Spartan Roll Off Model - titan Installation Manual Roll Off Model - titan Installation Manual 12266 Branford Street Sun Valley, CA 91352 Phone: (818) 899-1111 Fax: (818) 897-4366

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Phone: (818) 899-1111

Fax: (818) 897-4366

www.spartantruck.com

Spartan RollOff Model - titan

Rev Rev Rev Rev 5/6/20105/6/20105/6/20105/6/2010 SPARTAN TRUCK COMPANY, INC. 2

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.



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 improperly 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.



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.



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.



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 oi l. Hydraulic Cylinders Inspect cylinder rods, fittings and operation. Apply grease to the grease fittings on the hydraulic cylinder every week.



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 joints. 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 thorough 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.



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

� 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

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



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]

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 # PREPARE TRUCK CHASSIS QTY WEIGHT

1

BLACK SPRAY PAINT - CAN 1 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 # INSTALL REAR APRON QTY WEIGHT

1

REAR APRON ASSEMBLY 1 255 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 # LIGHT BAR ASSEMBLY QTY WEIGHT

1

UNIVERSAL LIGHTBAR WITH ENDCAP & MOUNTING PLATE 2 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 # TOOLBOX INSTALLATION QTY WEIGHT

1

TOOLBOX SUPPORT LEG 2 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

1 133 LBS

3

HYDRAULIC TANK FILTER ASSEMBLY 1 2 LBS

4

BOLT 3/8” X 1 1/4” G5 (FILTER ASSY) 4 0.1 LBS

5

LOCK WASHER 3/8” (FILTER ASSY) 4 0.1 LBS

6

STRAIGHT ADAPTER (MALE) (FILTER ASSY) 1 0.2 LBS

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

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

FLARED HYDRAULIC PIPE – 96” X 1” OD WITH FLARED

FITTINGS

2 14 LBS

3

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)

1 5 LBS

7

RETURN LINE – LOOP CLAMP 1.5 WITH 3/8” X 1.5” BOLT, NUT AND WASHERS

1 0.1 LBS

8

SHUT OFF VALVE 1-1/2” – HVO150 1 0.5 LBS

9

REEVING HOSES – 42” X 3/4” WITH JACKETS (REAR MAIN

LINE PIPES – REEVING CYLINDERS)

2 5.5 LBS

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 # INSIDE CONTROL BOX INSTALLATION QTY WEIGHT

1

INSIDE CONTROL BOX (TWO LEVER) (AIR OPERATED) WITH AIR OPERATED PTO SWITCH, BED UP LIGHT & PTO ON

LIGHT

1 4 LBS

2

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

AIR SAFETY CHECK VALVE WITH 1/4” AIR FITTING (19800308)

1 0.25 LBS

13

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


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


1

PLUG & PLAY MAIN WIRING HARNESS – RO24 2768 1 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


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

2 15 LBS

4

PIPE HOLDER 3/8” X 1 1/2" G5 BOLTS 4 0.1 LBS

5

PIPE HOLDER – LOCKNUT 3/8” 4 0.1 LBS

6

PIPE HOLDER – WASHERS 3/8” 8 0.1 LBS

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

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


1

HOIST ASSY – 2 CYLINDER REEVING, 6 SIDE ROLLERS 1 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


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 # PINTLE HOOK INSTALLATION QTY WEIGHT

1

QUICK DISCONNECT (FEMALE) 1 0.25LBS

2

QUICK DISCONNECT (MALE) 1 0.25 LB’S

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


1

HOIST CYLINDERS 94” X 6” BORE / 4” ROD 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

4

WASHER 1/2” – (CYLINDER CLASP) 8 0.1 LB’S

5

LOCK NUT 1/2" – (CYLINDER CLASP) 4 0.2 LB’S

6

LOWERSHAFT SECUREMENT WASHER 4-1/8 OD 3-1/2 ID 1”

LONG

2 2 LB’S

7

BOLT 3/8” X 2” GRADE 5 – (SECUREMENT RING) 2 0.1 LB’S

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

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 # REAR LIGHTS & ELECTRICAL QTY WEIGHT

1

CLEARENCE LIGHT PLATE 1 2 LBS

2

3/8” X 1” G5 BOLTS (CLEARENCE LIGHT PLATE)

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


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.

EQUIPMENT AND SUPPLIES 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 QTY WEIGHT

1

OUTSIDE CONTROL BOX WITH 2 SECTION AIR CONTROL

VALVE.

1 20 LBS

2

1/4” ORANGE AIR HOSE (15FT) (OUTSIDE CONTROL BOX)

(RAISE HOIST)

1 0.2 LBS

3

1/4" YELLOW AIR HOSE (15FT) (OUTSIDE CONTROL BOX)

(LOWER HOIST)

1 0.2 LBS

4

1/4" BLUE AIR HOSE (15FT) (OUTSIDE CONTROL BOX)

(CABLE IN)

1 0.2 LBS

5

1/4" GREEN AIR HOSE (15FT) (OUTSIDE CONTROL BOX) (CABLE OUT)

1 0.2 LBS

6

1/4" SILVER AIR HOSE (15FT) (OUTSIDE CONTROL BOX)

(SUPPLY)

1 0.2 LBS

7

1/4" BLACK AIR HOSE (3FT) (OUTSIDE CONTROL BOX)

(EXHAUST)

1 0.2 LBS

8

1/4” ORANGE AIR HOSE (15FT) (VALVE BODY) (RAISE

HOIST)

1 0.2 LBS

9

1/4" YELLOW AIR HOSE (15FT) (VALVE BODY) (LOWER

HOIST)

1 0.2 LBS

10

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


16


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

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 # STICKERS & DECALS QTY 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

SPARTAN SERIAL NUMBER PLATE (ATTACHED TO LH SIDE

OF HOIST RAIL)

1 N/A

10

GREASE FITTING STICKERS – CIRCULAR 7 N/A

11

GREASE FITTING STICKERS – SQUARE 12 N/A

Z:\Spartan\Forms\Manuals\SRO 60 Kit SOPs\Spartan Titan I Limited Warranty.doc

Page 1 of 2

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.

12266 Branford Street, Sun Valley, CA 91352

Tel (818) 899-1111 Fax (818) 897-4366

www.spartantruck.com

Z:\Spartan\Forms\Manuals\SRO 60 Kit SOPs\Spartan Titan I Limited Warranty.doc

Page 2 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.

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.

12266 Branford Street

Sun Valley, CA 91352

Phone (818) 899-1111

Fax (818) 897-4366

email [email protected]

website www.spartantruck.com

Built Right, Right Now

Additional Services

• Winch to reeving conversions

• Hydraulic parts and services

• Roll-off repairs and estimates

• Cylinder repair service

• Big truck paint booth

SCT

SPT 40 Pup Trailer

SCD/R

SSS 70SST 80

SRO 60

SPP 12

STT 40

SBT 10

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 carryand deliver multiple bins. In addition it is able to lift a full bin and then rotate itso 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 # QUARTER FENDER INSTALLATION QTY WEIGHT

1

SAFETY STAND WITH BOLTED FRONT FENDER MOUNT

ATTATCHMENT

2 5 LBS

2

5/8” X 2 1/2" G8 BOLTS (SAFETY STAND) 4 0.5 LBS

3

5/8” FLAT WASHER 8 0.1 LBS

4

5/8” LOCK NUT 4 0.2 LBS

5

HOGBUILT QUARTER FENDER (PAIR) WITH U BOLT KIT &

TOP FENDER GUARD

1 20 LBS

6

FENDER POLE WITH MOUNTING BRACKET & CLEARENCE

LIGHT HOLDER

2 6 LBS

7

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

Spartan Roll Off Model - titan Installation Manual Roll Off Model - titan Installation Manual 12266 Branford Street Sun Valley, CA 91352 Phone: (818) 899-1111 Fax: (818) 897-4366

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