
Compartment Depth17” (43.2 cm)
Floor Width75"/78" (190.5/198.1 cm)
Net Weight3,665 lbs (1662 kg)
Crane ModelsEC4000, EC5000, EC6000
4421, 5521, 7621, 7630

Page viii | Stellar®TMAX™ Owner’s Manual
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Stellar®TMAX™ Owner’s Manual | Page 1
Stabilizer Operation
Before operating the stabilizers, make sure that the service truck is parked on an even
surface and be aware of the surface the truck has been positioned upon. The area should
be a rm supporting surface.
Keep clear of stabilizer legs during operation. Moving stabilizers can
cause serious crushing injuries. Make certain that all personnel are clear of the stabilizer
and the ground contact point before operating.
Do not raise the rear tires of the truck off the ground with the stabilizers.
Conrm that the stabilizers are positioned on stable, at ground and that the truck is as
level as possible both front to rear and side to side. Use stabilizer pads to ensure the proper
distribution of weight.
Step 1: Fully extend the stabilizer beam. Note: Manual beams will have to be pulled out. If
equipped with a power out option, push downward on the valve bank lever labled
‘CS Extend’ or ‘SS Extend’ until the beam stops moving outward.
Step 2: Lower the curbside stabilizer leg by pushing down on the valve bank lever labled
‘CS Down.’ Lower the stabilizer until it makes good contact with the rm supporting
surface. If equipped with manual crankdown legs, manually lower the legs until
they make good contact with the supporting surface. Avoid over-extending the
stabilizer leg. The truck tires should remain in contact with the ground surface.
Step 3: Lower the streetside stabilizer leg by pushing downward on the valve bank control
lever labled ‘SS Down.’ Lower the stabilizer until it makes good contact with the
rm supporting surface. If equipped with manual crankdown legs, manually
lower the legs until they make good contact with the supporting surface. Avoid
over-extending the stabilizer leg. The truck tires should remain in contact with the
ground surface.
WARNING
WARNING
Air Drain Operation
Depending on where and how the air drain valve is mounted to the body determines the
operation. Follow the decal instructions for correct positioning of the valve handle.
Always drain air tank/receiver before leaving a job or work site. Air tank
should not have compressed air while driving the service truck.
WARNING
Masterlock Operation
Step 1: Close all doors.
Step 2: Rotate the handle into the locked position, aligning the holes.
Step 3: Insert the locking device into the aligned holes.
Note: Perform these steps for each applicable side pack.
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 efcient operation of the service body.

Page 2 | Stellar®TMAX™ Owner’s Manual
Door Latch Operation
Step 1: To open, pull the T-Handle portion of the latch outward.
Step 2: Turn T-Handle as follows:
Curbside Door Latches: Turn handle clockwise to open the door.
Streetside Door Latches: Turn handle counter-clockwise to open the door.
Crane Drain Pan Operation
Removing the Drain Pan
Step 1: Pull the quick release pin located on the right side of the drain pan.
Step 2: Slide the drain pan to the right (Toward the right side wall of the crane
compartment).
Step 3: Lower the drain pan and clean as needed. Remove debris and clean the drain
tube.
Re-Installing the Drain Pan
Step 1: Lift the drain pan, staying toward the right side of the crane compartment.
Step 2: Re-align the tab brackets to the drain pan slots.
Step 3: Slide the drain pan pin to the left (Toward the rear of the body).
Step 4: Re-install the quick release pin.
Sliding Top Operation
Opening the Sliding Top
Step 1: Pull the latch assembly T-Handle outward.
Step 2: Turn the T-Handle counter-clockwise to unlatch the door rods from the rod guides.
Step 3: Pull the door assembly upward and over until the door holders snap into the holder
sockets.
Step 4: Using both hands, apply even pressure and push the rear sliding top assembly
forward until it stops.
Closing the Sliding Top
Step 1: Using both hands, pull the rear sliding top section toward the rear of the body until it
stops.
Step 2: With the tailgate assembly in the stowed and locked position, pull up and then
downward on the door assembly.
Step 3: Turn the T-Handle clockwise until the door rods slide into the rod guides.
Step 4: Push the T-Handle back into the latch assembly pocket.
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.
Step 3: Pull downward on the red post/bar to lock the tailgate in place.