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Stepp SPHD series Operation, Maintenance And Parts Manual

Diesel burner systems dump style premix heater
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Rev. 12/2014
Operations/MAINTENANCE/PARTS
MANUAL
12325 River Road North Branch MN 55056 ~ Phone: 651-674-4491 ~ Fax: 651-674-4221
www.steppmfg.com

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  • Page 1 Rev. 12/2014 OPERATIONS/MAINTENANCE/PARTS MANUAL Diesel Burner Systems 12325 River Road North Branch MN 55056 ~ Phone: 651-674-4491 ~ Fax: 651-674-4221 www.steppmfg.com...
  • Page 2 (1) year from the date of purchase. Stepp Mfg., at its discretion, will provide for the repair or replacement of any part found upon examination by Stepp Mfg. to be defective, except as noted below. Such repair or re- placement will be free of charge to the original purchaser for a period of one (1) year from the date of purchase, except as noted below.

  • Page 3: Introduction

    In addition, the operator must re- ceive instruction from their supervisor, or the manufacturer, on how to safely operate the Stepp Hot Pack Dump Style Trailer. Contact the manufacture if any questions arise or if you desire training for additional staff members.

  • Page 4: Table Of Contents

    This manual explains the basic operations, maintenance and use of the Stepp SPHD Premix Heater. The main objective of this equipment is to maintain heat in patching ma-...
  • Page 5 Before Starting or Operating this Machine Understand and observe all the following Warnings, Cautions, and Notes. WARNINGS This equipment contains mechanical and heating components that may cause serious injury or death if not  handled or maintained properly. All personnel must be properly trained in the operation and maintenance of this equipment.
  • Page 8 OPERATIONS Loading Loading Main Hopper WARNING: Hydraulic equipment can crush any object with tremendous force, causing injury or death. Keep yourself and all other persons clear when raising and lowering hopper. Hydraulically Operated Doors 1. Shut OFF the heating system. 2.
  • Page 9 OPERATIONS Dumping Hydraulic Dump WARNING: Hydraulic equipment can crush any object with tremendous force causing injury or death. Keep yourself and all other persons clear when operating hydraulic equipment. 1. Find the magnet remote mounted toward rear curbside of unit. 2.
  • Page 10 OPERATIONS Diesel Burner w/ Thermostat NOTE: This system incorporates a 12 volt burner and blower assembly and burns #2 diesel fuel. A 12 volt battery and charging circuit supply power to the burner, blower motor, and ther- mostat. The charging circuit may consist of an engine driven alternator mounted on the unit, or a hook-up to the tow vehicles charging system.

  • Page 11: Contents

    OPERATIONS Diesel Burner Tack Tank (optional) An optional tack tank is available to pre-heat the tack oil used to obtain better repairs. The tack tank incorporates its own heating system similar to the systems used to heat the Pre-Mix Heater. Burner operating instructions for the tack tank are included with the burner instruc- tions for the Pre-Mix Heater main hopper on the previous pages.

  • Page 12: Operations

    OPERATIONS Tack Tank & Pumping System CONT. 1. System Flush. (optional) Flushing solvent is pumped through the pump and wand to clean material from the system. WARNING: Do not allow flushing solvent to contaminate the contents of the tack tank. a.
  • Page 13 OPERATIONS Overnight Heat/Washdown Overnight Heaters (optional) The overnight heaters are designed to pre-heat, or maintain the temperature of the heat transfer oil up to the capacity of the heating elements. This will decrease the amount of time necessary to bring the materials up to the recommended application temperatures. The burner is automatically disconnected from the system and the electric heating elements are activated when the power cord is plugged in.

  • Page 16: Maintenance

    PRE-MIX HEATER MAINTENANCE SCHEDULE ITEM OPERATION TO PERFORM DAILY EVERY EVERY EVERY EVERY EVERY WEEK MONTH YEAR Burner Diffuser Inspect burner diffuser for damage and deterioration. Burner Diffuser Replace burner diffuser. Refer to parts list for P/N Burner Fuel Replace fuel nozzle. Refer to parts Nozzle section for P/N Door Hinges...
  • Page 17 PRE-MIX HEATER MAINTENANCE RECORD DATE MAINTENANCE PERFORMED HOUR METER SERVICED BY All maintenance items must be performed according to the maintenance schedules All maintenance items must be performed according to the maintenance schedules and documented for warranty coverage to be effective. and documented for warranty coverage to be effective.

  • Page 20: Troubleshooting

    Test the Primary control- condition, turn main power ler function, replace if Check the photo switch “off” then “on” again to faulty. Contact Stepp electric eye for a reset the system. Mfg. if this does not cor- dirty lens and prop- Check to see if : rect problem.
  • Page 21 Diesel Burner Adjustments 1. Bleed all air from fuel system through bleeder screw. electrode 5/32” See Fig. 4 (burner motor must be running). 2. Check and adjust igniter electrodes as shown in Fig. 1. 3. Verify dimensional adjustments. The “Z” in dimen- nozzle sion is set to 1 1/8’...
  • Page 22 TROUBLE SHOOTING Diesel Burner Component Primary Controller Burner MTD/Hard Wired NOTE: The primary controller can be bench tested for proper operation us- ing an automotive type, 12 volt battery as a power source. Refer to the wir- ing schematics for wire identification. 1.
  • Page 23 TROUBLE SHOOTING Diesel Burner Photo Electric Eye NOTE: The Photo Electric Eye can be bench tested for proper oper- ation using an ohm meter. Assure the lens of the Photo Electric Eye is clean prior to testing. 1. Block off all light to the Photo Electric Eye. Test across the leads with your ohm meter;...

  • Page 26: Replacement Parts

    REPLACEMENT PARTS 2.0 Hopper Assembly...
  • Page 27 REPLACEMENT PARTS 2.0 Hopper Assembly...
  • Page 28 REPLACEMENT PARTS 2.0 Hopper Assembly...
  • Page 29 REPLACEMENT PARTS 2.0 Hopper Assembly...
  • Page 30 REPLACEMENT PARTS 3.0 Hopper Assembly...
  • Page 31 REPLACEMENT PARTS 3.0 Hopper Assembly...
  • Page 32 REPLACEMENT PARTS 3.0 Hopper Assembly...
  • Page 33 REPLACEMENT PARTS 3.0 Hopper Assembly...
  • Page 34 REPLACEMENT PARTS 2.0 Hopper Assembly w/ Hyd. Doors...
  • Page 35 REPLACEMENT PARTS 2.0 Hopper Assembly w/ Hyd. Doors...
  • Page 36 REPLACEMENT PARTS 2.0 Hopper Assembly w/ Hyd. Doors...
  • Page 37 REPLACEMENT PARTS 2.0 Hopper Assembly w/ Hyd. Doors...
  • Page 38 REPLACEMENT PARTS 3.0 Hopper Assembly w/ Hyd. Doors...
  • Page 39 REPLACEMENT PARTS 3.0 Hopper Assembly w/ Hyd. Doors...
  • Page 40 REPLACEMENT PARTS 3.0 Hopper Assembly w/ Hyd. Doors...
  • Page 41 REPLACEMENT PARTS 3.0 Hopper Assembly w/ Hyd. Doors...
  • Page 42 REPLACEMENT PARTS Hydraulic Door– Curb Side...
  • Page 43 REPLACEMENT PARTS Hydraulic Door– Street Side...
  • Page 44 REPLACEMENT PARTS Discharge Door Cylinder Mount...
  • Page 45 REPLACEMENT PARTS Shovel Platform...
  • Page 46 REPLACEMENT PARTS 2.0 Trailer Assembly w/ Electric Brakes...
  • Page 47 REPLACEMENT PARTS 2.0 Trailer Assembly w/ Electric Brakes...
  • Page 48 REPLACEMENT PARTS 3.0 Trailer Assembly w/ Electric Brakes...
  • Page 49 REPLACEMENT PARTS 3.0 Trailer Assembly w/ Electric Brakes...
  • Page 50 REPLACEMENT PARTS 2.0 Trailer Assembly w/ Hydraulic Brakes...
  • Page 51 REPLACEMENT PARTS 2.0 Trailer Assembly w/ Hydraulic Brakes...
  • Page 52 REPLACEMENT PARTS 2.0 Hitch w/ Hydraulic Brakes...
  • Page 53 REPLACEMENT PARTS 3.0 Trailer Assembly w/ Hydraulic Brakes...
  • Page 54 REPLACEMENT PARTS 3.0 Trailer Assembly w/ Hydraulic Brakes...
  • Page 55 REPLACEMENT PARTS 3.0 Hitch w/ Hydraulic Brakes...
  • Page 56 REPLACEMENT PARTS Pintle Hitch...
  • Page 57 REPLACEMENT PARTS Ball Hitch...
  • Page 58 REPLACEMENT PARTS Tow Connector– 7RV...
  • Page 59 REPLACEMENT PARTS Tow Connector– 7 Round...
  • Page 60 REPLACEMENT PARTS Tow Connector– 6 Round...
  • Page 61 REPLACEMENT PARTS Light Package– Incandescent...
  • Page 62 REPLACEMENT PARTS Light Package– LED...
  • Page 63 REPLACEMENT PARTS 4 Light System...
  • Page 64 REPLACEMENT PARTS 4 Light System...
  • Page 65 REPLACEMENT PARTS 4 Light System...
  • Page 66 REPLACEMENT PARTS Diesel Burner...
  • Page 67 REPLACEMENT PARTS Burner Rain Cover...
  • Page 68 REPLACEMENT PARTS Burner Rain Cover...
  • Page 69 REPLACEMENT PARTS Burner Rain Cover...
  • Page 70 REPLACEMENT PARTS Burner Enclosure...
  • Page 71 REPLACEMENT PARTS Fuel Tank and Filter...
  • Page 72 REPLACEMENT PARTS Battery Box w/ Charger...
  • Page 73 REPLACEMENT PARTS Battery Box w/ Charger...
  • Page 74 REPLACEMENT PARTS Control Box...
  • Page 75 REPLACEMENT PARTS Control Box...
  • Page 76 REPLACEMENT PARTS Recessed Strobe Light– Street Side...
  • Page 77 REPLACEMENT PARTS Recessed Strobe Light– Curb Side...
  • Page 78 REPLACEMENT PARTS Beacon Style Strobe Light...
  • Page 79 REPLACEMENT PARTS Arrowboard...
  • Page 80 REPLACEMENT PARTS Tack Tank...
  • Page 81 REPLACEMENT PARTS Pumping System for Tack Tank...
  • Page 82 REPLACEMENT PARTS Pumping System for Tack Tank...
  • Page 83 REPLACEMENT PARTS Spray Wand for Pumping System...
  • Page 84 REPLACEMENT PARTS Washdown Assembly w/ Hose Reel...
  • Page 85 REPLACEMENT PARTS Washdown Kit...
  • Page 86 REPLACEMENT PARTS Catwalk...
  • Page 87 REPLACEMENT PARTS Catwalk...
  • Page 88 REPLACEMENT PARTS Shovel Shelf...
  • Page 89 REPLACEMENT PARTS Shovel Shelf...
  • Page 90 REPLACEMENT PARTS Shovel Shelf...
  • Page 91 REPLACEMENT PARTS Spare Tire Carrier...
  • Page 92 REPLACEMENT PARTS Compactor Plate Carrier...
  • Page 93 REPLACEMENT PARTS Shovel Cleaning Compartment...
  • Page 94 REPLACEMENT PARTS Tool Box...
  • Page 95 REPLACEMENT PARTS Water Tank...
  • Page 96 REPLACEMENT PARTS Water Tank Fender Mount...
  • Page 97 REPLACEMENT PARTS Water Tank Fender Mount...
  • Page 98 REPLACEMENT PARTS Water Tank Fender Mount...
  • Page 99 REPLACEMENT PARTS Engine Control Package...
  • Page 102 REPLACEMENT PARTS Diesel Burner ITEM DESCRIPTION PART# Burner, fuel oil, Beckett Mod ADC W/CON 5-02 A10008215 Air Tube 509070 Photo electric eye (under ignition transformer) A10007678 Valve, fuel control 509091 Ignition Transformer 509087 Primary Controller A10008216 Motor, fan and pump 509092 Coupling, pump to motor 509086...
  • Page 103 REPLACEMENT PARTS Controls ITEM DESCRIPTION PART# Thermostat, Watlow 0-550°, (12volt) P10003540 Sensor, RTD Watlow 0-550°, (12volt) A10001017 Switch– SPST Toggle ON/OFF P10000180 Light– Call For Heat 12V P10000181 Volt Meter P10000184 20 Amp Breaker P10000179 ** Not Shown ITEM DESCRIPTION PART # Light 2.5”...
  • Page 104 If you believe that your vehicle has a defect in which could cause a crash or could cause injury or death, you should imme- diately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying STEPP MANUFAC- TURING CO., INC..
  • Page 105 Consumer Warranty Guide 12325 River Road, North Branch, MN 55056~ Phone: 651-674-4491~ Fax: 651-674-4221 www.steppmfg.com...
  • Page 106 If you do not have the facilities, or the technicians, to perform the repair, the unit can be brought to a local repair facility. In either case, Stepp Manufacturing MUST be contacted and authorize the warranty repair PRI- OR to any work being performed.
  • Page 107 Stepp Manufacturing Co., Inc. hereby warrants, to the original purchaser of new equipment, that products manufactured by Stepp Manufacturing will be free from defects in material and workmanship for a period of one (1) year from the date of purchase from Stepp Manufacturing.
  • Page 108 The pro-rated adjustment is based on the total number of months elapsed since the purchase date of the new equipment from Stepp Manufacturing. This rate is then applied to the one-half (0.5) hour labor rate and the current suggested retail price of the proper replacement heated asphalt hose or heating element supplied by Stepp Manufacturing.
  • Page 109 All parts returned must be tagged with the warranty authorization number and a copy of this claim. Retain all parts until credit is received from the factory. When requested, return the parts, along with this claim, to: Stepp Manufacturing Co., Inc. Attn: Warranty Department...
  • Page 112 Watlow 12v Series PM Temperature Controller Operators Programming Sequence for 12 volt devices. PN EZ-ZONE– P1003540 This programming sequence is taken from the manufacturers programming manual for this con- troller and reduced to eliminate the non-essential entries. Please follow the entries carefully and if any questions arise because of misunderstanding the instructions, see your supervisor or call the factory for clarification.
  • Page 113 Watlow Series PM-12 volt controller Sample Display Illustrations This display shows a typical temperature selection by the operator.  Upper display shows actual product temperature in red color.  Lower display shows operator desired maximum temp setting in green col- ...
  • Page 114 Watlow Series PM-12volt Temperature Controller Operators Programming Sequence for 12 volt devices This programming sequence is taken from the manufacturers programming manual for this controller and con- densed to eliminate the non-essential entries for ease of setup. Please follow the entries carefully and if any questions arise because of misunderstanding the instructions, please call the manufacturer for clarification.
  • Page 115 Watlow Series PM-12volt Temperature Controller Operators Programming Sequence for 12 volt devices Home Menu: Procedure for programming the Series PM-12 volt Watlow Control. Step 1: Connect all wires to Watlow control including RTD (temp sensor). Step 2: Connect power to Watlow controller. Step 3: Enter the Setup menu.
  • Page 116 Step 7: Press either the up or down key to select the Loop submenu. LOOP will be in the upper display and SEt will be in the lower display. If this is shown, press the advance key to enter the Loop submenu.
  • Page 117 Step 11: Use the up or down keys to select the global submenu gLbL will be in the upper dis play and SEt will be in the lower display. Press the advance key to enter the global menu. Parameter Value Description 11-1 display units...
  • Page 118 Parameter Value Description 18-3 id.5 75 degree F. Idle set point Advance key 18-4 h.hy 3.0 degree F. Heat hysteresis Advance key reads 3 on display 18-5 o.SP 0.0% Open loop set point Advance key Step 19: Pressing the advance key at parameter o.SP will advance you back to parameter C.r7 Press the infinity key...
  • Page 119 Step 28: Repeat steps 26 and 27 for display values of 4 through 2, changing each parameter to nonE. Note: The upper display will show the previous value you changed. You must increment this value from 4 through 20! Step 29: When all 20 parameters are set, press the infinity key once to return you to the main...
  • Page 124 MATERIAL SAFETY DATA SHEET SECTION 1 PRODUCT AND COMPANY IDENTIFICATION PRODUCT Product Name: EXXON TERESSTIC 100 Product Description: Base Oil and Additives Product Code: 16013 Intended Use: Circulating oil COMPANY IDENTIFICATION Supplier: Canada Imperial Oil Limited, An Affliate of Exxon Mobil Corporation P.O.
  • Page 125 Wash contact areas with soap and water. EYE CONTACT Flush thoroughly with water. If irritation occurs, get medical assistance. INGESTION First aid is normally not required. Seek medical attention if discomfort occurs. SECTION 5 FIRE FIGHTING MEASURES EXTINGUISHING MEDIA Appropriate Extinguishing Media: Use water fog, foam, dry chemical or carbon dioxide (CO2) to extinguish flames.
  • Page 126 however, geographic conditions, wind, temperature, (and in the case of a water spill) wave and current direction and speed may greatly influence the appropriate action to be taken. For this reason, local experts should be con- sulted. Note: Local regulations may prescribe or limit action to be taken. ENVIRONMENTAL PRECAUTIONS Large Spills: Dike far ahead of liquid spill for later recovery and disposal.
  • Page 127 Hand Protection: Any specific glove information provided is based on published literature and glove manufac- turer data. Work conditions can greatly affect glove durability; inspect and replace worn or damaged gloves. The types of gloves to be considered for this material include: No protection is ordinarily required under normal conditions of use.
  • Page 128 SECTION 10 STABILITY AND REACTIVITY STABILITY: Material is stable under normal conditions. CONDITIONS TO AVOID: Excessive heat. High energy sources of ignition. MATERIALS TO AVOID: Strong oxidizers HAZARDOUS DECOMPOSITION PRODUCTS: Material does not decompose at ambient temperatures. HAZARDOUS POLYMERIZATION: Will not occur. SECTION 11 TOXICOLOGICAL INFORMATION ACUTE TOXICITY...
  • Page 129 SECTION 12 ECOLOGICAL INFORMATION The information given is based on data available for the material, the components of the material, and similar materials. ECOTOXICITY Material -- Not expected to be harmful to aquatic organisms. MOBILITY Base oil component -- Low solubility and floats and is expected to migrate from water to the land. Expected to partition to sediment and wastewater solids.
  • Page 130 SECTION 14 TRANSPORT INFORMATION LAND (DOT) : Not Regulated for Land Transport LAND (TDG) : Not Regulated for Land Transport SEA (IMDG) : Not Regulated for Sea Transport according to IMDG-Code AIR (IATA) : Not Regulated for Air Transport SECTION 15 REGULATORY INFORMATION OSHA HAZARD COMMUNICATION STANDARD: When used for its intended purposes, this material is not classi- fied as hazardous in accordance with OSHA 29 CFR 1910.1200.
  • Page 131 The information and recommendations contained herein are, to the best of ExxonMobil's knowledge and belief, accurate and reliable as of the date issued. You can contact ExxonMobil to insure that this document is the most current available from ExxonMobil. The information and recommendations are offered for the user's consideration and examination. It is the user's responsibility to satisfy itself that the product is suitable for the intended use.
  • Page 134 MATERIAL SAFETY DATA SHEET SECTION 1 PRODUCT AND COMPANY IDENTIFICATION PRODUCT Product Name: UNIVIS N 32 Product Description: Base Oil and Additives Product Code: 8259 Intended Use: Hydraulic fluid COMPANY IDENTIFICATION Supplier: Canada Imperial Oil Limited, An Affliate of Exxon Mobil Corporation P.O.
  • Page 135 SECTION 4 FIRST AID MEASURES INHALATION Remove from further exposure. For those providing assistance, avoid exposure to yourself or others. Use adequate respiratory protection. If respiratory irritation, dizziness, nausea, or unconsciousness oc- curs, seek immediate medical assistance. If breathing has stopped, assist ventilation with a mechanical device or use mouth-to-mouth resuscitation.
  • Page 136 SECTION 6 ACCIDENTAL RELEASE MEASURES NOTIFICATION PROCEDURES In the event of a spill or accidental release, notify relevant authorities in accordance with all applicable regulations. U.S. regulations require reporting releases of this material to the environment which exceed the reportable quantity or oil spills which could reach any waterway including intermittent dry creeks. The National Response Center can be reached at (800)424-8802.
  • Page 137 PERSONAL PROTECTION Personal protective equipment selections vary based on potential exposure conditions such as applica- tions, handling practices, concentration and ventilation. Information on the selection of protective equipment for use with this material, as provided below, is based upon intended, normal usage. Respiratory Protection: If engineering controls do not maintain airborne contaminant concentrations at a level which is adequate to protect worker health, an approved respirator may be appropriate.
  • Page 138 OTHER INFORMATION Freezing Point: N/D Melting Point: N/A Pour Point: -48°C (-54°F) DMSO Extract (mineral oil only), IP-346: < 3 %wt SECTION 10 STABILITY AND REACTIVITY STABILITY: Material is stable under normal conditions. CONDITIONS TO AVOID: Excessive heat. High energy sources of ignition. MATERIALS TO AVOID: Strong oxidizers HAZARDOUS DECOMPOSITION PRODUCTS: Material does not decompose at ambient temperatures.
  • Page 139 SECTION 12 ECOLOGICAL INFORMATION The information given is based on data available for the material, the components of the material, and similar materials. ECOTOXICITY Material -- Not expected to be harmful to aquatic organisms. MOBILITY Base oil component -- Low solubility and floats and is expected to migrate from water to the land. Ex- pected to partition to sediment and wastewater solids.
  • Page 140 SECTION 14 TRANSPORT INFORMATION LAND (DOT) : Not Regulated for Land Transport LAND (TDG) : Not Regulated for Land Transport SEA (IMDG) : Not Regulated for Sea Transport according to IMDG-Code AIR (IATA) : Not Regulated for Air Transport SECTION 15 REGULATORY INFORMATION OSHA HAZARD COMMUNICATION STANDARD: When used for its intended purposes, this material is not classified as hazardous in accordance with OSHA 29 CFR 1910.1200.
  • Page 141 SECTION 16 OTHER INFORMATION N/D = Not determined, N/A = Not applicable THIS SAFETY DATA SHEET CONTAINS THE FOLLOWING REVISIONS: No revision information is available. ---------------------------------------------------------------------------------------------------------------------------------------- ------------- ---------------------------------------------------------------------------------------------------------------------------------------- ------------- The information and recommendations contained herein are, to the best of ExxonMobil's knowledge and belief, accurate and reliable as of the date issued.
  • Page 144 1. Tire Safety Information This portion of the user’s manual contain tire safety information as required by 49 CFR 575.6. Section 2.0 contains “Steps for determining correct load limit-trailer” Section 2.2 contains “ Steps for determining correct load limit-tow vehicle” Section 2.3 contains a Glossary of Tire Terminology, including “cold”...

  • Page 145: Tire Information

    Excessive loads and/or under inflation cause tire overloading and, as a result abnormal tire flexing occurs. This situation can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that enables as tire to support the load., so proper inflation is critical. The proper air pressure may be found on the 1.1.1 Trailers 10,000 Pounds GVWR or Less Tire and Loading Information Placard-Figure 1...
  • Page 146 1.3 Glossary Of Tire Terminology Accessory Weight The combined weight (in excess of those standard items which may be replaced) of automatic transmission, power steering ,power brakes, power windows, power seats radio and heater, to extent that these items are available as factory-installed equipment (whether installed or not) Bead The part of the tire is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the rim...
  • Page 147 Hitch Weight The downward force exerted on the hitch ball by the trailer coupler Interliner The layer (s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire Innerliner Separation The parting of the innerliner from cord material in the carcass Intended Outboard Sidewall The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward...
  • Page 148 Normal Occupant Weight This means 68 kilograms (150 lbs. ) time the number of occupants specified in the second column of Table 1 of 49 CFR 571.110. Occupant Distribution The distribution of occupants in a vehicle as specified in the third column of Table 1 of 49 CFR 571.110. Open Splice Any parting of any junction of tread, sidewall, or innerliner that extends to cord material Outer Diameter...
  • Page 149 Rim Type Designation This means the industry of manufacturer’s designation for a rim by style or code Rim Width This means the normal distance between rim flanges Section Width The linear distance between the exteriors of the sidewalls of an inflated tire, excluding elevations due to labeling, decoration, or protective bands.
  • Page 150 1.4. Tire Safety-Everything Rides On It The national Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that discusses all aspects of Tire Safety, as required by CFR 575.6 This brochure is reproduced in part below. It can be obtained and downloaded from NHTSA, free of charge, from the following website: http:www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tireindex/ html Studies of tire safety show that maintain proper tire pressure, observing tire and vehicle load...
  • Page 151 1.5.2. Understanding Tire Pressure and Load Limits Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the overall performance of the vehicle. The tire inflation pressure is a number that indicates the amount of air Pressure-measured in pounds per square inch (psi) -a tire requires to be properly inflated.
  • Page 152 If you have been driving your vehicle and think that a tire is underinflated, fill it to the recommended cold inflation pressure indicated on your vehicle's tire information placard or certification label. While your tire may still be slightly underinflated due to the extra pounds of pressure in the warm tire, it is safer to drive air pressure that is slightly lower than the vehicle manufacturer’s recommended cold inflation pressure than to drive with a significantly underinflated tire.
  • Page 153 1.5.9.1. Information on Passenger Vehicle Tires Please Refer to the Diagram Below The “P” indicates the tire is for passenger vehicles Next Number This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In gen- eral, the larger the number, the wider the tire.
  • Page 154 Tire Safety Information Letter Rating Speed Rating 99 Mph 106 Mph 112 Mph 118 Mph 124 Mph 130 Mph 149 Mph 168* Mph 186* Mph * For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use the letters ZR. For those with a maximum speed capability over 186 mph, tire manufacturers always use the letters ZR U.S.
  • Page 155 1.5.9.3. Additional Information on Light Truck Tires Please refer to the following diagram Tire for light trucks have other markings besides those found on the sidewalls of passenger tires. The “LT” indicates the tire is for light truck or trailers. An “ST”...
  • Page 158 Omaha Standard Operator’s Manual Installation, Operating, Safety and Maintenance Instructions With Parts Lists DTH Series Dump Trailer Hoists 415 DTH, 515 DTH, 519DTH, 520 DTH, 625 DTH, 630 DTH Omaha Standard, Inc. Truck Bodies and Hoists 3501 South 11th Street Council Bluffs, IA 51501-3633 U.S.A Phone (712) 328-7444 Fax (712) 328-8383...
  • Page 159 Omaha Standard’s Limited Warranties Dump Trailer Hoists-DTH Series These warranties cover the Omaha Standard DTH series Dump trailer hoists 3-Year Limited Warranty-Hoist Mainframe and Hydraulic Cylinder Omaha Standard warrants to the original owner that each new Omaha Standard hoist mainframe and hydraulic cylinder shall be free from defects in material and manufacturing workmanships for THREE YEARS from the date of purchase.
  • Page 160 Forward This manual contains information necessary for the proper operation and installation of you Omaha Standard DTH series dump trailer hoist. This manual also contain specifications, parts lists, maintenance information, safety suggestion, and other general information. Please read this manual carefully and understand it before attempting to install, operate, maintain, or repair your Omaha Standard DTH series dump trailer hoist.
  • Page 161 Trailer Manufacturer This manual contains instructions to correctly install the Omaha Standard DTH series dump trailer hoist and components. If components are used that are not provided by Omaha Standard, then it is the responsibility of the trailer manufacture to ensure proper installation and operation of the system.
  • Page 162 Table Of Contents DTH Trailer Hoist Operating Instructions General Information Hoist Operating Instructions  Figure 1-Body Prop Operating Instructions DTH Trailer Hoist Maintenance, Repair, and Trouble Shooting Hoist Preventive Maintenance  Figure 2-415/515/519 Grease Zerk Locations  Figure 3-520/625/630 Grease Zerk Locations Hoist Troubleshooting Cylinder Rebuild Procedure ...
  • Page 163 OMAHA STANDARD General Information The Omaha Standard DTH series dump trailer hoists are designed for 8-20 foot bodies. The low mounting height, rigid construction, light weight, and easy installation make the DTH series sump trailer hoists a standard in the industry Single-acting electric is standard with some of the DTH series dump trailer hoist models.
  • Page 164 OMAHA STANDARD Operating Instructions . To Raise Body: WARNING! FOR SAFERTY REASONS, OPERATE HOIST ONLY WITH TRAILER PARKED ON LEVEL AND FIRM GROUND. 1. Depress “up” button on control station 2. When hoist reaches desired height, release “up” button. Hoist will hold body in position. B.
  • Page 165 OMAHA STANDARD Body Safety Prop Operating Instructions...
  • Page 166 OMAHA STANDARD Preventative Maintenance WARNING! PROP OR BRACE BODY BEFORE SERVICING HOIST OR WORKING UNDER BODY! CAUTION! DO NOT USE SAFETY PROP TO SUPPORT A LOADED BODY CAUTION! MAKE SURE NO UNAUTHORIZED PERSONNEL HAVE ACCESS TO CONTROL 1. The hoist (including rear hinge) requires frequent lubrication-once a week during heavy use periods.
  • Page 167 OMAHA STANDARD 415/515/519 Grease Zerk Locations NOTE: TRAILER MANUFACTURES MAY HAVE INSTALLED A REAR HINGE OTHER THAN THE OMAHA STANDARD REAR HINGE SHOWN HERE ITEM NO. LOACTION ITEM NO. LOCATION LOWER CROSS TUBE CROSS HEAD TUBE LOWER CROSS TUBE SCISSOR HINGE TUBE CYLINDER MOUNT TUBE SCISSOR HINGE TUBE CYLINDER MOUNT TUBE...
  • Page 168 OMAHA STANDARD 520-625/630 DTH GREASE ZERK LOCATIONS NOTE: TRAILER MANUFACTURES MAY HAVE INSTALLED A REAR HINGE OTHER THAN THE OMAHA STANDARD REAR HINGE SHOWN HERE ITEM NO. LOACTION ITEM NO. LOCATION CYLINDER MOUNT TUBE CROSS HEAD TUBE CYLINDER MOUNT TUBE CROSS HEAD TUBE LOWER MOUNT SCISSOR HINGE TUBE...
  • Page 169 OMAHA STANDARD WARNING! PROP OR BRACE BODY BEFORE SERVICING HOIST OR WORKING UNDER BODY! CAUTION! DO NOT USE SAFETY PROP TO SUPPORT A LOADED BODY 1. HOIST WILL NOT RAISE LOAD: A. Body overloaded or loaded too far forward: 1) Reduce load or shift load rearward B.
  • Page 170 OMAHA STANDARD CAUTUION! DO NOT USE SAFETY PROP TO SUPPORT A LOADED BODY 1) Check reservoir filter screen and breather cap. Clean if dirty 2) Replace pump if hoist performance has degraded over time 3. HOIST DELAYS BEFORE LIFTING: A. Air trapped in system: 1) Cycle hoist to full stroke 7-8 times to remove all air from cylinder 2) Change hydraulic oil to non-foaming, non detergent type B.
  • Page 171 OMAHA STANDARD WARNING! PROP OR BRACE BODY BEFORE SERVICING HOIST OR WORKING UNDER BODY! B. Cylinder mounts/hoist frame needs lubrication: 1) Wipe dirt from fittings and lubricate hoist pivot points with premium, graphite base grease 7. PUMP UNUSALLY NOISY: A. Pump mounting bolts loose: 1) Re-tighten bolts B.
  • Page 172 OMAHA STANDARD CYLINDER REBUILD PROCEDURE REPALCEMENT OF SEALS (SEE FIGURE 4) CAUTION: ONLY AN AUTHORIZED DEALER OR SKILLED PROFESSIONAL FAMILAIAR WITH HYDRAULIC PRODUCTS SHOULD ATTEMPT CYLINDER REBULD. CALL FACTORY BEFORE ATTEMPING REPAIR. WARNING: PROP OR BRACE BODY BEFORE SERVICING HOIST OR WORKING UNDER BODY! CAUTION! DO NOT USE SAFETY PROP TO SUPPORT A LOADED BODY 1.
  • Page 173 OMAHA STANDARD 5. Secure the rod so that the piston nut can be removed. Be careful to not mar the chromed surface of the rod. The rod cannot be repaired if it is dented or scratched. If securing the rod in a vise, use clean cardboard to pad the vise jaws.
  • Page 174 OMAHA STANDARD HOIST SEAL KIT PART NO. HOIST SEAL KIT PART NO 3169554 3169550 515/520 3169553 625/630 3169551...
  • Page 175 OMAHA STANDARD TRAILER HOIST INSTALLATION INSTRUCTIONS INSTALLATION CHECKLIST The following is a step-by-step checklist, in proper order for hoist installation. Please study complete installation procedure before beginning. Go over this checklist again, after installing hoist ,to make sure you did not miss any steps. NOTE: These instructions are only for components supplied by Omaha Standard.
  • Page 176 OMAHA STANDARD 1. Plan installation of hoist by reviewing the hoist mounting diagrams (Figure 5-6) and capacity charts in the hoist reference information section of this manual (tables 4-9) From these determine: A. Desire dump angle and capacity. B. Mounting distance (centerline of hoist upper cross shaft to centerline of rear hinge pivot point) the mounting distance for each dump angle is in the bottom row of tables 4-9 NOTE: Lift capacity ratings are based on the mounting distance.
  • Page 177 OMAHA STANDARD REVERSE MOUNT E. INSTALL REAR HINGE ASSEMBLY (See figures 7 and 8) NOTE: The installation instructions apply to an Omaha Standard rear hinge. If a rear hinge other than an Omaha Standard rear hinge is used, proper installation of the rear hinge is the responsibility of the installer.
  • Page 178 OMAHA STANDARD REAR HINGE INSTALLATION TYPICAL APPLICATION...
  • Page 179 OMAHA STANDARD F. MOUNT HOIST TO CHASSIS FRAME (See Figure 9) 1. Clamp LOWER MOUNT ATTACHMENT ANGLES to outside of each frame member, with top of mounting angle leg even with frame (see figure 9). Drill three 11/16” holes through frame member using mounting angle as a template. Secure angles with 5/8-11 X 1 3/4”...
  • Page 180 OMAHA STANDARD G. INSTALL HYDRAULIC SYSTEM 1. Attach pump mount bracket channels to pump assemble with 3/8-16 X 1” hex head bolts, flat washers, and lock nuts 2. Locate pump and bracket assembly and attach to frame with 5/8-11 X 1 3/4” hex head bolts and lock nuts NOTE: Vertical legs of pumps mount bracket channels attach to outside of frame 3.
  • Page 181 OMAHA STANDARD SA ELECTRIC PUMP INSTALLATION ITEM PART NO DESCRIPTION 1300040 Pump complete, M319-0175 SA Electric w/ Push Button 1030125 Bolt, 3/8-16 X 1 HHCS GR8 Zinc Plated 1070120 Washer, 3/8” Zinc Plated Flat 1061155 Nut, 3/8-16 NYlock GR8 Zinc Plated 1030520 Bolt, 5/8-11 X 1 3/4 HHCS GR8 Zinc Plated 1061200...
  • Page 182 OMAHA STANDARD SA ELECTRIC PUMP WIRING RECOMMENDATIONS...
  • Page 183 OMAHA STANDARD DA ELECTRIC PUMP INSTALLATION ITEM PART NO. DESCRIPTION QTY. 1300094 Pump complete, M3551-0105 DA electric w/ push button 1030125 Bolt, 3/8-16 X 1 HHCS GR8 Zinc Plated 1070120 Washer, 3/8” Zinc Plated Flat 1061155 Nut, 3/8-16 NYlock GR8 Zinc Plated 3122157 Pump Mount Bracket Channel 1030520...
  • Page 184 OMAHA STANDARD DA ELECTRIC PUMP WIRING RECOMMENDATIONS...
  • Page 185 OMAHA STANDARD H. ATTACH HARDWOOD RISERS: Place hardwood risers on frame to either side of hoist lower mount angles. Verify that top of risers are flush with rear hinge pivot pads (see figures 5 or 6) Note: Riser must sit flush on the top flange of frame. Locate risers to clear obstacles in frame flange or drill clearance holes in risers.
  • Page 186 OMAHA STANDARD 415/515/519 UPPER MOUNT INSTALLATION STANDARD MOUNTING OPTIONAL MOUNTING...
  • Page 187 OMAHA STANDARD 520/625/630 UPPER MOUNT INSTALLATION STANDARD MOUNTING 3. RUNSILL REINFORCEMENT A. Reinforcement of runsill lift brackets and/or body runsills is necessary when distance from front of body to lift point of hoist exceeds the following: 4” Channel runsill=66” lift point to front of body 6”...
  • Page 188 OMAHA STANDARD D. Longitudinal: Certain applications require reinforcement of body runsills lengthwise. This is a function of body side height, load density (weight per cubic food of material), runsill size, and distance from hoist lift point to front of body (“front overhang”) 1.
  • Page 189 OMAHA STANDARD RUNSILL REINFORCEMENT LATERAL REINFORCEMENT Figure 17 LONGITUDINAL REINFORCEMENT Figure 18...
  • Page 190 OMAHA STANDARD...
  • Page 191 OMAHA STANDARD I. AFFIX ALL WARNING DECALS: NOTE: THE DECALS SUPPLIED ARE GENERAL IN NATURE FO RTHE USE OF THE HOIST. IF MORE DECALS ARE NEEDED FOR YOUR APPLICATION, IT IS THE TRAILER MANUFACTURER’S RESPONSIBILITY TO PROVIDE THE PROPER WARNING DECALS. WARNING: YOU MUST AFFIX AND MANINTAIN ALL DECALS.
  • Page 192 OMAHA STANDARD K. REVIEW INSTALLATION CHECKLIST: Refer to installation checklist on Page 13 to make sure you did not omit any steps WARNING: MAKE OPERATORS OF THIS HOIST FAMILIAR WITH ALL KEY FEATURES AND PROPERLY INSTRUCT THEM IN SAFE OPERATION OF ALL EQUIPMENT SAFETY FIRST: THE BEST SAFETY PROGRAMS STARTS WITH A SAFETY CONSCIOIUS OPERATOR...

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