DMF ROTO-180, Installation And Parts & Service Manual

Page 1: ...a com Service Department 404 879 7882 service dmfatlanta com Phone 404 875 1512 Fax 404 875 4835 info dmfatlanta com http www dmfatlanta com Installation and Parts Service Manual ROTO 180 September 20...

Page 2: ...our product to be satisfactory in every way We take product support very seriously so if you have any questions please contact us Manuals service bulletins and general information are available on ou...

Page 3: ...alves 4 13 4 7 Electrical Installation PVG Valves 4 16 4 8 Initial Operation PVG Valves 4 19 SECTION 5 0 ROTO 180 OPTIONS 5 1 Toolbox Fuel Tank Options 5 2 5 2 Hydraulic Tank Options 5 3 5 3 Dump Body...

Page 4: ...TION 7 0 ROTO 180 ELECTRICAL 7 1 HydraForce Manifold Electrical Schematic 3 Proximity Switches 7 2 7 2 In Cab Control 3 Proximity Switches 7 3 7 3 HydraForce Manifold Subframe Electrical Schematic 3 P...

Page 5: ...ns 2 7 Figure 2 2 5 Joystick Operation 2 8 Figure 2 3 Wireless Remote 2 10 Figure 2 4 PVG Valves 2 13 Figure 2 4 1 Manual Operation of PVG Valves 2 14 Figure 3 4 2 Keypad LED Identification 3 10 Figur...

Page 6: ...ENERAL INFORMATION 1 1 GENERAL DESCRIPTION 1 2 1 1 1 HydraForce Manifold ROTO 180 System Controls 1 2 1 1 2 PVG Valve ROTO 180 System Controls 1 2 1 2 SPECIFICATIONS 1 3 1 2 1 Standard Dump Body 1 3 1...

Page 7: ...ption on both 1 1 1 HydraForce Manifold ROTO 180 System Controls The HydraForce ROTO 180 system is operated by a manifold mounted within the subframe Toggle switches mounted in the cab active 12 VDC s...

Page 8: ...p combination System Requirements 21 GPM at 2 000 PSI Reservoir Capacity 25 gal minimum 1 2 3 Rotating Sub frame Hoist Maximum Lifting Capacity 60 000 lbs Hoist Speed 50 Secs to 40 Unloaded Floor Heig...

Page 9: ...le System 2 7 2 2 4 Operator Presence Switch 2 7 2 2 5 Raising Body In Cab Operation 2 7 2 2 6 Lowering Body In Cab Operation 2 8 2 2 7 Swinging Body In Cab Operation 2 9 2 3 OPERATIONS PVG VALVES WIR...

Page 10: ...provided with the truck 2 If the truck is equipped with a hydraulic selector valve shift it to activate the ROTO 180 system 3 PULL out or toggle the SYSTEM ENABLE switch to enable the system The red l...

Page 11: ...pletely at 40 Releasing the switch at any time will stop the body from raising 3 The tailgate may be operated at any time by moving the TAILGATE switch to RELEASE and holding until fully opened The au...

Page 12: ...ildogs deployed There is an increased risk of tipping when the dump body is raised This is especially true when the truck is on super elevated track or the body is rotated away from center 1 Before sw...

Page 13: ...d are attached to the joystick mount see Figure 2 2 1 A The keypad may be relocated to the dashboard when space is available Figure 2 2 1 B shows a top view of the keypad and its available options A w...

Page 14: ...stem can only be enabled while the PTO is engaged 2 If the truck is equipped with a hydraulic selector valve shift it to activate the ROTO 180 system 3 Press the ROTO ENABLE button found on the keypad...

Page 15: ...h an operator presence switch located on the joystick grip This switch when activated must be held by the operator to perform all functions of the joystick The operator presence switch has been added...

Page 16: ...E TAILGATE button on the keypad until fully opened The automatic tailgate release may be overridden by holding the AUTO GATE OVERRIDE button on the joystick while raising the body 5 If equipped the vi...

Page 17: ...inging the dump body ensure the center lock pin has cleared the body lock 2 Move the joystick to rotate the back of the body in the intended direction See Figure 2 2 5 An alarm will sound while the bo...

Page 18: ...he steps in Section 2 2 2 to enable the system 2 Press the REMOTE ENABLE button on the keypad The left and center LEDs will become illuminated At this time the system will not react to any inputs from...

Page 19: ...1 Check the position of the tarp and open it completely if not already done so 2 Press and hold the BODY RAISE button on the wireless remote Releasing the button at any time will stop the body from r...

Page 20: ...s rotated away from center 1 Before swinging the dump body ensure the center lock pin has cleared the body lock 2 Press and hold the desired swing direction on the remote to rotate the back of the dum...

Page 21: ...Manual operation of the PVG Valves bypasses many of the safety features associated with this system thus should be only used as a backup operation method NOTE The following subsections assume the ope...

Page 22: ...irection of RAISE BODY to raise the body Releasing the lever from this position at any time will stop the body from moving See Figure 2 4 1 3 When the body reaches 40 an alarm will sound to indicate t...

Page 23: ...used to swing while on rail and with Raildogs deployed There is an increased risk of tipping when the dump body is raised This is especially true when the truck is on super elevated track or the body...

Page 24: ...in must be fully engaged as shown in Figure 2 1 4 A 2 Release and store the Raildogs following the instructions outlined in the Raildog Manual 3 Latch the tailgate shut 4 Disable the ROTO 180 system f...

Page 25: ...s for Common Issues 3 5 3 3 2 Movement Troubleshooting 3 5 3 3 3 Hydraulic Troubleshooting 3 8 3 3 4 Electrical System Troubleshooting 3 8 3 4 TROUBLESHOOTING PVG VALVES 3 10 3 4 1 General Procedures...

Page 26: ...s and exhaust systems are in place Replace if cracked or worn 3 1 1 Weekly Perform daily maintenance Grease all ROTO fittings according to the locations in Section 3 2 Check level of hydraulic oil and...

Page 27: ...dard Citgo Syndurance Premium Synthetic 460 2 o Warm Climates Mystik JT 6 Hi Temp Multi Purpose Grease 2 or equivalent Hydraulic Oil ASTM D6158 HM Unax RX 46 Hydraulic Oil Shell Tellus EE 46 or equiva...

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Page 29: ...ance between the upper and lower subframes They should never contact unless the dump body has been overloaded or the subframe has been bent If in contact the ROTO 180 will have difficulty swinging 3 3...

Page 30: ...Listen for the swing alarm and look for hydraulic loading in the hoses If none of the other functions operate and there is no hydraulic loading the issue is with the hydraulic system See Section 3 3 3...

Page 31: ...the cylinder does not move or moves in the opposite direction there is a hydraulics issue reference hydraulic troubleshooting Section 3 3 3 C Tailgate is not closing properly 1 Verify latch is proper...

Page 32: ...ck for hydraulic leaks 1 Check the hydraulic tank fluid level for adequate fluid If the dump body has been raised take this into account when checking the level 2 Check around the truck for any signs...

Page 33: ...and wires Repair as necessary 2 Test for voltage when operating the problematic function Reference the electrical schematic in Section 7 3 Test the voltage of another operation Refer to the electrica...

Page 34: ...has been switched to operate the ROTO 180 system 5 Ensure hydraulic fluid levels are adequate to operate all cylinders If the hoist cylinder has been raised the fluid level in the tank will appear low...

Page 35: ...enabled Center Button pressed Right Button pressed Fault see fault codes 3 4 3 Keypad Fault Codes The PVG Valves are operated by a PlusOne Controller located in the electrical box which is attached t...

Page 36: ...anually using the PVG Valves Make sure to first lift the body above the center lock pin before any testing Caution the auto tailgate will not function when the dump body is raised manually nor will th...

Page 37: ...icate the movement not working properly see Section 2 4 If the system responds correctly the issue is electrically related If the system does not respond correctly there is a hydraulic issue Reference...

Page 38: ...ng repositioned ensure the body does not contact any part of the truck when raised Do not overextend the hoist cylinder 3 4 7 Wireless Remote Troubleshooting A Address common errors see Section 3 4 1...

Page 39: ...on 3 4 9 for electrical system troubleshooting C Check for Hydraulic Leaks 1 Check the hydraulic tank fluid level for adequate fluid If the dump body has been raised take this into account when checki...

Page 40: ...placing If there is a voltage across the terminal strip a signal is being sent from the PlusOne Controller Continue on to the next step 3 Follow the wire from the terminal strip to its next connection...

Page 41: ...ork Area 4 3 4 1 6 Preliminary Truck Preparation 4 3 4 1 7 Purchased Fastener Torque Specifications 4 3 4 2 SUBFRAME MOUNTING PROCEDURE 4 5 4 3 HYDRAULIC SYSTEM CONNECTION HYDRAFORCE MANIFOLD 4 8 4 3...

Page 42: ...work on the ROTO 180 system 4 1 2 Tools Required for Installation Welder Arc or Mig Hoist or Overhead Crane Frame Drill with 5 8 Drill Bit Angle Finder General Mechanic Tools Cutting Torch Hand Grind...

Page 43: ...ent of the subframe Lighting The work area should be adequately lighted Space There should be enough space to maneuver the subframe and truck body components into position and to safely work around ot...

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Page 45: ...orward allows for better weight transfer to the front axle See Figure 4 2 A for the subframe positioning These values have been listed in the table below Dump Body Length Minimum Cab to Axle Distance...

Page 46: ...o hold the lower subframe firmly against the truck frame and match drill through the truck frame Bolt the clips to the truck frame as with the angles Then weld the shear plates to the ROTO subframe 4...

Page 47: ...875 1512 X ANGULAR BREAK SHARP EDGES 0 030 X 45 MAX 1 16 005 030 015 1 32 063 1 2A AND 2B 125 MICRO DRILL SIZES SURF FINISH THREADS XXX XX TOLERANCES FRAC MACH UNLESS SPECIFIED FRAC OTHER 7 27 15 MROT...

Page 48: ...two 12 JIC bulkhead fittings and one 12 JIC hydraulic fitting in the center See Figure 4 3 1 2 Connect the two bulkhead fittings to the tank The bulkhead fitting on the driver s side must be a dedica...

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Page 50: ...t the green wire from the ROTO ENABLE switch to a 15A fused ignition source 4 Connect the indicator lamp ground black wire to a good location under the dash 5 Connect the truck body clearance light wi...

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Page 52: ...lowing the steps found in Section 2 1 1 2 On the control panel hold the hoist switch in the raise position Raise the body a few inches to clear the center lock pin 3 Active the SWING switch and rotate...

Page 53: ...e port locations 3 Connect the P port on PVG Valves to the power beyond of the rear Railgear first passing through a pressure filter Use sized hoses with swivel fittings 4 Connect the T port on the sa...

Page 54: ...DIVERSIFIED METAL FABRICATORS INC ROTO 180 4 14 2017 DMF Inc All Rights Reserved Figure 4 6 1 B Subframe Hydraulic Electrical Connections...

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Page 56: ...cessible for the operator The best spot is typically between the driver and passenger seats 2 Route the provided wiring harness into the cab through the bottom of the joystick The harness is labeled C...

Page 57: ...nnect the cable to the connector on the outside of the electrical box 8 Within the battery box mount a 150A circuit breaker within 18 of the positive battery terminal 9 Route the 16 3 Cable 1 from the...

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Page 59: ...ction 2 2 2 3 Pull the joystick back towards the rear of the truck to raise the dump body a few inches and clear the center lock pin 4 Move the joystick to the left and right a few times in both direc...

Page 60: ...PTIONS MROTO102 5 4 5 4 ROTO 180 DUMP BODY OPTIONS CONTINUED MROTO103 5 5 5 5 ROTO 180 DUMP BODY LADDER OPTIONS MROTO104 5 6 5 6 ROTO 180 DUMP BODY SPARE TIRE CARRIER ASSEMBLY 20290 5 7 5 7 ROTO 180 O...

Page 61: ...K SHARP EDGES 0 030 X 45 MAX 1 16 005 030 015 1 32 063 1 2A AND 2B 125 MICRO DRILL SIZES SURF FINISH THREADS XXX XX TOLERANCES FRAC MACH UNLESS SPECIFIED FRAC OTHER 07 08 15 MROTO100 DJJ REV DRAWING N...

Page 62: ...METAL FABRICATORS INC 404 875 1512 X ANGULAR BREAK SHARP EDGES 0 030 X 45 MAX 1 16 005 030 015 1 32 063 1 2A AND 2B 125 MICRO DRILL SIZES SURF FINISH THREADS XXX XX TOLERANCES FRAC MACH UNLESS SPECIF...

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Page 65: ...BY APP FOLDING LADDER 42 BOTTOM OF CROSS MEMBER TO TOP OF STEP ROTO 180 DUMP BODY LADDER OPTIONS ROTO 180 MANUAL DRAWN BY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 X ANGULAR BREAK SHARP EDGES 0 0...

Page 66: ...DETAIL 2 818121 2 GUSSET 3 7 8 X 4 3 4 X 1 2 3 20294 1 SPARE TIRE RETAINER ASSEMBLY 4 20291 1 ROTO FNT 8 CHANNEL X MEMBER 5 818134 1 RW 1630 FRONT HEX NUT SLOTTED SLHN 1 1 2 6 6 605145 1 COTTER PIN 1...

Page 67: ...APP ITEM NO PART NUMBER QTY DESCRIPTION 1 20185 1 ROTO VIBRATOR COUGAR DC 3200 POST 95 2 20179 1 COUGAR VIBRATOR MOUNTING PLATE 3 605090 1 CIRCUIT BREAKER 60A MANUAL RESET SURFACE MOUNT NOT SHOWN NOT...

Page 68: ...GES 0 030 X 45 MAX 1 16 005 030 015 1 32 063 1 2A AND 2B 125 MICRO DRILL SIZES SURF FINISH THREADS XXX XX TOLERANCES FRAC MACH UNLESS SPECIFIED FRAC OTHER 08 05 15 MROTO107 DJJ REV DRAWING NUMBER TITL...

Page 69: ...605077 18 NYLON LOCKNUT 3 8 16 NOT SHOWN 9 605356 18 HEX HED CAP SCREW 3 8 16 X 3 4 GR8 NOT SHOWN 10 102408 6 HEX HD CAP SCREW 3 8 16 X 1 1 2 GR8 NOT SHOWN 11 818508 48 FLAT WASHER 3 8 GR8 NOT SHOWN A...

Page 70: ...ER STEP ASSEMBLY LH W GRIPSTRUT TREAD DESCRIPTION 20331 BJF APP BY REV DRAWING NUMBER TITLE DATE APPD BY DATE DRAWN BY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DESCRIPTION REV B RUBBER STRAP DET...

Page 71: ...UNC NOT SHOWN RUBBER STEP ASSEMBLY RH W GRIPSTRUT TREAD DESCRIPTION 20332 BJF APP BY REV DRAWING NUMBER TITLE DATE APPD BY DATE DRAWN BY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DESCRIPTION REV...

Page 72: ...O 180 5 SECTION PVG VALVES HYDRA SCHEM 31030 6 8 6 8 ROTO 180 3 SECTION PVG VALVES HYDRA SCHEM 31029 6 9 6 9 12 ROTO 180 SUBFRAME PVG VALVES Hydra SCHEM 18955 6 10 6 10 14 ROTO 180 SUBFRAME PVG VALVES...

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Page 85: ...10456 JDI A 9 19 2012 REDRAWN IN SOLIDWORKS JDI ITEM NO PART NUMBER QTY DESCRIPTION 1 18952 3 04 JIC X 06 O RING 90 FITTING 2 240107 1 HYD CYL O RING 1 3 240201 1 HYD CYL PISTON 3 1 2 4 240204 2 HYD C...

Page 86: ...BEARING 15SF24 10 240324 1 SNAP RING 2 7 16 11 240325 1 HYD CYL ROD ASSEMBLY ROTO 12 241105 1 1 1 2 DIA ROD SEAL 13 241106 1 1 1 2 DIA ROD WIPER 14 605119 1 NYLON LOCK NUT 1 14 NOTE DMF P N 240335 RO...

Page 87: ...RAWN BY 18280 A X ANGULAR BREAK SHARP EDGES 0 030 X 45 MAX 1 16 005 030 015 1 32 063 1 2A AND 2B 125 MICRO DRILL SIZES SURF FINISH THREADS XXX XX TOLERANCES FRAC MACH UNLESS SPECIFIED DIVERSIFIED META...

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Page 92: ...SWITCHES 20757 7 4 7 4 ROTO 180 PARKER MANIFOLD ELECTRICAL SCHEMATIC 18900 7 5 7 5 ROTO 180 PVG VALVES ELECTRICAL SCHEMATIC TARP VIBRATOR WIRELESS 30037 7 6 7 6 ROTO 180 PVG VALVES SUBFRAME ELECTRICAL...

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Page 102: ...Location 4 Weld the proximity bracket for the 22 40 degree proximity switches 20751 onto the sub frame Refer to Figure 2 for proper location of proximity bracket TAILGATE OPEN LONG SILL PROXIMITY SEN...

Page 103: ...of the bed Refer to Figure 5 for the proper bracket location 9 Place the tailgate proximity switch into the tailgate proximity bracket so there is an approximately 1 8 gap between the face of the swi...

Page 104: ...f the sensor and the detection plate Tighten the proximity switch jam nuts with blue Loctite 243 14 Test the system by raising the bed from the stowed position Check that the gate opens at 22 degrees...

Page 105: ...gate trip cam 18279 on the tailgate latch rod and weld in place Refer to Figures 1 through 3 for location details Note the length of the subframe The position of the limit switch mount plate 18653 is...

Page 106: ...TLE DATE APPD BY DATE DRAWN BY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 B SUBFRAME MOUNT PLATE 18653 LIMIT SWITCH BODY BOTTOM OF TRIP CAM 18279 TAILGATE LONG SILL 1 1 1 2 1 1 4 DESCRIPTION REV 1...

Page 107: ...ally 40 degrees Check to make sure the other limit switch fully raised switch is activated by the tailgate latch rod with the bed in the fully raised position If it is not loosen the bolt on the arm a...

Page 108: ...defective Such repair or replacement does not include the cost of installing the new part or any other expenses incident thereto however the outbound direct ground freight on the part will be prepaid...