Spartan Roll Off Model - titan Installation Manual

Transcription

Spartan Roll Off Model - titan
Installation Manual
1 2 2 6 6 B r a nf o r d St r e e t
S u n V a l l e y , C A 9 1 3 52
Phone: (818) 899-1111
Fax: (818) 897-4366
www.spartantruck.com
Spartan RollOff Model - titan
Operating Precautions
Spartan Truck Co. strives to optimize our designs to incorporate every possible safety
feature into each roll-off unit. However, designs are not foolproof and still require
responsible operators to follow protocol. Therefore, the following precautions should be
considered regarding the risks from mechanical or hydraulic components:
•
All malfunctions or indications of improper operation should be reported
to the owner(s) to allow for immediate inspection and repair.
•
No adjustments, modifications, alterations, or repairs should be made to
the equipment by anyone other than qualified personnel.
•
All individuals authorized to operate the equipment should be trained in
the proper use of the controls. All potential danger points should be specifically
pointed out to the operator(s). The owner(s) of the equipment should keep in
mind that newly hired employees might acquire bad working habits or
misinformation from older employees. All training activities should be delegated
only to responsible individuals.
Note: It is suggested that a periodic review of safety measures be conducted for all
operators, particularly where equipment is leased to and operated by customers
unfamiliar with refuse equipment.
•
No untrained personnel should be allowed to operate the equipment at
any time. No one other than the authorized operator(s) should be allowed to
have the keys to this equipment.
Note: The presence of hydraulic oil beneath the equipment may indicate a leak in
need of repair.
•
All indications of a need for repair should be carefully monitored. These
indications include but are not limited to blown fuses, electrical equipment
sparking, electrical shocks from touching the equipment, bulging or deformed
structural members, cracked welds or steel members, excessive oil leaks, or
abnormal appearance or performance of the equipment.
Warning! To prevent possible injury or death,
hoist must be in the full down position for
over the road travel.
Warning!
Owner(s) and operator(s) are
responsible for safe operation of equipment.
Warning! Before working around a raised
hoist, the hoist must be supported by the
hoist safety prop. Failure to do so could
result in serious injury or death.
Rev 5/6/2010
SPARTAN TRUCK COMPANY, INC.
2
Warning! Escaping fluid under pressure can penetrate
the skin causing serious injury. Avoid the hazard by
relieving pressure before disconnecting hydraulic lines.
Tighten all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands and
body from high pressure fluids. If an accident occurs, see
a doctor immediately, as gangrene may result.
Warning!
Spartan Truck Co. makes no warranties
regarding the safety of the equipment unless these
safety instructions are observed by the owner(s) and
operator(s) at all times.
Recommended Loading Procedures
The following information is a guideline for operat ing a tail to ground roll-off-hoist. These
instructions do not exhaust every possible situation that could occur when operating the
equipment, but are intended to promote efficient and proper operation.
Before operating the equipment:
•
•
•
•
•
•
Be sure the area is clear of people.
Carefully inspect the area directly above the hoist for any overhead interference.
Never operate equipment which is damaged and/or im properly maintained.
NOTE: Even the smallest crack must be repaired.
Always operate the equipment within its rated capacity.
Study this entire manual and become properly trained with this equipment before
attempting to operate this equipment.
Respect yourself, others, and this equipment. Use safe working habits and
common sense when operating this equipment.
1) Align the hoist rails with the nose rollers on the container, back the truck as squarely
as possible to the container. Allow approximately 3 to 4 feet between the container and
the hoist.
2) Put the transmission in neutral and engage the P.T.O.
Rev 5/6/2010
3
3) Raise the hoist until the tail touches the ground. (Note: Do not allow the tail to lift
the truck up by raising the hoist after the tail is touching the ground.)
4) Set truck brakes. Extend reeving cable and connect to container hook.
Warning! Be sure cable ring is securely attached and in good working condition.
5) Release truck brakes. Pull container onto hoist, allowing truck to roll under container.
Warning! Be absolutely sure container rails are properly lined up on hoist.
Note: Container nose roller ahead of rear hinge on hoist.
Rev 5/6/2010
4
6) Continue pulling container onto hoist. After container front rollers are ahead of hoist
rear hinge point, lower hoist enough to keep container rails and hoist rails in line and
even with each other.
7) Note: Center of Gravity (C.G.) of container is past rear hinge point of hoist.
8) After C.G. of container is past rear hinge point of hoist, lower hoist completely.
Warning! Do not attempt to lower hoist before C.G. of container is past rear hinge
point of hoist. This can cause excessive stress and/or damage to equipment.
9) Pull container completely forward in to hoist front stops. In addition to the front
stops, container and hoist should always have a rear container hold-down device.
Disengage P.T.O. before driving away.
Rev 5/6/2010
5
Maintenance Introduction
Trained, qualified and competent personnel should perform all operation, inspections,
service and maintenance on this equipment.
Spartan Truck Co. strongly urges each owner/operator set up a preventive maintenance
program that will provide adequate inspection, servicing and repair of roll-off unit and its
components for the purpose of providing safe operation and to maximize the service life
of this equipment.
Note: Suggested preventative maintenance inspections and time intervals may need to
be adjusted due to factors such as: severe or heavy usage, muddy or dusty
environment, special application, warranty and maintenance history issues.
Suggested Preventive Maintenance
Lubrication
Proper lubrication is essential to all types of bearings, gearing, and friction producing
mechanical devices. Lack of adequate and proper lubrication will result in premature
wear of components due to increased abrasion or excessive heat. Lubricate unit
weekly.
Grease
All grease fittings should be properly greased after 50 hours of service or once a week.
Hydraulic System
Inspections should be performed daily for leaks, loose hydraulic lines and fittings, oil
level and proper operation of hydraulic system.
Hydraulic Oil & Filter
Every three months: Inspect oil for proper color, odor and feel. Replace oil if milky or
darkens in color, begins to have an odor, or lacks lubricity to the touch. Metal particles
in oil indicate serious damage – schedule to bring to service center immediately!
Every six months: Replace oil filter.
Every twelve months: Replace oil with AW ISO 68 hydraulic oil.
Suction Strainer
Inspect suction strainer when changing hydraulic oil.
Hydraulic Cylinders
Inspect cylinder rods, fittings and operation. Apply grease to the grease fittings on the
hydraulic cylinder every week.
Rev 5/6/2010
6
MECHANICAL
Structural & Weld Integrity
Check to insure proper and safe working condition of structural members. Make sure it
is within normal wear guidelines. Inspect weld join ts.
Front & Adjustable Stops
Check to insure proper and safe working condition of stops.
Nuts, Bolts, Shafts, Cotter Keys, Etc.
Check to insure proper and safe working condition. Make sure items are within normal
wear and proper torque guidelines.
Rollers, Pulleys, Trolleys, Rear Hinge
Check to insure proper lubrication, adjustment and operating functions.
Container Hold Down Devices
Check to insure proper and safe working condition.
Hoist Cable
Cable should be inspected daily, along with a thoro ugh inspection every 50 hours for
breakage, unraveling or flat spots as well as cable ends and clamps. Cable should be
replaced when you see 6 or more broken wires in 1 lay or every 6 months.
NOTE: Spartan recommends replacing cable clamps when replacing the cable.
ELECTRICAL SYSTEM
Reflectors/Lights
Daily inspection all lamps and reflectors. Make sure they are cleaned and in proper
working order.
Electrical Wiring
Inspect all visible wiring to see that it is not frayed and is properly supported and
protected and that all connections are tight.
Hoist Up & Back Up Alarms
Check to insure proper and safe operation.
Rev 5/6/2010
7
Quick Reference Preventive Maintenance Interval Chart
These inspections are intended to verify that the hoist and its components are in the
proper and safe operating condition and are within normal wear guidelines. If there are
any items that do not pass your inspection, you must notify your supervisor and a
lockout tag must be placed on the equipment if it is unsafe to operate.
QUICK REFERENCE PREVENTIVE MAINTENANCE INTERVAL CHART
Daily Inspections
Weekly Inspections
Grease all grease fittings every forty hours of
operation. It may be necessary to grease more
frequently during periods of heavy usage.
Grease reeving trolley & tracks
Every Three Months
Inspect the condition of hydraulic oil for proper color,
odor and feel
Every Six Months
Replace hydraulic oil filter
Every Twelve Months
Replace hydraulic oil
Replace suction strainer
Inspect cable & replace if worn or damaged
Rev 5/6/2010
Hydraulic components
Hydraulic and air leaks
Oil level
Structural components and welds
Front and adjustable stops
Sheave blocks/reeving trolley
Rear hinge
Rollers
Cable and cable ends
Nuts, Bolts & Cotter pins
LED lights
Reflectors
Electrical wiring
Back up & hoist up warning systems
Safety props
8
Receipt of Owners Manual
I acknowledge that I have received a copy of “Spartan Roll-Off Model SRO
60 Owner’s Manual” and will distribute it to the equipment operators and
maintenance staff for the safe and proper use of the equipment.
Company name
Unit Serial Number
Signature
Date
Print Name
Please fill out and fax back to (818) 897-4366 or scan and email to
[email protected]
Rev 5/6/2010
9
SOP# 1
DEFINITION: PREPARE TRUCK CHASSIS
METHOD: - PROCEDURAL STEPS
1) REMOVE ANY OBSTRUCTIONS AT THE BACK OF THE VEHICLE (LIGHTS, MUDFLAPS ETC)
2) A JIG IS PROVIDED FOR THE CUTTING OF THE REAR SECTION. PLACE THE END OF THE JIG ON
TOP OF THE TRUCK FRAME AT THE CENTER OF THE REAR AXLE
3) FIX JIG IN POSITION WITH CLAMP.
4) MARK THE HOLE POSITIONS AND THE L SECTION AT THE REAR OF THE FRAME.
5) CUT THE FRAME VERTICALLY AT THIS POINT USING A SAW OR FLAME CUTTER.
6) CENTER PUNCH AND DRILL 7 HOLES USING A ¾” MAG DRILL OR EQUIVELANT
7) REPEAT STEPS 1 TO 7 ON OTHER SIDE.
8) TOUCHUP TRUCK CHASSIS WITH BLACK PAINT.
EQUIPMENT AND SUPPLIES
AIR IMPACT, SQUARE, TAPE MEASURE, HAMMER, CENTER PUNCH, ¾” DRILL BIT, MAGNET DRILL, G
CLAMPS, EDGE DRILL CREAM, BLACK SPRAY PAINT
PICTURES
ITEM #
1
PREPARE TRUCK CHASSIS
BLACK SPRAY PAINT - CAN
QTY
1
WEIGHT
0.25
2
REAR APRON JIG
1
1.5
SOP# 2
DEFINITION: INSTALL REAR APRON
1) MEASURE INSIDE OF TRUCK CHASSIS TO DETERMINE HOW MANY ¼” SHIMS ARE REQUIRED.
THE REAR APRON OUTSIDE TO OUTSIDE MEASUREMENT IS 32 1/2 “
2) INSERT APPROPRIATE NUMBER OF SHIMS INTO LH & RH SIDE TRUCK CHASSIS CHANNEL.
3) INSERT REAR APRON ASSEMBLY INTO POSITION AND SLIDE INTO TRUCK FRAME CHANNEL
USING FORK LIFT TRUCK.
4) HAMMER SHIMS INTO CORRECT POSITION OR IF PREFERED TACK WELD TO THE APRON.
MANOUVERE APRON SO ALL HOLES ALIGN USING HOLE ALLIGNMENT TOOL. ONCE IN
POSITION CLAMP SECURELY AND CHECK FOR SQUARENESS AND ALLIGNMENT
5) BOLT (14) 3” X 3/4” -GRADE 8 BOLTS THROUGH TRUCK FRAME, SHIMS AND APRON. SECURE
WITH NUT & WASHERS.
FORK LIFT TRUCK, CENTER ALLIGNMENT TOOL, G CLAMPS, AIR IMPACT, 1 5/8” SOCKET, HAMMER, 1
5/8” WRENCH
PICTURES
ITEM #
1
INSTALL REAR APRON
REAR APRON ASSEMBLY
1
QTY
WEIGHT
255 LBS
2
SHIMS FOR REAR APRON
2-4
9LBS EACH
3
BOLTS 3” X 3/4"” – GRADE 8
14
3.5 LBS
4
WASHERS 3/4”
28
0.25 LBS
5
LOCK NUTS 3/4”
14
3.5 LBS
SOP# 3
DEFINITION: LIGHT BAR ASSEMBLY
1) LIFT RH SIDE LIGHTBAR UP AND ALIGN INTO POSITION WITH BOLT PATTERN ON SIDE OF
REAR APRON.
2) BOLT (10) 1 ¾ X ½ - GRADE 8 BOLTS THROUGH LIGHTBAR SUPPORT PLATE AND THROUGH
APRON SIDE USING BOLT PATTERN. TIGHTEN ALL BOLTS WITH AIR IMPACT OR WRENCH TO
ENSURE RH SIDE LIGHTBAR IS SECURE AND ALLIGNED TO THE APRON. USE WASHERS
BETWEEN BOLT MATING SURFACES.
3) REPEAT STEPS 1 – 3 ON LH SIDE.
AIR IMPACT, ¾ SOCKET, ¾ WRENCH
PICTURES
ITEM #
1
LIGHT BAR ASSEMBLY
UNIVERSAL LIGHTBAR WITH ENDCAP & MOUNTING PLATE
QTY
2
WEIGHT
62 LBS
2
1 ¾” X ½” - GRADE 8 BOLTS
10
1 LB
3
½” WASHER
20
0.25 LB
4
½” LOCK NUTS
10
0.25 LB
SOP# 4
DEFINITION: FISHPLATES AND LOWERSHAFT MOUNT
1) MEASURE 113.5” BACK FROM THE CENTER OF THE REAR HINGE BACK DOWN THE FRAME.
THIS WILL BE THE POSITION OF THE FISHPLATE (CENTER OF THE FISHPLATE BUSHING)
** CRITICAL **
2) REMOVE ANY NUTS OR BOLTS THAT PROTRUDE FROM THE FRAME WITHIN THAT AREA. IF
NECESSARY RELOCATE ANY PERIPHERAL ITEMS THAT ARE WITHIN THE FRAME AREA, SUCH AS
AIR CANNISTERS ETC.
3) CLEAN FRAME WITH CLOTH AND DEGREASE IF NECESSARY.
4) LIFT LH SIDE FISHPLATE INTO POISTION. SECURING THE LIP OF THE FISHPLATE OVER THE
FRAME RAIL. POSITION EXACTLY PER ITEM 1 THEN SECURE INTO POSITION USING G CLAMPS
ENSURING THE FISHPLATE IS SQUARE AND FLUSH TO THE FRAME.
5) MARK ANY PRE-EXISTING FRAME HOLES ONTO THE BACK OF THE FISHPLATE AND FURTHER
HOLES IF NECCESARY. THERE NEEDS BE A MINIMUM OF (8) 5/8” HOLES TO SECURE THE
FISHPLATE TO THE FRAME.
6) REMOVE FISHPLATE, CENTER PUNCH HOLES AND DRILL WITH 11/16”” DRILL BIT OR CUTTER.
7) LIFT LH SIDE FISHPLATE BACK ONTO TRUCK FRAME AND LINE UP WITH FRAME HOLES THEN
G CLAMP BACK INTO POSITION. THEN DRILL FURTHER HOLES, DRILLING THROUGH THE
FISHPLATE AND FRAME.
8) BOLT LH FISHPLATE TO FRAME USING 5/8” X 2 ½” GRADE 8 BOLTS, WASHERS AND
LOCKNUTS PROVIDED.
9) REPEAT PROCEDURE 1- 8 ON THE RIGHT HAND SIDE BUT DO NOT BOLT THE FISHPLATE INTO
POSITION.
10) SLIDE LOWERSHAFT INTO FISHPLATE BUSHING FROM RH SIDE UNTIL FLANGES MEET.
11) BOLT RH FISHPLATE TO FRAME USING 5/8” X 2 ½” GRADE 8 BOLTS, WASHERS & LOCKNUTS
PROVIDED. DO NOT FULLY TORQUE AS FLEX MAYBE NEEDED TO INSTALL THE SPACER RINGS
ON THE LOWER SHAFT.
12) MEASURE THE GAP BETWEEN THE TWO MATING PLATES ON THE LOWER SHAFT. THIS GAP
NEEDS TO BE SHIMMED WITH THE SPACER RINGS PROVIDED, EACH SHIMS IS ¼ THICK. THE
SHIMS SHOULD BE EQUISPACED TO BOTH THE LEFT AND RIGHT IF NO GAP IS PRESENT GO TO
PROCEDURE 14
13) SLIDE THE APPROPRIATE NUMBER OF SHIMS AROUND THE LOWER SHAFT BETWEEN THE
TWO MATING PLATES.
14) SECURE FISHPLATE SHIMS AND LOWER SHAFT WITH (10) 5/8” X 3” GRADE 8 BOLTS
PROVIDED.
15) FULLY TIGHTEN RH SIDE FISHPLATE BOLTS TO FRAME CHANNEL.
16) INSPECT ALL BOLTS TO ENSURE BOTH FISHPLATES AND LOWER SHAFT ARE FULLY SECURE.
TAPE, HAMMER, CENTER PUNCH, AIR IMPACT, 15/16” SOCKET, 15/16” WRENCH, 11/16” CUTTER OR
DRILL, EDGE CREAM, MAG DRILL, G CLAMPS, SOAPSTONE, CLOTH, DEGREASER, HOLE ALLIGNMENT
TOOL.
ITEM #
FISHPLATES & LOWERSHAFT
QTY
WEIGHT
1
FISHPLATE LH SIDE WITH VALVE PLATFORM
1
132
2
FISHPLATE RH SIDE
1
104
3
LOWERSHAFT
1
109
4
BOLT 5/8” X 2 ½” GRADE 8 – FISHPLATE L & R
16
2.5
5
WASHER 5/8” – FISHPLATE L & R
32
0.5
6
LOCKNUT 5/8” – FISHPLATE L & R
16
0.75
7
¼” SPACER SHIMS FOR LOWER SHAFT
4
9
8
BOLTS 5/8” X 3” GRADE 8 – LOWERSHAFT L & R
10
1
9
WASHERS 5/8” – LOWERSHAFT L & R
20
0.25
10
LOCKNUT 5/8” – LOWERSHAFT L & R
10
0.5
SOP# 5
DEFINITION: TOOLBOX INSTALLATION
1) MANOUVERE TOOLBOX INTO POSITION ON TO TOP OF BOTH TOOLBOX SUPPORT LEGS.
2) BOLT TOOLBOX TO TOOLBOX SUPPORT LEGS. BOLT DIRECTLY INTO THE THREADED INSERTS
USING 3/8” X 2 ½” BOLTS SECURE WITH A STANDARD WASHER & SPRING WASHER AT THE
TOP OF THE BOLT HEAD.
3) MEASURE CHANNEL FOR BEST LOCATION ON PASSENGER SIDE. TRY TO USE PRE EXSISTING
FRAME BOLTS WHERE POSSIBLE.
4) REMOVE ANY PRE EXISTING FRAME BOLTS THAT WILL BE USED TO MOUNT THE TOOLBOX.
5) MARK A LINE 1” HORIZONTALLY DOWN FROM TOP OF CHANNEL WHERE THE TOP OF BOTH
TOOLBOX SUPPORTS WILL SIT.
6) MARK POSITION FOR HOLES ON FRAME RAIL IF PRE EXISTING HOLES ARE NOT AVAILABLE
AND DRILL HOLES USING A 11/16” BIT OR MAG DRILL. ENSURE SQUARENESS BEFORE
DRILLING.
7) LIFT TOOLBOX AND SUPPORTS ONTO JACK AND LIFT UP TO HIGHLIGHTED MARKS.
8) CLAMP INTO POSITION AND SQUARE UP.
9) MARK THROUGH THE FRAME HOLES ONTO TOOLBOX SUPPORT LEGS TO IDENTIFY WHERE
THEY NEED TO BE DRILLED
10) REMOVE TOOLBOX ASSEMBLY, CENTER PUNCH AND DRILL USING A 11/16” BIT OR MAG
DRILL.
11) LIFT THE TOOLBOX ASSEMBLY BACK INTO POSITION AND BOLT TO FRAME USING 5/8” X 2 ½
BOLTS, NUTS & WASHERS
12) IF ONE SUPPORT LEG SITS ON THE FISHPLATE AND ONE ON THE FRAME IT MAY BE
NECESSARY TO ADD A FRAME SPACER (PROVIDED) TO ALLIGN THE TOOLBOX HORIZONTALLY
WITH THE FRAME RAIL.
G CLAMPS, MAGDRILL, 9/16 SOCKET OR WRENCH, TAPE MEASURE, AIR IMPACT SQUARE,
CENTER LOCATION TOOL, JACK FOR TOOLBOX ASSY, 11/16 BIT, CENTER PUNCH, ½
SOCKET, ½ WRENCH, MARKER OR SOAPSTONE
PICTURES
ITEM #
1
TOOLBOX INSTALLATION
TOOLBOX SUPPORT LEG
QTY
2
WEIGHT
72 LBS
2
TOOLBOX (36” X 18” X 18”) WITH ANGLE MOUNTS
1
89 LBS
3
3/8” BOLTS 2-1/2”
6
0.5 LBS
4
3/8” WASHERS
6
0.2 LBS
5
3/8” LOCK WASHERS
6
0.1 LBS
6
5/8” X 2 1/2" GRADE 8 BOLTS
4
1 LBS
7
5/8” X WASHERS
8
0.2 LBS
8
5/8” X LOCKNUT
4
0.4 LBS
9
TOOLBOX KEYS
2
0.1 LBS
10
TOOLBOX FRAME SPACER 1/4 – 1/2"
1
1 LBS
SOP# 6
DEFINITION: HYDRAULIC TANK INSTALLATION
1) INSTALL FILTER ASSEMBLY ONTO HYDRAULIC TANK USING 3/8” X 1 1/4" BOLTS AND SPRING
WASHERS. ENSURE INLET IS POINTING TOWARDS THE FLOOR.
2) INSTALL STRAIGHT ADAPTER ONTO INLET OF FILTER ASSEMBLY.
3) MANOUVERE HYDRAULIC TANK INTO POSITION ON TO TOP OF BOTH HYDRAULIC TANK
SUPPORT LEGS.
4) BOLT HYDRAULIC TANK TO HYDRAULIC TANK SUPPORT LEGS. BOLT DIRECTLY INTO THE
THREADED INSERTS USING 3/8” X 1 ½” BOLTS SECURE WITH A STANDARD WASHER &
SPRING WASHER AT THE TOP OF THE BOLT HEAD.
5) THE TOOLBOX (CENTER) SHOULD BE MOUNTED APPROXIMATELY 165” BACK FROM THE REAR
HINGE POINT THIS WILL ENSURE THE RETURN LINE HOSE FROM THE VALVE IS SUITABLE.
6) MARK A LINE 1” HORIZONTALLY DOWN FROM TOP OF CHANNEL WHERE THE TOP OF BOTH
HYDRAULIC TANK SUPPORTS WILL SIT.
7) MARK POSITION FOR HOLES ON FRAME RAIL IF PRE EXISTING HOLES ARE NOT AVAILABLE
AND DRILL HOLES USING A 11/16” BIT OR MAG DRILL. ENSURE SQUARENESS BEFORE
DRILLING.
8) LIFT HYDRAULIC TANK AND SUPPORTS ONTO JACK AND LIFT UP TO HIGHLIGHTED MARKS.
9) CLAMP INTO POSITION AND SQUARE UP.
10) MARK THROUGH THE FRAME HOLES ONTO THE HYDRAULIC TANK SUPPORT LEGS TO
IDENTIFY WHERE THEY NEED TO BE DRILLED
11) REMOVE HYDRAULIC TANK ASSEMBLY, CENTER PUNCH AND DRILL USING A 11/16” BIT OR
MAG DRILL.
12) LIFT THE HYDRAULIC TANK ASSEMBLY BACK INTO POSITION AND BOLT TO FRAME USING
5/8” X 2 ½ G8 BOLTS, NUTS & WASHERS PROVIDED.
C CLAMPS, MAGDRILL, CENTER SUPPORT, 9/16 SOCKET OR SPANNER, TAPE, AIR IMPACT
SQUARE, CENTER LOCATION TOOL, JACK FOR TOOLBOX ASSY, 11/16 BIT, SQUARE, PUNCH,
½ SOCKET, ½ SPANNER, MARKER
PICTURES
ITEM #
HYDRAULIC TANK INSTALLATION
QTY
WEIGHT
1
HYDRAULIC TANK SUPPORT LEG
2
72 LBS
2
40 GALLON HYDRAULIC TANK WITH SIGHT GAUG, CAP &
STRAINER
HYDRAULIC TANK FILTER ASSEMBLY
1
133 LBS
1
2 LBS
BOLT 3/8” X 1 1/4” G5 (FILTER ASSY)
4
0.1 LBS
LOCK WASHER 3/8” (FILTER ASSY)
4
0.1 LBS
STRAIGHT ADAPTER (MALE) (FILTER ASSY)
1
0.2 LBS
6
7
3/8” BOLT 1 1/2" (SUPPORT LEGS)
6
0.5 LBS
8
3/8” WASHERS (SUPPORT LEGS)
6
0.2 LBS
9
3/8” SPRING WASHERS (SUPPORT LEGS)
6
0.1 LBS
10
5/8” X 2 1/2" GRADE 8 BOLTS (SUPPORT LEGS)
4
1 LBS
11
5/8” X WASHER (SUPPORT LEGS)
8
0.2 LBS
12
5/8” X LOCKNUT (SUPPORT LEGS)
4
0.4 LBS
13
HYDRAULIC TANK FRAME SPACER 1/4” OR 1/2"
1
1 LBS
3
4
5
SOP# 7
DEFINITION: AIR CANISTER MOVE
IT MAY BE NECESSARY TO MOVE AND RELOCATE PERIPHERAL EQUIPMENT FROM WITHIN THE TRUCK
FRAME TO ACCOMMODATE THE HYDRAULIC TANK, FISHPLATE OR LOWERSHAFT MOUNTING. EG –
AIR CANNISTERS AND AIR DRYERS ETC. ALWAYS USE TRUCK MANUFACTURERS GUIDANCE WHEN
UNDERTAKING SUCH MOVES.
1) SLACKEN NUT FROM U BOLT WHICH SECURES THE AIR CANISTER
2) SLIDE CANISTER THROUGH U BOLTS AND RE-POSITION (MOVE BOLTS TO ALTERNATIVE
LOCATION IF NECESSARY). REMOVE FITTINGS IF NECESSARY.
3) TIGHTEN NUT ON U BOLT TO SECURE AIR CANISTER BACK INTO POSITION.
4) ALWAYS REPLACE AIRLINES IN THE CORRECT POSITION. TOOLS REQUIRED MAY CHANGE
BASED UPON TRUCK MANUFACTURES SPEC
PICTURES
SOP# 8
DEFINITION: INSTALL VALVE BODY
1) LIFT VALVE BANK INTO POSITION ON LH SIDE FISHPLATE AND SECURE INTO POSITION USING
3/8” X 4 ½ GRADE 8 BOLTS, NUTS & WASHERS PROVIDED. THE HOLES REQUIRED WILL BE
DEPENDANT UPON THE NUMBER OF VALVE SECTIONS ORDERED.
2) ATTACH TWIN PIPE CLAMPS TO RH FISHPLATE AND FRONT SIDE OF LOWER SHAFT
3) INSTALL T FITTINGS ONTO 1” HOIST PIPES
4) FEED 1” X 33” (2) HOIST PIPES THROUGH THE TWIN PIPE CLAMPS ENSURING THAT THE T
FITTINGS ARE FACING THE DRIVERS SIDE.
5) THE PIPE SHOULD BE SECURED WITHIN THE TWIN PIPE CLAMPS WHEN THE END OF THE T
FITTING IS APPROXIMATELY 3/4" AWAY FROM THE INSIDE OF THE FISHPLATE. ONCE IN
POSITION TIGHTEN PIPE CLAMPS TO SECURE THE PIPES.
WRENCH 9/16”, SOCKET 9/16”, WRENCH 7/16”, SOCKET 7/16”
PICTURES
ITEM #
VALVE BODY INSTALLATION
QTY
WEIGHT
1
3 BANK VALVE BODY WITH HYDRAULIC & AIR FITTINGS
1
70 LBS
2
1” PIPE X 33” WITH FLARED FITTINGS (HOIST PIPES)
2
8 LBS
3
T FITTING 2093-16-16S (HOIST PIPES)
2
0.3 LBS
4
1” DUAL PIPE CLAMP (HOIST PIPES)
2
0.25 LBS
5
BOLTS 3/8” X 4 1/2” GRADE 8 – (VALVE)
3
0.25 LBS
6
WASHERS 3/8” – (VALVE)
6
0.1 LBS
7
LOCKNUT 3/8” - VALVE
3
0.2 LBS
SOP# 9
DEFINITION: PIPEWORK INSTALLATION (WITHOUT TRAILER)
1) MEASURE 28” FROM THE CENTER OF THE REAR HINGE BACK ALONG THE FRAME ON BOTH
SIDES. THIS WILL BE THE CENTER POSITION FOR THE REAR PIPE SUPPORT.
2) ONCE IN POSITION SECURE TO UNDERSIDE OF FRAME RAIL WITH 3/8” BOLTS THROUGH THE
SPRING STEEL FASTENER.
3) THE SECOND REAR PIPE SUPPORT SHOULD BE POSITIONED APPROXIMATLY 80” FROM THE
CENTER OF THE FIRST PIPE SUPPORT, JUST BEFORE THE FISHPLATE. ENSURE SQUARENESS
THEN SECURE TO FRAME AS PER PROCEDURE (2).
4) ATTACH BLACK PIPE CUSHION AROUND THE PIPE AND SLIDE INTO POSITION ALONG C
CHANNEL ON REAR PIPE SUPPORT. POSITION THE END OF THE PIPE 24” FROM THE CENTER
OF THE REAR HINGE. ALSO ENSURE THAT THE FIRST PIPE IS POSITIONED CLOSE TO THE
DRIVER SIDE FRAME RAIL ON THE PIPE SUPPORT.
5) POSITION CLAMP OVER CUSHION AND TIGHTEN INTO POSITION USING RATCHET OR AIR
DRIVER. REPEAT ON REAR PIPE SUPPORT ENSURING THE PIPE IS FULLY SECURE ON BOTH
SUPPORTS.
6) REPEAT STEPS (4) & (5) FOR FURTHER PIPES ENSURING ADEQUATE SPACE BETWEEN THE
PIPES. ALLOW ENOUGH SPACE BETWEEN PIPES SO THAT THE NUTS CAN BE TIGHTENED WHEN
THE HOSE INSTALLATION IS IN PROGRESS. SEPARATE APPROX 2” FROM CENTER TO CENTER.
7/16 WRENCH, 9/16 SOCKET, 7/16 SOCKET, RATCHET OR AIR DRIVER
PICTURES
ITEM #
PIPEWORK INSTALLATION
QTY
WEIGHT
1
MAIN RAIL PIPE HOLDER WITH SPRING STEEL SECUREMENT 2
15 LBS
2
2
14 LBS
3
FLARED HYDRAULIC PIPE – 96” X 1” OD WITH FLARED
FITTINGS
HYDRAULIC PIPE – SLEEVES # 900605-16S
4
0.25 LBS
4
HYDRAULIC PIPE – NUT # 1290-16S
4
0.25 LBS
5
OMEGA 1 ¼ (FOR 1”) PIPE CLAMPS & CUSHIONS
4
0.25 LBS
6
PIPE HOLDER - BOLTS GRADE 5 3/8 X 1.5” -16
4
0.25 LBS
7
PIPE HOLDER - NUTS 3/8”
4
0.1 LBS
8
PIPE HOLDER – WASHERS 3/8”
8
0.1 LBS
SOP# 10
DEFINITION: PTO & PUMP INSTALLATION
PTO INSTALLATION
INSTALL PTO BY THE MANUFACTURERS INSTRUCTIONS SUPPLIED WITH THE PTO.
CAUTION
THE POWER TAKE OFF SELECTION SHOULD BE DONE WITH CARE. FOR DIESEL ENGINES, THE PTO
SHOULD BE 100% TO 115% OF THE ENGINE RPM. FOR GAS ENGINES THE PTO SHOULD BE 65% TO
80% OF THE RPM. THE TORQUE REQUIRED IS 110 FT LBS MINIMUM.
PUMP INSTALLATION
IF INSTALLING A DIRECT MOUNT PUMP (INCLUDED) INSTALL DIRECTLY TO THE PTO USING
SUPPORT BRACKETS FROM THE PUMP TO THE TRANSMISSION HOUSING IF NECCESSARY. IT IS
RECCOMENDED THAT DIRECT MOUNTED HYDRAULIC PUMPS BE SUPPORTED TO THE TRASMISSION
WITH A 4 POINT SUPPORT BRACKET. THE BRACKET IS TO BE ATTACHED AT THE TRANSMISSION
WITH 2 ATTACHMENT BOLTS IN ORDER TO PREVENT MOVEMENT OF THE PUMP IN ALL DIRECTIONS.
GUIDELINES ARE FOUND IN THE PTO INSTALLATION & OWNERS MANUAL. PUMP WEIGHT, SIZE &
TYPE ARE VARIABLES WHICH CONTRIBUTE TO THE REQUIREMENT FOR THE USE OF A BRACKET,
BUT SYSTEM CYCLES, TERRAIN AND OTHER EXTERNAL INFLUENCES CAN BE FACTORS IN
DETERMINING THE FACTORS FOR PROPER INSTALLATION.
1) REMOVE P51 PUMP FROM PACKAGING & REMOVE PLUGS FROM PUMP. CLEAN INLETS/OUTLETS
WITH A CLOTH TO ENSURE NO CONTAMINENTS ENTER THE PUMP HOUSING.
2) REVIEW MANUFACTURERS PTO SHAFT DIRECTION TO DETERMINE IN & OUT PORTS FOR THE
PUMP.
3) APPLY PIPE JOINT COMPOUND TO KING NIPPLE THEN INSERT INTO CORRECT PORT ON THE
PUMP THEN TIGHTEN WITH A WRENCH.
4) APPLY PIPE JOINT COMPOUND TO MALE / MALE STRAIGHT ADAPTER THEN INSERT INTO
CORRECT PORT ON THE PUMP THEN TIGHTEN WITH A WRENCH
5) INSERT BOLTS INTO MOUNTING PLATE AND BOLT DIRECTLY TO THE PTO. TORQUE TO PTO
MANUFACTURERS RECOMMENDATION.
3/4" WRENCH, PIPE WRENCH, 1-3/4 WRENCH, 15/16 WRENCH, JOINT COMPOUND.
PICTURES
ITEM #
PTO & PUMP INSTALLATION
QTY
WEIGHT
1
P51 PUMP
1
55LBS
2
BOLT 1 3/4 X ½ GRADE 8 (PUMP – PTO)
6
0.25 LBS
3
LOCK WASHER (PUMP TO PTO)
6
0.1 LBS
4
STC 2015 – KING NIPPLE
1
0.25 LBS
5
20-21-2016 STRAIGHT ADAPTER MALE / MALE
1
0.25 LBS
SOP# 11
DEFINITION: VALVE HOSE INSTALLATION
NOTE: REFER TO THE HYDRAULIC SCHEMATIC FOR DETAIL OF HOSE ROUTING.
1) CONNECT TWO SMALL HOSES (3/4” x 13”) FROM HOIST SECTION UNDER FISHPLATE TO 1ST
VALVE SECTION. (HOIST) TIGHTEN WITH WRENCH.
2) CONNECT TWO LARGE HOSES (3/4” x 34”) FROM MAIN LINE TO 2ND VALVE SECTION
(REEVING) TIGHTEN WITH WRENCH.
5/8 WRENCH, 1-1/2 WRENCH, 1-1/4 WRENCH
PICTURES
ITEM #
DESCRIPTION
VALVE HOSE INSTALLATION
QTY
WEIGHT
1
MATCHMATE HYDRAULIC HOSE 3/4” X 34” WITH 1 90
DEGREE PIPE FITTING (1AA12FJB12) & ONE STRAIGHT
FITTING (1AA16MJ12)
2
5 LBS
2
MATCH MATE HYDRAULIC HOSE 3/4” X 13” WITH 2 90
DEGREE PIPE FITTINGS (1AA12FJB12) (SMALL) &
(1AA16FJ12) (LARGE)
2
3.5 LBS
SOP# 12,13 &14 DEFINITION:
SUCTION HOSE/RETURN LINE/REEVING HOSE
SUCTION HOSE LINE
1) APPLY PIPE JOINT COMPOUND ON 1 1/4" THREAD INSERT FOR TANK. APPLY PIPE JOINT
COMPOUND ON THREADS ON THE KING NIPPLE. INSTALL BOTH ON EITHER END OF THE SHUT
OFF VALVE. TIGHTEN WITH 1 7/8” WRENCH.
2) MEASURE THE DISTANCE REQUIRED FOR SUCTION HOSE BETWEEN TANK AND PTO THEN CUT
THE SUCTION HOSE TO THE CORRECT SIZE.
3) ATTACH ONE END OF THE SUCTION HOSE ONTO THE KING NIPPLE ON THE HYDRAULIC TANK.
SECURE IN PLACE WITH 1 1/2" PIPE CLAMP. RUN OTHER END TO THE KING NIPPLE ON THE
PUMP AND SECURE WITH 1 1/2" PIPE CLAMP.
4) ENSURE THAT THE SUCTION HOSE IS SUPPORTED BETWEEN THE TANK AND PUMP BY USING
THE (2) 2.25 LOOP CLAMPS PROVIDED
RETURN HOSE LINE
1. ATTATCH 1” RETURN LINE HOSE TO THE FITTING ON THE FILTER ASSEMBLY ON THE HYDRAULIC
TANK. TIGHTEN SECURELY WITH WRENCH. ATTATCH OTHER END TO THE RETURN ON THE VALVE
BODY AND TIGHTEN SECURELY WITH A WRENCH.
2. SECURE HOSE WITH 1.5 LOOP CLAMP ON HYDRAULIC TANK MOUNTING LEG IF NECESSARY.
REEVING HOSES
1. ATTATCH (2) 3/4” X 42” REEVING HOSES TO THE PIPES ON THE REAR PIPE SUPPORT. SECURE
WITH WRENCH. THE OTHER ENDS WILL BE FITTED TO THE REEVING CYLINDERS ONCE THE RAIL
HAS BEEN MOUNTED LATER
***NOTE*****
ADDITIONAL PIPE & HOSES WILL BE REQUIRED FOR TRAILER APPLICATION
5/8 WRENCH, 1/4 WRENCH, 3/8 WRENCH, 7/8 WRENCH, 9/16 SOCKET & WRENCH, PIPE
JOINT COMPOUND, TAPE MEASURE, DRILL, 7/16 DRILL BIT
PICTURES
ITEM #
DESCRIPTION SUCTION/RETURN/REEVING HOSES
QTY
WEIGHT
1
SUCTION HOSE 1 1/2" x 85’
1
5LBS
2
SUCTION HOSE - LOOP CLAMP 2.25 WITH 3/8” X 1.5” BOLT,
NUT AND WASHERS
2
0.2 LBS
3
SUCTION HOSE - PIPE CLAMP 1 ½”
2
0.2 LBS
4
KING NIPPLE – ST2015
1
0.3 LBS
5
THREAD INSERT FOR TANK 1-1/4
1
0.2 LBS
6
RETURN HOSE - 44” X 1” WITH 2 STRAIGHT 1AA16FJ16
FITTINGS ON EACH END (TANK FILTER – VALVE)
RETURN LINE – LOOP CLAMP 1.5 WITH 3/8” X 1.5” BOLT,
NUT AND WASHERS
SHUT OFF VALVE 1-1/2” – HVO150
1
5 LBS
1
0.1 LBS
1
0.5 LBS
REEVING HOSES – 42” X 3/4” WITH JACKETS (REAR MAIN
LINE PIPES – REEVING CYLINDERS)
2
5.5 LBS
7
8
9
SOP# 15
DEFINITION: INSIDE CONTROL BOX INSTALLATION (AIR PTO)
1) REMOVE INSIDE CONTROL BOX FROM PACKAGING AND LOOK FOR SUITABLE PLACE WITHIN
THE TRUCK CAB TO LOCATE THE INSIDE CONTROL BOX. FLOOR MOUNTED UNITS ARE
AVAILABLE FOR CONVENTIONAL CAB TRUCKS.
2) ALL AIR HOSES & ELECTRICAL WIRING NEEDS TO BE FED THROUGH THE CAB FIREWALL OR
THROUGH THE CAB FLOOR AND ALONG THE FRAME RAIL. DRILL A SUITABLE HOLE AS
REQUIRED THEN FEED ALL AIR HOSES AND ELECTRICAL WIRE THROUGH TO THE FRAME RAIL.
3) SECURE THE INSIDE CONTROL BOX TO THE FLOOR OR CAB USING THE 5/16” BOLTS,
WASHERS AND NUTS PROVIDED.
4) ENSURE THAT ALL AIR LINES ARE LOOMED WHEN LEAVING THE CONTROL BOX TO THE FRAME
AND CABLE TIED EVERY 12 – 18 INCHES. USE THE LOOP CLAMPS AND BOLTS SUPPLIED AS
REQUIRED TO SECURE THE LOOM AT SUITABLE POSITIONS. THE BLUE / GREEN / ORANGE
/YELLOW/BLACK AIR LINES SHOULD BE CUT APPROXIMATELY 3 FEET PAST THE CAB ON THE
FRAME RAIL. THESE AIRLINES WILL BE TEED INTO THE OUTSIDE CONTROLS LATER
5) RUN THE RED AIR LINE TO THE PTO. REVIEW PTO MANUFACTURERS INSTALLATION FOR
CORRECT SETUP. NOTE ** IF THE PTO IS ELECTRIC AND NOT AIR AN ALTERNATIVE PTO
ON/OFF SWITCH WILL BE REQUIRED ***
6) RUN THE SILVER (SUPPLY) AIR LINE CLOSE TO THE AIR CANNISTER THAT WILL SUPPLY THE
AIR FOR THE SYSTEM.
7) THE RED ELECTRCAL WIRES FROM THE BED RAISED LIGHT AND PTO ON LIGHT SHOULD BE
RAN TO A ALWAYS ON POWER SOURCE INCORPORATING THE INLINE 10 AMP FUSE SUPPLIED
8) THE BLACK ELECTRICAL WIRE FROM THE PTO ON/OFF LIGHT SHOULD BE RAN DIRECTLY TO
THE PTO. REVIEW PTO MANUFACTURERS INSTALLATION FOR CORRECT SETUP.
9) THE BLACK ELECTRICAL WIRE FROM THE BED RAISED LIGHT SHOULD BE RAN TO BED UP
MICRO SWITCH. THE WHITE WIRE FROM THE MICRO SWITCH SHOULD BE GROUNDED TO A
SUITABLE LOCATION ON THE TRUCK FRAME. THE MICRO SWITCH AND BRACKET SHOULD BE
MOUNTED TO THE TRUCK FRAME ONCE THE RAIL HAS BEEN INSTALLED LATER USING THE
5/16” BOLTS, WASHERS AND LOCKNUTS SUPPLIED.
10) INSTALL THE AIR SAFETY CHECK VALVE TO THE AIR SUPPLY CANNISTER FROM THE TRUCK.
ATTACH A PIECE OF SILVER ¼” AIR LINE FROM THE FITTING AND THEN ATTACH A ¼”
STANDARD AIR T TO THE OTHER END.
11) ATTACH THE SILVER SUPPLY LINE FROM THE INSIDE CONTROL BOX TO ONE OUTLET OF THE
T FITTING.
KNIFE, AIR HOSE CUTTER, TAPE MEASURE, DRILL, DRILL BITS, ELECTRICAL TAPE, CABLE
TIES, 1 1/16 WRENCH, DRILL BIT 9/16, 14-16 AWG BUTT CONNECTORS, WIRE STRIPPERS,
WIRE CRIMPERS
PICTURES
ITEM #
1
2
INSIDE CONTROL BOX INSTALLATION
QTY
WEIGHT
4 LBS
INSIDE CONTROL BOX (TWO LEVER) (AIR OPERATED) WITH 1
AIR OPERATED PTO SWITCH, BED UP LIGHT & PTO ON
LIGHT
ELECTRICLY OPERATED PTO SWITCH (OPTIONAL)
1
0.1 LBS
3
5/16” X 2” G5 BOLTS
4
0.1 LBS
4
5/16” FLAT WASHERS
8
0.1 LBS
5
5/16” LOCK NUT
4
0.1 LBS
6
INLINE 10 AMP FUSE
1
0.1 LB
7
1 1/2" LOOM (8FT)
1
1 LBS
8
LOOP CLAMP 2.25
3
0.2 LBS
9
3/8” X 1 1/2" G5 BOLT (LOOP CLAMP)
3
0.1 LBS
10
3/8” WASHER
6
0.1 LBS
11
3/8” LOCKNUT
3
0.1 LBS
12
1
0.25 LBS
13
AIR SAFETY CHECK VALVE WITH 1/4” AIR FITTING
(19800308)
BED UP SWITCH (ECCO SW15)
1
0.3 LBS
14
BED UP SWITCH MOUNTING BRACKET
1
0.25 LBS
15
5/16” X 2” BOLT G5 (BED UP BRACKET)
2
0.1 LBS
16
5/16” FLAT WASHERS
4
0.1 LBS
17
5/16” LOCKNUT
2
0.1 LBS
18
14” CABLE TIES
25
0.2 LBS
19
21” CABLE TIES
25
0.3 LBS
SOP# 16
DEFINITION: WIRING LOOM
THE SPARTAN WIRING HARNESS (RO24 2768) IS FULLY PLUG AND PLAY WITH TRUCK
MANUFACTURERS OEM STANDARD TRUCK LIGHT PLUGS. SEE WIRING SCHEMATIC FOR DETAILED
ROUTING INFORMATION.
1) ATTACH WIRING LOOM MAIN JUNCTION BOX ONTO CENTER CROSS MEMBER ON APRON
ASSEMBLY USING ¼” BOLT ALREADY WELDED TO THE CROSS MEMBER. THE HARNESS
SHOULD SLIDE OVER THE BOLT AND BE SECURED WITH A ¼ NUT & WASHER.
2) FROM THE MAIN HARNESS FEED THE LEFT HAND WIRING LOOM THROUGH TO THE LEFT
HAND LIGHT BAR (YELLOW)
3) FROM THE MAIN HARNESS FEED THE RIGHT HAND WIRING LOOM THROUGH TO THE RIGHT
HAND LIGHT BAR. (GREEN)
4) FROM THE MAIN HARNESS FEED THE REAR CLEARENCE LIGHTS THROUGH TO THE CENTER OF
THE APRON. (BROWN & WHITE DAISY CHAIN)
5) FROM THE MAIN MARNESS FEED THE LEFT HAND CENTER MARKER LIGHTS BACK DOWN THE
FRAME CHANNEL TO THE FISHPLATE (THESE WILL BE FULLY INSTALLED WHEN THE FENDERS
ARE MOUNTED)
6) FROM THE MAIN MARNESS FEED THE RIGHT HAND CENTER MARKER LIGHTS BACK DOWN THE
FRAME CHANNEL TO THE FISHPLATE (THESE WILL BE FULLY INSTALLED WHEN THE FENDERS
ARE MOUNTED)
7) FROM THE MAIN HARNESS THERE ARE TWO WIRES THAT FEED TO THE REAR OF THE HOIST
RAILS. THESE WILL BE INSTALLED ONCE THE RAIL HAS BEEN INSTALLED. FOR NOW PUT THEM
IN SECURE POSITION FOR INSTALL LATER. (YELLOW / GREEN SINGLE LED CONNECTOR)
8) THE SPARTAN WIRING HARNESS COMES WITH A 5 WIRE FEMALE METRIPACK CONNECTION
THAT SHOULD ACCOMODATE THE TRUCK MANUFACTURERS MALE 5 WIRE CONNECTOR,
SIMPLY PUSH THE TRUCK MALE CONNECTOR INTO THE FEMALE CONNECTOR ON THE
HARNESS UNTIL THE SAFETY CATCH CLICKS INTO POSITION.
9) NOTE: THE HARNESS COMES PRE-WIRED FOR PETERBILT TRUCKS. IT MAY BE
NECESSARY TO RELOCATE 1 OR MORE PINS FROM WITHIN THE METRIPACK
CONNECTOR ON THE TRUCK SIDE. AN ADAPTER IS AVAILABLE FOR KENWORTH
VEHICLES TO ALLOW INTEGRATION OF THE WEATHERPACK CONNECTOR TO A
METRIPACK CONNECTOR.
10) IF THE TRUCK MANUFACTURERS OEM CONNECTOR IS UNAVAILABLE OR INCOMPATIBLE DO
NOT SPLICE DIRECTLY TO THE HARNESS. USE ALTERNATIVE PART ME 2794 (MAIN
EXTENSION). PLUG THIS INTO THE HARNESS AND ADAPT THE TRUCKS WIRING TO SUIT.
NOTE – ALL WIRING SHOULD BE SECURED TO OR WITHIN CURRENT TRUCK HARNESSES USUALLY
ATTAHCED TO THE MAIN FRAME RAILS. USE CABLE TIES, AND LOOM COVERS WHERE NECESSARY.
EQUIPMENT AND SUPPLIES - 7/16 RATCH, SNIP, AIR RATCHET, ELECTRICAL TAPE
PICTURES
ITEM #
1
PLUG & PLAY MAIN WIRING HARNESS – RO24 2768
QTY
1
WEIGHT
8 LBS
2
¼” NUT & WASHER (ON REAR APRON)
1
0.1 LBS
3
1.25 LOOP CLAMP
4
0.2 LBS
4
2” X 3/8” G5 BOLT
4
0.1 LBS
5
3/8” FLAT WASHER
8
0.1 LBS
6
3/8” LOCKNUT
4
0.1 LBS
SOP# 17
DEFINITION: PRESSURE LINE INSTALLATION
1) ATTACH 1” X 45” HOSE TO THE PUMP .
2) ATTACH 1” X 45” HOSE TO PRESSURE PORT ON THE MAIN VALVE.
3) MEASURE THE GAP BETWEEN THETWO HOSES & CUT THE 1 1/4" PIPE TO THE CORRECT SIZE.
(THE NON FLARED END.) ENSURE THE CUT IS THE CORRECT LENGTH AS THE FLARELESS
FITTING CAN ONLY BE SET ONCE.
4) SMOOTH THE NON FLARED PIPE END WITH EMERY CLOTH ENSURING THAT THE PIPE IS FREE
FROM DIRT, OIL OR BURRS. THIS WILL ENSURE OPTIMUM MATING FOR THE FLARELESS
FITTING.
5) PRESET THE FLARELESS FITTING PER MANUFACTURES INSTRUCTION (INCLUDED)
6) CONNECT THE FLARED FITTING ON THE PIPE TO THE PUMP HOSE USING THE ADAPTER
FITTING INCLUDED.
7) CONNECT THE FLARELESS FITTING ON THE PIPE TO THE VALVE PRESSURE LINE HOSE USING
THE ADAPTER FITTING INCLUDED.
8) PLACE AND SECURE TWO PIPE CLAMP SUPPORTS WITH SPRING STEEL CLAMPS ONTO TRUCK
FRAME IN A SUITABLE POSITION AND THEN SECURE.
9) PLACE PIPE THROUGH CLAMPS AND SECURE TO SUPPORT.
1-1/2 WRENCH, 1-3/4 WRENCH, 2” WRENCH, 9/16 WRENCH, 9/16 SOCKET, AIR IMPACT,
TAPE, EMERY CLOTH.
PICTURES
ITEM #
PRESSURE LINE INSTALLATION
QTY
WEIGHT
1
PIPE WITH FLARE AT 1 END – 8 FT 1-1/4” OD
1
3 LBS
2
OMEGA 1 1/2” (FOR 1 1/4" PIPE CLAMP AND CUSHIONS)
2
0.25 LBS
3
PRESSURE LINE PIPE HOLDER WITH SPRING STEEL
SECUREMENT
PIPE HOLDER 3/8” X 1 1/2" G5 BOLTS
2
15 LBS
4
0.1 LBS
PIPE HOLDER – LOCKNUT 3/8”
4
0.1 LBS
PIPE HOLDER – WASHERS 3/8”
8
0.1 LBS
6
7
NUT / FLARELESS FITTING-1-1/4 FC2875
1
0.5 LBS
8
SLEEVE – FLARELESS FITTING – 1-1/4 FF9602-205
1
0.1 LBS
9
ADAPTER 2027-20-20S (PIPE TO HOSE)
2
0.25 LBS
10
1” X 45” HOSE 1AA20FJ16 / 1AA16FJ16 (VALVE TO PIPE)
1
3 LBS
11
1” X 45” HOSE 1AA20FJ16 / 1AA16FJ16 (PUMP TO PIPE)
1
3 LBS
4
5
SOP# 18
DEFINITION: RAIL INSTALLATION
1) SECURE MAIN RAIL ONTO FORK LIFT TRUCK OR CRANE WITH STRAPS. SECURE AT THE FRONT
AND REAR. USING APPROPRIATE SIZE FORK LIFT TRUCK (NOTE: THE RAIL ASSEMBLY
WEIGHS APPROX 3,500 LBS)
2) LOAD RAIL FROM PASSENGER SIDE ONTO THE TRUCK FRAME RAIL. USING THE REAR HINGE
POINT AS A DATUM POINT. ONCE IN POSITION SQUARE THE HOIST ON THE RAIL BOTH BACK
AND FRONT.
3) INSERT REAR HINGE PIN THROUGH HINGE PLATE AND TRUCK REAR APRON.
4) SECURE HINGE PIN WITH SECUREMENT RING AND 3/8” BOLT
STRAPS OR CHAINS, FORK LIFT TRUCK OR CRANE, ½” SOCKET, ½” WRENCH
PICTURES
ITEM #
1
HOIST ASSY – 2 CYLINDER REEVING, 6 SIDE ROLLERS
QTY
1
WEIGHT
3,448 LB’S
2
HINGE PIN 2” OD X 42.5”
1
38 LB’S
3
SECUREMENT RING 2 ¾” OD, 1”
1
0.15 LB’S
4
3/8 BOLT G5 3 1/2”
1
0.1 LB’S
5
3/8” WASHER
2
0.1 LBS
6
3/8 LOCK NUT
1
0.1 LB’S
SOP# 19
DEFINITION: PINTLE HOOK INSTALLATION (OPTION)
IF THE ROLL OFF UNIT IS NOT SPECIFIED WITH A TRAILER PACKAGE OPTION BOLT THE PINTLE
HOOK COVER PLATE TO THE REAR APRON WITH THE BOLTS PROVIDED AND SKIP THE REST OF THE
INSTALLATION PROCEDURE
1) INSTALL PINTLE HOOK AND SECURE WITH ¾ G8 BOLTS.
2) INSTALL AIR CANNISTER – BOLT IN PLACE.
3) ADJUST AIR CANNISTER SHAFT TO SUIT PINTLE HOOK.
4) INSTALL HYDRAULIC FITTINGS INTO APRON AFTER APPLYING PIPE JOINT COMPOUND THEN
TIGHTEN WITH A WRENCH. THEN ATTACH QUICK DISCONNECTS TO THE FITTINGS AND
TIGHTEN.
5) INSTALL AIR GLADHAND (SERVICE & EMERGENCY) AS ABOVE.
1-1/8 WRENCH, 1-1/8 SOCKET, 15/16 SOCKET, 7/8 WRENCH, 1-7/16 WRENCH, AIR
IMPACT, 1-3/4 WRENCH
PICTURES
ITEM #
1
PINTLE HOOK INSTALLATION
QUICK DISCONNECT (FEMALE)
QTY
1
WEIGHT
0.25LBS
QUICK DISCONNECT (MALE)
1
0.25 LB’S
2
3
PIPE FITTINGS FOR DISCONNECTS
2
0.25 LB’S
4
PINTLE HOOK AND AIR CANNISTER
1
30 LB’S
5
3/4” X 3” G8 BOLTS (PINTLE HOOK)
6
0.5 LB’S
6
6X3/4 WASHERS
12
0.2 LB’S
7
RED GLADHAND - EMERGENCY
1
0.2 LB’S
8
BLUE GLADHAND - SERVICE
1
0.2 LB’S
9
FITTINGS FOR GLADHAND
2
0.2 LB’S
SOP# 20
DEFINITION: HOIST CYLINDER & ADJUSTABLE STOP HOLDER INSTALLATION
1) REMOVE TOOLBOX FROM MOUNTING BRACKETS IF REQUIRED.
2) FLT OR CRANE CYLINDER INTO POSITION. SLIDE CYLINDER ONTO THE LOWER SHAFT ON THE
FISHPLATE AND THE TOP SHAFT ON THE FRAME RAIL AT THE SAME TIME AND PUSH THE
CYLINDER INTO POSITION
3) SLIDE CYLINDER CLASP ONTO TOP SHAFT AND SECURE TOP WITH (2) 1/2" X 2” G8 BOLTS,
WASHERS & LOCKNUTS.
4) SLIDE SECUREMENT RING ONTO THE LOWER SHAFT. SLIDE BOLT(1) 3/8” X 2” G5 BOLT
THROUGH RING AND SHAFT THEN SECURE WITH LOCKNUT & WASHERS.
5) INSTALL TWO 3/4” X 31” HOSES FROM RIGHT HAND HOIST CYLINDER TO PIPEWORK UNDER
RIGHT HAND FISHPLATE PER THE HYDRAULIC SCHEMATIC.
6) REPLACE TOOLBOX AND TIGHTEN BOLTS.
7) LOOSEN OIL TANK BY REMOVING BOLTS TO ALLOW CLEARENCE FOR DRIVER SIDE HOIST
CYLINDER INSTALLATION
8) INSTALL CYLINDER AS PER THE PASSENGER SIDE – ADJUSTING FOR OBSTRUCTIONS IF
NESSESARY.
9) REINSTALL OIL TANK. WHEN TIGHTENING ADD ADJUSTABLE STOP HOLDER TO TOOLBOX OR
HYDRAULIC TANK USING EXISTING HOLES ON THE SUPPORT LEGS.
10) FIX TWO 3/4” X 31” HOSES FROM LEFT HAND HOIST CYLINDER TO PIPEWORK UNDER LEFT
HAND FISHPLATE PER THE HYDRAULIC SCHEMATIC.
11) FILL HYDRAULIC TANK WITH OIL. APPROX 35 GALLONS INITIALLY THEN AFTER TESTING A
FURTHER 10-15 GALLONS. CHECK SIGHT GAUGE WITH ALL THECYLINDERS IN A RETRACTED
POSITION. FINAL OIL FILL SHOULD BE BETWEEN THE LOW – HIGH MARK ON THE SIGHT
GAUGE.
12) RAISE RAILS AND CONNECT PREVIOUSLEY INSTALLED REEVING HOSES (2) TO FITTINGS ON
THE HOIST. CABLE TIE AS REQUIRED.
9/16 WRENCH, 9/16 SOCKET, 1-1/2 WRENCH, AIR IMPACT, AIR SOCKET, 3/4 WRENCH,
3/4 SOCKET, 1-7/16 WRENCH, PIPE JOINT COMPOUND, 1-1/8 WRENCH
PICTURES
ITEM #
1
HOIST CYLINDERS 94” X 6” BORE / 4” ROD
QTY
WEIGHT
2
680 LBS
2
TOP SHAFT CYLINDER CLASP
2
3 LBS
3
BOLT 1/2 “ X 2’ GRADE 8 – (CYLINDER CLASP)
4
0.25 LB’S
WASHER 1/2” – (CYLINDER CLASP)
8
0.1 LB’S
LOCK NUT 1/2" – (CYLINDER CLASP)
4
0.2 LB’S
LOWERSHAFT SECUREMENT WASHER 4-1/8 OD 3-1/2 ID 1”
LONG
BOLT 3/8” X 2” GRADE 5 – (SECUREMENT RING)
2
2 LB’S
2
0.1 LB’S
7
8
WASHER 3/8” – (SECUREMENT RING)
4
0.1 LB’S
9
LOCKNUT 3/8” – (SECUREMENT RING)
2
0.1 LB’S
10
CYLINDER HOSES – 31” M/F 3/4”
4
6 LBS
11
ADJUSTABLE STOP HOLDER
1
2 LBS
12
ADJUSTABLE STOPS
2
7 LBS
4
5
6
SOP# 21
DEFINITION: ICC BUMPER BAR INSTALLATION
1) LIFT MAIN BAR INTO POSITION ON RAIL ASSEMBLY AND SECURE WITH PINS ON BOTH SIDES,
THEN FULLY SECURE WITH WASHER AND COTTER PIN.
2) SECURE LEFT & RIGHT HAND PIVOT ARM ONTO MAIN BAR, INSERT PINS & SECURE OTHER
END WITH COTTER PIN AND WASHER ONTO MAIN APRON.
3) RAISE AND LOWER RAILS TO ENSURE THE SELF COLLAPSING ICC BUMPER OPERATES
CORRECTLY AND UNIFORMLY.
HAMMER, PLIERS
PICTURES
ITEM #
ICC BUMPER BAR INSTALLATION
QTY
WEIGHT
1
ICC BUMPER - MAIN BAR
1
60 LBS
2
L SHAPED SWINGING ARMS
2
29 LBS
3
PINS 1” X 3 1/8” WITH WASHERS
6
3.25 LBS
4
COTTER PINS 1/4” X 2”
2
0.25 LB’S
SOP# 22
DEFINITION: MUDFLAP & REAR FENDER INSTALLATION
1) SECURE ANGLE MUDFLAP HOLDER BRACKET TO UNDERSIDE OF LIGHTBAR USING 1/2” X 1 1/4"
BOLTS, WASHERS & LOCK WASHERS.
2) MOUNT THE MUDLAP BETWEEN THE ANGLE AND THE FLATBAR AND SECURE WITH 3/8” X 1
1/4" BOLTS, WASHERS & LOCK WASHERS.
3) MOUNT DIAMOND PLATE QUARTER FENDERS ONTO LIGHT BAR. SECURE WITH 1/2” BOLTS,
WASHERS & LOCKWASHERS
4) REPEAT STEPS 1-3 ON OTHER SIDE
9/16 SOCKET, AIR WRENCH, 3/4” WRENCH
PICTURES
ITEM #
MUDFLAP AND REAR FENDER INSTALLATION
QTY
WEIGHT
1
DIAMOND PLATE QUARTER FENDERS
2
42 LBS
2
SPARTAN MUDFLAPS
2
5 LBS
3
MUDFLAP HOLDER BRACKET - ANGLE
2
0.5 LBS
4
MUDFLAP HOLDER BRACKET - FLATBAR
2
0.2 LBS
5
BOLT X 1/2" X 1-1/4 G5
16
1 LB
6
WASHER 1/2"
16
0.1 LBS
7
SPRING WASHER 1/2"
16
0.1 LBS
8
BOLT 3/8” X 1” G5
8
0.25 LBS
9
WASHER 3/8”
8
0.1 LBS
10
SPRING WASHER 3/8”
8
0.1 LBS
SOP# 23
DEFINITION: REAR LIGHTS & ELECTRICAL
1) BOLT BACKUP ALARM INTO POSITION ON REAR OF CLEARENCE LIGHT PLATE. ONCE BOLTED
ONTO THE REAR APRON ATTACH THE RED WIRE ON THE BACKUP ALARM TO THE BLACK WIRE
ON THE ELECTRICAL HARNESS VIA THE BULLET CONNECTOR. GROUND THE BLACK WIRE TO
ONE OF THE SECUREMENT BOLTS ON THE REAR APRON OR TRUCK FRAME (SEE ATTACHED
MANUFACTURERS INSTRUCTIONS)
*** ENSURE THAT THE BACKUP ALARM SAFETY STICKER IS ATTACHED TO THE
DASHBOARD IN FULL VIEW OF THE OPERATOR***
2) BOLT LICENSE PLATE LIGHT TO THE CLEARENCE LIGHT PLATE USING 5/32” BOLTS, WASHERS
& LOCKNUTS, ALSO ENSURING THAT THE RUBBER PAD SUPPLIED IS IN BETWEEN.
3) BOLT LICENSE PLATE ONTO LIGHTBAR STRIP USING 5/32” BOLTS, WASHERS & LOCKNUTS.
4) BOLT LIGHTBAR STRIP INTO PLACE ON TRUCK USING (8) 3/8” X 1” G5 BOLTS.
5) INSTALL (3) 2” (RED) CLEARENCE LIGHTS & GROMMETS ONTO LIGHTBAR STRIP. CONNECT TO
HARNESS USING 3 X PL10 DAISYCHAIN CONNECTORS.
6) CONNECT LICENSE PLATE LIGHT TO PL10 CONNECTOR ON THE HARNESS, IF NECCESARY USE
1.25” LOOP CLAMP TO SECURE.
7) FEED THE LEFT (YELLOW) & RIGHT (GREEN) SINGLE LED HARNESS WIRES THROUGH THE PIPE
ON THE RAIL AND INTO THE REAR CROSS MEMBER (USE LOOP CLAMP IF NECCESARY). ONCE
IN PLACE INSTALL (2) 4” RED LED LIGHTS AND GROMMETS INTO THE CROSS MEMBERS.
8) INSTALL (2) 4” CLEAR LED REVERSE LIGHTS AND GROMMETS INTO THE LIGHTBAR. USE THE 2
HOLES IN THE LIGHTBAR CLOSEST TO THE CENTER.
9) INSTALL (4) 4” RED LED LIGHTS INTO THE REMAINING HOLES.
10) INSTALL (2) 2” RED CLEARENCE LIGHTS & GROMMETS INTO THE LIGHTBAR SIDES
11) TEST LIGHTS – LEFT/RIGHT/STOP/REVERSE/MARKER/LICENSE PLATE/BACKUP ALARM.
12) THE AMBER 2” MIDDLE MARKER LIGHTS WILL BE INSTALLED ONCE THE FRONT FENDER
INSTALLATION IS COMPLETE.
AIR RATCHET , 7/16 WRENCH, 9/16 WRENCH, 5/16 SOCKET, 7/16 SOCKET, 3/8 SOCKET
PICTURES
ITEM #
1
2
REAR LIGHTS & ELECTRICAL
CLEARENCE LIGHT PLATE
3/8” X 1” G5 BOLTS (CLEARENCE LIGHT PLATE)
QTY
WEIGHT
1
2 LBS
8
0.25 LBS
3
3/8” SPRING WASHERS (CLEARENCE LIGHT PLATE)
8
0.1 LBS
4
3/8” WASHERS (CLEARENCE LIGHT PLATE)
8
0.1 LBS
5
1/4” X 1” BOLT (LICENSE PLATE)
2
0.1 LBS
6
1/4” WASHER (LICENSE PLATE)
4
0.1 LBS
7
1/4" LOCKNUT (LICENSE PLATE)
1
0.1 LBS
8
LICENSE PLATE LIGHT & HOUSING
1
0.25 LBS
9
5/32” X 1” BOLT (LICENSE PLATE LIGHT)
2
0.1 LBS
10
5/32” WASHER (LICENSE PLATE LIGHT)
4
0.1 LBS
11
5/32” LOCKNUT
2
0.1 LBS
12
4” RED LED LIGHTS (STOP/TAIL/TURN)
6
1.25 LBS
13
4” WHITE LED LIGHTS (REVERSE)
2
0.5 LBS
14
4” GROMMETS
8
1 LBS
15
2” RED LED LIGHTS (CLEARENCE)
5
0.5 LBS
16
2” AMBER LED LIGHTS (MID CLEARENCE)
2
0.2 LBS
17
2” GROMMETS
7
0.3 LBS
18
1.25 LOOP CLAMP
1
0.1 LBS
19
VALVAC BACKUP ALARM WITH BULLET CONNECTOR
1
0.2 LBS
20
5/32” X 1” BOLT (BACKUP ALARM)
2
0.1 LBS
21
5/32” LOCKNUT (BACKUP ALARM)
2
0.1 LBS
22
5/32” WASHER (BACKUP ALARM)
4
0.1 LBS
SOP# 25
DEFINITION: BODY GUIDES & HOIST FRAME SUPPORTS
METHOD: - PROCEDURAL STEPS – BODY GUIDES
1) WITH BED DOWN FIND AN APPROPRIATE POSITION FOR THE BODY GUIDES, PREFERBLY
USING PRE EXCISTING HOLES ON THE TRUCK FRAME. THE GUIDES ARE DESIGNED TO GUIDE
THE HOIST RAIL DOWN ONTO THE FRAME RAIL WHEN POWERING DOWN. ENSURE THAT THE
GUIDES ARE INSTALLED SYMETRICALLY ON BOTH SIDES. DUE TO TRUCK FRAME & HOIST
ASSEMBLY VARYING WIDTHS 2 X 1/4" SPACERS ARE SUPPLIED TO ALLOW MOVEMENT
OUTWARDS OF THE BODY GUIDES
2) MARK BODY GUIDES AND SPACERS FOR HOLES. CENTER PUNCH THEN DRILL WITH 11/16”
DRILL BIT OR CUTTER.
3) SECURE BODY GUIDES TO THE TRUCK USING 5/8” X 2 1/2" G8 BOLTS, WASHERS & LOCKNUTS.
METHOD: - PROCEDURAL STEPS – HOIST FRAME SUPPORTS
1) THE HOIST ASSEMBLY WILL SIT APPROXIMATELY 1/4" – 1/2" ABOVE THE FRAME RAIL AT THE
FRONT AND BACK OF THE TRUCK DUE TO THE POSITIONING OF THE HINGE AND THE
FISHPLATE ON THE FRAME RAIL. TWO L SHAPED FRAME SUPPORTS SHOULD BE USED AT THE
FRONT AND REAR OF THE TRUCK FRAME TO ALLOW THE HOIST RAIL TO SIT FLUSH ALONG
THE FRAME RAIL.
2) FIND A SUITABLE POSITION FOR PLACEMENT OF THE FRAME SUPPORTS. CENTER PUNCH
THEN DRILL WITH 11/16” DRILL BIT OR CUTTER.
3) SECURE HOIST FRAME SUPPORTS TO THE TRUCK USING 5/8” X 2 1/2" G8 BOLTS, WASHERS &
LOCKNUTS.
CENTER PUNCH, SQUARE, 15/16 SPANNER, 11/16 DRILL, G CLAMPS
PICTURES
ITEM # DEFINITION: BODY GUIDE & HOIST FRAME SUPPORT
QTY
WEIGHT
1
BODY GUIDES 5/8”
2
6 LBS
2
¼” BODY GUIDE SPACER PLATE
2
3 LBS
3
5/8” X 2 1/2" G8 BOLTS (BODY GUIDES)
4
0.25LBS
4
5/8” WASHER (BODY GUIDES)
8
0.1 LBS
5
5/8” LOCKNUT (BODY GUIDES)
4
0.2 LBS
6
1/4" OR 1/2" L SHAPE FRAME SUPPORTS
4
4 LBS
7
5/8” X 2 1/2" G8 BOLTS (FRAME SUPPORTS)
4
0.25LBS
8
5/8” WASHER (FRAME SUPPORTS)
8
0.1 LBS
9
5/8” LOCKNUT (FRAME SUPPORTS)
4
0.2 LBS
SOP# 26
DEFINITION: OUTSIDE CONTROL & REMOTE THROTTLE INSTALLATION
METHOD: - PROCEDURAL STEP
OUTSIDE CONTROL BOX
1) PLACE OUTSIDE CONTROL BOX AND MOUNTING BRACKET INTO A SUITABLE POSITION ON THE
DRIVERS SIDE. G CLAMP INTO POSITION. MARK & DRILL THEN SECURE WITH 5/8” X 2 1/2" G8
BOLTS, WASHERS & LOCKWASHERS
2) INSTALL STANDARD AIR T FROM AIR SUPPLY IN FRONT OF PRESSURE PROTECTION VALVE.
CONNECT SUPPLY LINE FROM INSIDE AND OUTSIDE CONTROLS TO THE TEE (SILVER)
3) RUN AIR HOSES FROM THE MAIN VALVE CLOSE TO WHERE THE OUTSIDE CONTROLS ARE
MOUNTED. THE COLORED HOSES FROM THE VALVE SHOULD MATCH THE SAME COLOR AS
BOTH THE OUTSIDE AND INSIDE CONTROLS. CUT HOSES TO CORRECT SIZE
(ORANGE – RAISE HOIST) (YELLOW – LOWER HOIST) (BLUE – CABLE IN) (GREEN – CABLE OUT)
4) THE AIR HOSES NOW MUST BE CONNECTED TO THE HUMPHREY S125 SHUTTLE VALVE. THE
AIR HOSES FROM THE VALVE SHOULD BE CONNECTED INTO THE (OUT) SECTION. THE INSIDE
& OUTSIDE CONTROLS SHOULD BE CONNECTED TO THE (IN) SECTION. LOOM AIR HOSES
ALONG TRUCK FRAME WITH 1 ½” LOOM SUPPLIED AND SECURE WITH CABLE TIES.
5) TEST BOTH INSIDE AND OUTSIDE CONTROLS TO ENSURE THAT THE AIR VALVES WORK
CORRECTLY IN CONJUNCTION WITH THE CONTROL BOX DECALS.
REMOTE THROTTLE
THE REMOTE THROTTLE IS DESIGNED TO RAISE THE ENGINE RPM WHEN OUTSIDE OF THE CAB
WHEN USING THE OUTSIDE CONTROLS WITH THE PTO ENGAGED. THE SWITCH IS DESIGNED
SPECIFICALLY AS A “DEAD MANS SWITCH” TO RESTRICT OPERATION WHEN THE OPERATOR DOES
NOT HAVE IT ENGAGED.
1) INSTALL PUSH BUTTON SWITCH ONTO THE OUTSIDE CONTROL BOX.
2) CONNECT RING TERMINALS TO DUAL AWG16 WIRE. THEN CONNECT TO THE SCREWS ON
BOTTOM OF THE PUSH BUTTON.
3) RUN THE WIRES FROM THE PUSHBUTTON INTO THE ENGINE COMPARTMENT. SECUREING
WITH CLAMPS AND CABLE TIES AS REQUIRED.
4) TO ENABLE THE REMOTE THROTTLE ONE WIRE FROM THE PUSHBUTTON MUST BE GROUNDED
AND THE OTHER CONNCETED TO A SPECIFIC PIN WITHIN THE ECM. REFER TO THE ENGINE
MANUFACTURERS INSTRUCTIONS AND WIRING DIAGRAMS ON HOW TO UNDERTAKE THIS.
THE ENGINE SHOULD BE PROGRAMMED TO HAVE 1 REMOTE PTO SPEED AT 1400RPM. REFER
TO THE ENGINE MANUFACTURERS SOFTWARE ON HOW TO PROGRAM THE ECM.
9/16” WRENCH, 1/2” WRENCH, AIR HOSE CUTTERS, 15/16 WRENCH, AIR IMPACT
PICTURES
OUTSIDE CONTROL & REMOTE THROTTLE INSTALLATION
1
QTY
WEIGHT
1
20 LBS
1
0.2 LBS
1
0.2 LBS
1
0.2 LBS
1
0.2 LBS
1
0.2 LBS
1
0.2 LBS
1
0.2 LBS
1
0.2 LBS
10
OUTSIDE CONTROL BOX WITH 2 SECTION AIR CONTROL
VALVE.
1/4” ORANGE AIR HOSE (15FT) (OUTSIDE CONTROL BOX)
(RAISE HOIST)
1/4" YELLOW AIR HOSE (15FT) (OUTSIDE CONTROL BOX)
(LOWER HOIST)
1/4" BLUE AIR HOSE (15FT) (OUTSIDE CONTROL BOX)
(CABLE IN)
1/4" GREEN AIR HOSE (15FT) (OUTSIDE CONTROL BOX)
(CABLE OUT)
1/4" SILVER AIR HOSE (15FT) (OUTSIDE CONTROL BOX)
(SUPPLY)
1/4" BLACK AIR HOSE (3FT) (OUTSIDE CONTROL BOX)
(EXHAUST)
1/4” ORANGE AIR HOSE (15FT) (VALVE BODY) (RAISE
HOIST)
1/4" YELLOW AIR HOSE (15FT) (VALVE BODY) (LOWER
HOIST)
1/4" BLUE AIR HOSE (15FT) (VALVE BODY) (CABLE IN)
1
0.2 LBS
11
1/4" GREEN AIR HOSE (15FT) (VALVE BODY) (CABLE OUT)
1
0.2 LBS
12
HUMPRHREY AIR T S125
4
0.3 LBS
13
1/4” STRAIGHT AIR FITTINGS
12
0.2 LBS
14
5/8” X 2 1/2" G8 BOLT
2
0.25 LBS
15
5/8” WASHER
4
0.1 LBS
16
5/8” LOCKNUT
2
0.1 LBS
17
OUTSIDE THROTTLE BUTTON – COLE HERSHEE 9126-03-BX
1
0.1 LBS
18
WIRE – DUAL AWG16 (10FT)
1
0.2 LBS
19
RING TERMINALS – HEAT SHRINK 14-16 AWG
2
0.1 LBS
2
3
4
5
6
7
8
9
SOP# 27
DEFINITION: STICKERS & DECALS
1) APPLY APPROXIMATELY 60” OF HIGH VIZIBILTY DOT TAPE TO THE REAR OF THE MAIN ICC
BUMPER BAR
2) APPLY APPROXIMATELY 12” OF HIGH VIZIBILTY DOT TAPE BETWEEN THE FIRST ROLLER AND
THE RATCHET TIE DOWNS ON BOTH SIDES OF THE RAIL.
3) APPLY APPROXIMATELY 12” OF HIGH VIZIBILTY DOT TAPE BETWEEN THE HINGE AND THE
SECOND ROLLER ON BOTH SIDES OF THE RAIL.
4) APPLY APPROXIMATELY 30” OF HIGH VIZABILITY TAPE BETWEEN THE SECOND & THIRD
ROLLER ON BOTH SIDES OF THE RAIL.
5) APPLY APPROXIMATELY 18” OF HIGH VIZABILTY TAPE ON THE OUTER EDGES OF THE SAFETY
STANDS ON BOTH SIDES
6) APPLY DECALS STE3 “HOIST PROP INSTRUCTION” BETWEEN THE THIRD ROLLER AND THE
SAFETY STAND ON BOTH SIDES OF THE RAIL
7) APPLY THE “CAUTION” & (2) “WARNING” DECALS AT A SUITABLE POSITION ON THE HOIST
FRAME OR TRUCK FRAME.
8) APPLY GREASE HERE STICKERS TO ALL ROLLERS, PULLEYS, BUSHINGS, HINGES ON THE HOIST
ASSEMBLY
SCISSORS, DRY CLOTH
PICTURES
ITEM #
QTY
STICKERS & DECALS
WEIGHT
1
SPARTAN LOGO STICKER – HYDRAULIC TANK & TOOLBOX
2
N/A
2
HIGH VIZIBILITY DOT-C2 TAPE (20FT)
1
N/A
3
HOIST PROP STICKER STE2 – “HOIST PROP INSTRUCTION”
2
N/A
4
WARNING STICKER STE1 – “TRAINED PERSONNEL”
2
N/A
5
WARNING STICKER STE3 – “HOIST WARNING”
2
N/A
6
CAUTION “HOIST SAFETY”
2
N/A
7
PTO WARNING STICKERS (SUPPLIED BY INSTALLER)
2
N/A
8
SPARTAN LOGO PLATE (ATTATCHE TO LH / RH HOIST RAIL)
2
N/A
9
1
N/A
10
SPARTAN SERIAL NUMBER PLATE (ATTACHED TO LH SIDE
OF HOIST RAIL)
GREASE FITTING STICKERS – CIRCULAR
7
N/A
11
GREASE FITTING STICKERS – SQUARE
12
N/A
12266 Branford Street, Sun Valley, CA 91352
Tel (818) 899-1111 Fax (818) 897-4366
www.spartantruck.com
LIMITED WARRANTY
SPARTAN TRUCK COMPANY, INC. (SPARTAN) warrants each new SPARTAN Roll-Off, Trailer, Bin Delivery
unit, or Power Pole unit for one (1) year on parts and labor (2 years on cylinders) and according to the following
terms:
This warranty coverage provides for original retail purchaser (Customer) only. The effective date is the original
retail sale date. The Warranty will be honored only when report of delivery report has been received by SPARTAN.
All Warranty work needs to be performed by an authorized SPARTAN service Agent/Dealer. Report of sale will be
required before any warranty work can proceed. Coverage during the first ninety (90) days will include labor
schedule, cost of parts replacement and freight charges for any parts return requested.
This Warranty does not cover service items subject to normal wear, such as - but not limited to - brake linings, tires,
belts, light bulbs, fuses etc. or components installed on products manufactured by SPARTAN.
This Warranty does not provide coverage for any unit that has been subject to misuse, neglect, negligence, accident
or operated in a way contrary to the operating or maintenance instructions as specified in the unit operator’s
manuals.
This warranty does not apply to any unit that as been altered or modified so as to adversely affect the unit’s
operation, performance or durability, or that has been modified so as to change its intended use. In addition, the
warranty does not extend to repairs made necessary by normal wear, or by the use of parts or accessories not
supplied by SPARTAN.
An authorized SPARTAN Agent/Dealer must perform repairs or replacements qualifying under this warranty.
SPARTAN responsibility with respect to claims is limited to making the required repairs or replacements. No claim
of breach of warranty shall be cause for cancellation of the contract of sale of any unit. SPARTAN assumes no
liability or responsibility for loss of use of the unit, loss of time, inconvenience, or other damage, consequential or
otherwise, including but not limited to all costs for delivering the units to the Agent/Dealer and all costs of
returning the units to the owner, mechanic travel time, telephone or fax charges, trailering or towing charges, rental
of like unit during the time warranty repairs are being performed, travel, lodging, loss or damage to personal
property, or loss of revenue.
SPARTAN reserves the right to change or improve the design of any unit without assuming the obligation to
modify units previously manufactured by SPARTAN.
All implied warranties are limited in duration to one (1) year for original unit standard parts and labor.
Accordingly any such implied warranties - including merchantability, fitness for a particular purpose or otherwise
- are disclaimed in their entirety after the expiration of the warranty period. SPARTAN obligation under this
warranty is absolutely and exclusively limited to repair or replacement of defective parts, and SPARTAN does not
assume and does not authorize anyone to assume for them, any other obligation.
Z:\Spartan\Forms\Manuals\SRO 60 Kit SOPs\Spartan Titan I Limited Warranty.doc
Page 1 of 2
Warranty Service
This policy only covers warranty performed by authorized by SPARTAN Agent/Dealer. A completed and accurate
installation report is required to verify any warranty claim.
Examples of Items not covered by Limited Warranty
Normal service requirements occurring during warranty, such as adjustments and cleaning or wear of drive belt or
drive chain.
Work over and above the repair and replacement of defective parts.
Unit subject to misuse, neglect, negligence or accident.
Units that have been altered or modified so as to adversely affect its operation, performance and durability or to
change its intended use.
Repairs made necessary by use of parts or accessories which are either incompatible with the unit or adversely
affect its operation, performance or durability.
Units not operated or maintained in accordance with the instructions in the SPARTAN service manual.
Units installed at Customer location in excess of one (1) year from SPARTAN ship date.
Periodic checking, lubricating the unit or service checkup.
All costs of delivering to the Agent/Dealer and all costs of returning the unit back to the owner, mechanics’s travel
time, trailering or towing charges, or rental of a like unit during the time, in which, warranty repairs are being
performed.
This warranty applies only to the original retail purchaser of the completed products shipped from a SPARTAN
facility. Second owner or subsequently owned units are not covered under the warranty.
This warranty applies to components and parts that are specific to the Titan I Roll-Off Kit. Improper installation or
damage to components by the Dealer, Distributor, or Customer, will void coverage to those specific components
and any other component damaged as a result of improper installation done at their location or facility. does not
apply to units shipped un-assembled to Agent/Dealer/Customer locations and assembly required at their facility.
Owners Obligation and Responsibility
Normal maintenance service and replacement of service items are the responsibility of the Agent/Dealer and as
such are not considered defects in material or workmanship with the terms of this warranty. Individual operating
habits and usage may contribute extensively to the need for maintenance service.
It is the responsibility of the installing SPARTAN Agent/Dealer to advise Customer on proper maintenance and
care of the unit.
To ensure warranty coverage the Agent/Dealer must verify that Customer has maintained all components in
proper adjustment and serviced the unit as specified in the owner’s manual. This includes proper lubrication for all
components and correct recommended battery maintenance, to maintain the battery fluid levels and charges as
specified, as well as maintain the correct pressure in the tires of the unit.
This warranty covers all products sold worldwide by SPARTAN on or after November 15th, 2005, and supersedes
all other warranty policies or statements.
Z:\Spartan\Forms\Manuals\SRO 60 Kit SOPs\Spartan Titan I Limited Warranty.doc
Page 2 of 2
Built Right, Right Now
STT 40
SRO 60
SPT 40 Pup Trailer
SST 80
SSS 70
SCT
SCD/R
SBT 10
SPP 12
Spartan Truck Company has been a leader in the
manufacturing of roll-off trucks and trailers for the
past 30 years. We are proud of our quick order lead
times, one of the best in the industry. We are known
for our high quality components and extremely
durable, low maintenance roll-off systems and trailers.
Additional Services
12266 Branford Street
Sun Valley, CA 91352
Phone (818) 899-1111
Fax (818) 897-4366
email [email protected]
website www.spartantruck.com
•
•
•
•
•
Winch to reeving conversions
Hydraulic parts and services
Roll-off repairs and estimates
Cylinder repair service
Big truck paint booth
SRO 60
This is our premier model and the mainstay of our product line. The SRO 60
features a lower center of gravity and is a lighter weight unit than comparable
models. It features LED lighting, the best tool box in the trade and it comes with
your choice of either single or double cylinder reeving system. Not only are
Spartan trucks the best built roll-off trucks in the industry, but we also offer the
fastest turnaround time in the business, saving you time and money.
SPT 40 PUP TRAILER
This unit is attached to a roll-off truck which then allows the driver to deliver,
load and empty the contents of the trash bins without unhitching the trailer
from the roll-off truck. Excellent time and money saver. Double your productivity.
STT 40
Commonly known in the trade as a pull trailer or transfer trailer. This unit works
in conjunction with a roll-off truck. A bin (empty or full) can be loaded on to this
trailer, delivered to a destination and then unloaded with the assistance of a
roll-off truck.
SST 80
Semi roll-off trailer. Super heavy duty used for those heavy payloads. LED
lights, full fenders and heavy duty suspension make this one of the best
equipped trailers on the market.
SSS 70
Compact semi roll-off trailer for easy manuverability. Excellent load capacity,
and heavy duty suspension. Full Fenders and LED lightings.
SCT
Scout Truck. This unit is generally built on a pickup chassis allows the movement
and manipulation of trash bins in locations that are inaccessible to the larger
trash hauling trucks.
SBT 10
This five bin trailer provides excellent maneuverability and easy handling of
three yard bins. Easy to load and unload hydraulic system. Fifth wheel or
conventional hitch set up available. High strength frame structure.
SCD/ R
Container Delivery Truck with optional rotator. This unit is designed to carry
and deliver multiple bins. In addition it is able to lift a full bin and then rotate it
so that the contents can be emptied in a trash truck or alternative location.
SPP 12
Power pole truck. Itʼs auger bit on the back of the truck allows the user to
drill holes in the ground which are then used to anchor temporary power
poles, providing temporary electrical power to construction sites. This unit is
also used to quickly install fence posts.
Contact our sales staff for a quote today.
Phone (818) 899-1111 or visit our website at www.spartantruck.com.
SOP# 24
DEFINITION: FRONT QUARTER FENDER INSTALLATION
1) MARK BACK DOWN THE FRAME HORIZONTALLY 93” FROM THE CENTER OF THE REAR HINGE
THEN MEASURE 1” DOWN FROM THE TOP OF THE FRAME RAIL.
2) PLACE SAFETY STAND IN POSITION – MARK BOLT HOLES ON THE FRAME THEN CENTER
PUNCH & DRILL. THEN SECURE WITH 5/8” X 2 1/2" G8 BOLTS, WASHERS & LOCKNUTS.
3) SECURE FENDER POLE TO SAFETY STAND MOUNTING BRACKET USING 1/2” X 2” G8 BOLTS,
WASHERS & LOCKNUTS. USE SUITABLE ALIGNMENT HOLES ON THE FENDER POLE MOUNTING
BRACKET
4) MOUNT QUARTER FENDER TO POLE USING U BOLT KIT.
5) INSERT GROMMET & 2” AMBER CLEARENCE LIGHT INTO FENDER POLE LIGHT BRACKET.
CONNECT TO PL10 PLUG SUPPLIED FROM THE MAIN WIRING HARNESS. SECURE WITH LOOP
CLAMPS OR CABLE TIES AS REQUIRED
9/16 SOCKET, 9/16” WRENCH, 3/4" SOCKET, 3/4" WRENCH, AIR IMPACT
PICTURES
ITEM #
1
2
QUARTER FENDER INSTALLATION
SAFETY STAND WITH BOLTED FRONT FENDER MOUNT
ATTATCHMENT
5/8” X 2 1/2" G8 BOLTS (SAFETY STAND)
3
QTY
2
WEIGHT
5 LBS
4
0.5 LBS
5/8” FLAT WASHER
8
0.1 LBS
4
5/8” LOCK NUT
4
0.2 LBS
5
1
20 LBS
2
6 LBS
7
HOGBUILT QUARTER FENDER (PAIR) WITH U BOLT KIT &
TOP FENDER GUARD
FENDER POLE WITH MOUNTING BRACKET & CLEARENCE
LIGHT HOLDER
BOLT 1/2" X 2” G8
4
0.2 LBS
8
WASHER 1/2"
8
0.1 LBS
9
LOCKNUT 1/2"
4
0.1 LBS
6

Spartan Roll Off Model - titan Installation Manual

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Softub T-140 - Softub of the Carolinas

VFX-9/13 Pneumatic Combination Tool for Polypropylene

Softub T-300 - Softub of the Carolinas

a5-or-250 trailer hoist

SHRINKFAST.

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SC-2300 spec

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