stellar labs TMAX1, Owner'S Manual

Page 1: ...s Service Body ownerS MAnuAl TMAX1 Stellar Industries Inc 190 State Street PO Box 169 Garner IA 50438 800 321 3741 Fax 641 923 2811 www stellarindustries com Last Revision 11 15 10 Subject to Change without Notification 2010 Stellar Industries Inc ...

Page 2: ...TMAX1 Manual Revisions Date of Revision Description of Revision Section Revised ...

Page 3: ...5 Mounting Kit Dodge Chassis PN 57645 6 Wiring Harness CS Compartment Lights PN 15915 7 Wiring Harness SS Compartment Lights PN 14427 7 Wiring Harness Rear Body PN 15690 8 Wiring Harness VEC System PN 34109 9 Wiring Harness VEC System Connector Breakdown 10 Wiring Harness Jumper VEC System PN 37051 11 Welder Installation 12 Electrical Circuit Grounding 12 Chapter 4 Assembly Drawings 13 Tailgate As...

Page 4: ...le situations Please be aware that some sections of this manual contain information pertaining to Stellar manufactured service bodies in general and may or may not apply to your specific model 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 purpo...

Page 5: ...d Vertical Compartment SS2V Streetside 1st Vertical Compartment SS1V Curbside 1st Vertical Compartment CS1V Curbside Horizontal Compartment Streetside Horizontal Compartment Crane Boom Support Crane Boom Support Streetside View Curbside View Applicable Chassis 16 000 to 19 000 GVWR Cab to Axle 84 213 36 cm Body Length Nominal 133 337 82 cm Body Height 44 111 76 cm Body Width 94 238 76 cm Compartme...

Page 6: ...iv TMAX1 Owner s Manual ...

Page 7: ...bilizer leg by pushing down on the center valve bank lever Lower the stabilizer until it makes good contact with the firm 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 stabilizers legs The truck tires should remain in contact with the ground surface Step 3 Lower the streetside stab...

Page 8: ...ts Step 4 Using both hands apply even pressure and push the rear sliding top assembly for ward 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 ...

Page 9: ...l spray Quarterly Body Mounting Hardware Inspect and Torque Inspect the mounting brackets for damage or cracks Check all mounting cap screws for proper torque Quarterly Compartment Drain Plugs Inspect and Replace Check the security of the compartment drain plugs Replace if they are cracked or loose Monthly Body Washing Wash the Body Wash the body to prevent damage from any type of corrosive substa...

Page 10: ...ews 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 5...

Page 11: ...FORD MOUNTING HOLES FROM CAB TO FRONT OF MOUNTING PLATE BODY MOUNT ON REAR BODY MOUNT ON FRONT OF SUBFRAME 2 13 00 30 00 PN 13258 ITEM PART DESCRIPTION 1 13251PC BRKT BODY MOUNT FRONT RF 2 13254PC BRKT BODY MOUNT FRONT LF 3 C1025 CAP SCR 0 63 11X2 00 HHGR8 ZY 4 C1038 WASHER 0 63 FLAT 5 24868 NUT 0 63 11 HHGR8 NYLOCK ZY 6 13113 SUBRAME WLDMT 6620 CRANE BODY ...

Page 12: ... FLAT 6 2826 NUT 0 63 11 HH NYLOC 7 24176 SPACER T1 5500 8 57646 SPACER FRONT D5500 2010 2 3 1 3 4 5 6 5 7 7 ARE SHOWN FOR REFERENCE ONLY NOTE FRAME AND SUBFRAME WELDMENT NOTE AFTER LOCATING THE PART IT CAN BE TACK WELDED IN PLACE FOR EASE OF INSTALLATION 8 BODY SUBFRAME MEASUREMENT FROM CENTER OF AXLE TO REAR OF FRONT MOUNT PN 57645 6 TMAX1 Owner s Manual Mounting Kit Dodge Chassis PN 57645 ...

Page 13: ...ent Lights PN 14427 PN 14427 Ground Light Connects to Rear Body Harness Streetside Routed Through Compartments Wiring Harness CS Compartment Lights PN 15915 PN 15915 Ground Light Connects to Rear Body Harness Curbside Routed Through Compartments ...

Page 14: ...8 TMAX1 Owner s Manual Wiring Harness Rear Body PN 15690 PN 15690 Chassis Turn Signal Back Up Tail Light Connections Connects to Main Body Harness Note Label Trailer Plug Wires ...

Page 15: ...Installation 9 Wiring Harness VEC System PN 34109 PN 34109 Grey Connector 2 Red Connector 2 Green Connector 11 Seen Next Page for Connector Breakdown Brown Connector 12 Grey Connector 1 ...

Page 16: ...10 TMAX1 Owner s Manual Wiring Harness VEC System Connector Breakdown DUAL VEC SINGLE VEC FRONT VIEW REAR FRONT PN 34109 ...

Page 17: ...ness Jumper VEC System PN 37051 PN 37051 FRONT VIEW REAR FRONT Connection to Secondary VEC Box Connection to Primary VEC Box Connection to Crane Harness Green Connector 4 Green Connector 4 Yellow Connector 10 Yellow Connector 10 ...

Page 18: ...sing the rear work bench bumper as a welding area Electrical Circuit Grounding When installing product which requires 12 volt power to operate the equipment always locate a good source for grounding the circuit A majority of electrical failures are due to poor grounding Poor grounding can cause intermittent operation of the equipment elec trical component failures and cause the equipment to not op...

Page 19: ... 50ODX0 13 THK NYLON 8 1 D R H T 5 7 1 X 0 0 4 X 3 1 0 5 D U T S 9 6 1 2 2 6 7 22170 CAP SCR 0 50 13X1 50 HHGR5 SS 7 8 S S C O L Y N 5 R G H H 3 1 0 5 0 T U N 4 6 1 2 2 8 1 S S C O L Y N M A J H H 3 1 0 5 0 T U N 5 6 1 2 2 9 10 D1482 BOLT CARRIAGE 0 38 16X1 25 SS 4 4 T A L F 8 3 0 R E H S A W 6 4 3 0 1 1 4 C O L Y N H H 6 1 8 3 0 T U N 7 4 3 0 2 1 13 15851 PLUG PLASTIC 1 50 HOLE 85985K29 4 14 C558...

Page 20: ...5 20X1 00 HHGR5 12 6 0333 NUT 0 25 20 HHGR5 NYLOC 12 7 10334 GROMMET 4 00 ROUND LAMP PETERSON 4 8 13143 LIGHT STOP TURN TAIL 4 RND LED 2 9 13144 LIGHT CLEARANCE AMBER RND 2 LED 2 10 13145 LIGHT CLEARANCE RED RND 2 LED 7 11 2320 LICENSE PLATE LIGHT ROUND 430 W 2 12 27626 LIGHT BACKUP LED 62391 2 13 C4862 GROMMET FOR 2 CLEARANCE 30700 9 14 0540 REFLECTOR 3 00 AMBER 2 15 0541 REFLECTOR 3 00 RED 4 2 1...

Page 21: ...ings 15 Grab Handle Assembly ITEM PART DESCRIPTION QTY 1 13489 GRAB HANDLE 11 BLACK AH4303 2 2 0340 WASHER 0 25 USS FLAT ZINC 4 3 0333 NUT 0 25 20 HHGR5 NYLOC 4 4 C6022 CAP SCR 0 25 20X1 00 BTNHD SS 4 3 2 4 1 PN 54547 ...

Page 22: ... Manual Mud Flap Assembly PN 19494 ITEM PART DESCRIPTION QTY 1 C4821 MUD FLAP 24 00X24 00 STELLAR 2 2 0485 CAP SCR 0 31 18X1 25 HHGR5 8 3 0343 WASHER 0 31 USS FLAT ZINC 8 4 0342 NUT 0 31 18 HH NYLOC 8 2 3 1 4 PN 19494 ...

Page 23: ...Assembly PN 54549 ITEM PART DESCRIPTION QTY 1 16727 CHANNEL HARNESS GUARD LH 1 2 16728 CHANNEL HARNESS GUARD RH 1 3 C6022 CAP SCR 0 25 20X1 00 BTNHD SS 4 4 0340 WASHER 0 25 USS FLAT ZINC 4 5 0333 NUT 0 25 20 HHGR5 NYLOC 4 3 4 1 2 5 PN 54549 ...

Page 24: ...18 TMAX1 Owner s Manual Ford Fuel Fill Assembly PN 54715 ITEM PART DESCRIPTION QTY 1 C4884 FUEL FILL FORD PLASTIC 1 2 D1362 RIVET AL 19X 062 437 MGLP B6 E 12 1 2 PN 54715 ...

Page 25: ...PN 54548 ITEM PART DESCRIPTION QTY 1 0654 NUT 0 25 20 WING 2 2 0521 WASHER 0 25 LOCK 2 3 0340 WASHER 0 25 USS FLAT ZINC 8 4 0333 NUT 0 25 20 HHGR5 NYLOC 2 5 0437 CAP SCR 0 25 20X1 25 HHGR5 2 3 4 2 3 3 3 5 1 Compartment wall between these washers PN 54548 ...

Page 26: ...20 TMAX1 Owner s Manual ...

Page 27: ...tments C4702 Non slip surfacing 4 wide strip C5992 Rubberized rock chip guard C4821 Mud Flap Stellar 24 X 24 54547 Grab Handle Assembly 37422 Solid State Solenoid 33552 Electrical Center Primary VEC C6072 Relay 20100 Light Box Right hand mount 20101 Light Box Le hand mount 13143 Light stop turn tail 4 00 round LED 13144 Light amber clearance 2 00 round LED 13145 Light red 2 00 round LED 27626 Ligh...

Page 28: ... owner any field service call charges and any towing and or transportation charges associated with moving the equipment to the designated repair service provider All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar In ...