SSP II Cart Tipper Service & Parts 2008 McNeilus Truck and Manufacturing, Inc. Rev. 0915 Cart Tipper P/N: 1147480 Manual P/N: 1330694
Disclaimer: This manual must not be used to repair your vehicle. Repair information is available by calling McNeilus Customer Service at (888) 686-7278. The information in this Manual will be your guide to operation, service, and maintenance for this equipment. All information, illustrations, and specifications in this manual are based on the information available at the time this manual was published. The illustrations used in this manual are intended as representative reference views only. Because of our continuous product improvement policy, we may modify information, illustrations, and/or specifications to explain and/or exemplify a product, service, or maintenance improvement. We reserve the right to make any change at any time without notice. Go to www.streetsmartparts.com for current information. No part of this publication may be reproduced by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems for any use of purpose - without the written permission of McNeilus Truck and Manufacturing, Inc. For a complete copy of the ANSI Standard contact: Waste Equipment Technology Association A Part of the Environmental Industry Associations 4301 Connecticut Avenue, NW Suite 300 Washington, D.C. 20008 Telephone: 202-244-4700 Fax: 202-966-4824 For assistance in ordering OSHA Publications contact: U.S. Department of Labor/OSHA OSHA Publications P.O. Box 37535 Washington, D.C. 20210 Telephone: 202-693-1888 Fax: 202-693-2498
Table of Contents Section 1: General Information Section 2: Safety Section 3: Specifications Section 4: Installation Section 5: Preventive Maintenance Section 6: Service Procedures Section 7: Illustrations and Parts
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General Information 1 General Information Thank You This manual provides safety, installation, maintenance, troubleshooting, and parts information for the SSP II Cart Tipper manufactured by McNeilus Street Smart Parts and Service. The information in this manual is your guide to operation, maintenance, parts illustrations, and part numbers for this equipment. The SSP II Cart Tipper was improved to provide exceptional performance and value and now ships with bronze bushings and spring bushings with grease fittings. Identification Plate An identification plate is attached to the right-hand side of the SSP II Cart Tipper face plate. The identification plate contains the part number, job number, and serial number. The serial number as shown in Figure 1 is located at the bottom of the plate. Figure 1 To serve you better, please identify and have the serial number ready when calling McNeilus Street Smart Parts and Service for parts or product information. 2008 McNeilus Truck and Manufacturing, Inc. 1-1 SSP II Cart Tipper
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General Information Table of Contents 1.0 PARTS AND SERVICE...5 2.0 CORPORATE HEADQUARTERS INFORMATION...5 3.0 PATENTS PENDING...5 4.0 MCNEILUS WARRANTY INFORMATION...5 5.0 PURPOSE OF THIS MANUAL...6 6.0 HOW TO USE THIS MANUAL...6 1 2008 McNeilus Truck and Manufacturing, Inc. 1-3 SSP II Cart Tipper
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1.0 Parts and Service Contact your McNeilus Parts and Service branch location to order parts, to receive service information, or for other assistance. Contact by phone or visit www.streetsmartparts.com. We have factory owned parts and service centers near you. Phone Number 888-686-7278 State City State City AZ Phoenix MO North Kansas City CA Colton NC High Point CA Stockton NV Las Vegas CO Denver NY Bronx CT East Granby OH Cincinnati FL Miami OH Columbus FL Tampa PA Morgantown GA Villa Rica TX Houston IL Sugar Grove TX Hutchins IN Fort Wayne UT West Valley City LA New Orleans WA Puyallup MN Dodge Center WI Oshkosh Canada Ontario and Western Provinces 800-265-1089 Quebec and Maritime Provinces 800-996-4937 General Information 2.0 Corporate Headquarters Information Contact McNeilus Truck and Manufacturing, Inc. directly at our corporate headquarters at the following address, phone numbers, and website address: McNeilus Street Smart Parts and Service 524 County Road 34 East Dodge Center, MN 55927 Telephone: 507-374-6321 Websites: www.mcneiluscompanies.com www.streetsmartparts.com 3.0 Patents Pending The SSP II Cart Tipper has many new and innovative designs for the industry. Several patents have been applied for by McNeilus Street Smart Parts and Service and are PATENT PENDING. 4.0 McNeilus Warranty Information We want you to be satisfied with our product and our warranty. The McNeilus warranty manual outlines the warranty procedures. Please refer to it for answers to any questions you have regarding the policy or its procedures. If you require a warranty manual, want to submit a warranty claim, have a dispute or any other comments regarding warranty, we request that you contact your local McNeilus Parts and Service branch locations. 1 2008 McNeilus Truck and Manufacturing, Inc. 1-5 SSP II Cart Tipper
1 General Information 5.0 Purpose of This Manual The purpose of this manual is to provide you with the most concise service and maintenance information for your McNeilus product. 6.0 How to Use This Manual This manual is divided into seven major sections as follows: General Information - This section provides general information about the service manual Safety - This section provides safety information applicable to the Cart Tipper Specifications - This section provides features, performance, and dimension data Installation - This section provides installation information and procedures Preventive Maintenance - This section provides preventive maintenance procedures Service Procedures - This section provides service and maintenance information Illustrations and Parts Lists - This section provides parts illustrations and part numbers SSP II Cart Tipper 1-6 2008 McNeilus Truck and Manufacturing, Inc.
Safety 2 Safety Table of Contents 1.0 SAFETY NOTICES...3 2.0 GENERAL SAFETY INFORMATION...3 2.1 LOCKOUT/TAGOUT PROCEDURE...4 3.0 PRODUCT SAFETY INFORMATION...4 4.0 SAFETY DECALS...8 4.1 SAFETY DECAL IDENTIFICATION...8 2008 McNeilus Truck and Manufacturing, Inc. 2-1 SSP II Cart Tipper
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1.0 Safety Notices Safety statements are one of the primary ways to call our attention to potential hazards. This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved. DANGER Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Danger is used in the most extreme situations. WARNING Warning indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death. CAUTION Caution indicates a situation that might result in personal injury or property damage. SAFETY NOTICE Failure to follow Safety Notice instructions could cause damage to the equipment or cause it to operate improperly. The signal words of DANGER, WARNING, and CAUTION have specific meanings to alert you to the relative level of hazard. Take the safety warnings seriously. If you do not understand them or have questions about them, call McNeilus Truck and Manufacturing, Inc. 2.0 General Safety Information Safety SAFETY NOTICE Read and understand this entire manual before operating, repairing, or adjusting your McNeilus refuse Packer. Those who use and maintain this equipment must be thoroughly trained and familiar with the product. If incorrectly used or maintained, this equipment can cause severe injury. Always keep this manual in a location where it is readily available for persons who operate or maintain the product. Additional copies of this manual are available from McNeilus Truck and Manufacturing, Inc. 888-686-7278. Please contact McNeilus Truck and Manufacturing, Inc. if you require additional manuals or if you have any questions concerning the information in this manual or this product. Some service operations may require special tools, equipment, or blocking devices (such as the body hoist or tailgate). If you require information on these items, please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 before attempting these repairs and service operations. This truck conforms to ANSI Z245.1-2008 standards. If you have questions on standards, please contact McNeilus Truck and Manufacturing, Inc. at 888-686- 7278 for assistance. Please read the ANSI manual and all other material provided with the truck. SAFETY NOTICE These safety procedures are for your own protection. Do not operate or service this machine until you have read and understood the operation manual and service instructions supplied with this equipment. Manuals can be obtained from McNeilus Truck and Manufacturing, Inc., P.O. Box 70, County Road 34 East, Dodge Center, MN 55927 or from your nearest McNeilus branch. Should an operator of this equipment have a reading or learning disability, dyslexia, or other such condition, he or she must be assigned a mentor/trainer to read and explain to such individual the entire contents of this manual as well as the safety guidelines, danger, caution and warning decals and placards affixed to this unit. 2 2008 McNeilus Truck and Manufacturing, Inc. 2-3 SSP II Cart Tipper
2 Safety Such individuals should not be allowed to operate this equipment until he or she thoroughly understands all of these materials. Failure to do so can result in serious personal injury or death. Safety and safe working procedures must be followed at all times. OSHA LOCKOUT/TAGOUT procedures must be followed when maintaining this equipment and performing Daily Checks, inspections, or Scheduled Maintenance. If you are unfamiliar with the OSHA LOCKOUT/TAGOUT procedures or any safety requirements, please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 for assistance. 2.1 Lockout/Tagout Procedure Before entering Packer body, or climbing or getting under the truck to perform any work, read and follow OSHA Regulations concerning entry and working in CONFINED SPACE OSHA 1910.146 and LOCKOUT/TAGOUT OSHA 1910.147. Follow OSHA Regulations while performing any work to the Packer. Confined Space means a space that has one or more of the following characteristics: 1. Is large enough and so configured that an employee can bodily enter and perform assigned work. 2. Has limited or restricted means for entry or exit (for example, tanks, vessels, silos, storage bins, hoppers, vaults, and pits are spaces that may have limited means of entry). 3. Is not designated for continuous employee occupancy. Permit-Required Confined Space (permit space) means a confined space that has one or more of the following characteristics: 1. Contains or has a potential to contain a hazardous atmosphere. 2. Contains a material that has the potential for engulfing an entrant. 3. Has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly converging walls or by a floor which slopes downward and tapers to a smaller cross-section. 4. Contains any other recognized serious safety or health hazard. Follow all safety instructions in your McNeilus Packer manual. Shut off truck engine, lock cab doors, and keep key in your pocket before entering or climbing on or getting under the truck to perform any work to the Packer. Place magnetic DANGER signs on both cab doors (McNeilus part number 9190.602477). Lockout supplies are available from McNeilus Truck and Manufacturing, Inc. Call 888-686-7278 for assistance. 3.0 Product Safety Information Read, understand, and follow the safety guidelines, dangers, and warnings listed below and contained in this manual as well as on the Packer itself to promote reliable operation and prevent serious personal injury. Contact McNeilus Truck and Manufacturing, Inc. if you require assistance or have questions at 888-686- 7278. Cart Tippers are powerful tools and must be operated with care. Make sure all persons are clear of the tipper before and during operation. Keep your hands and body away from the tipper while it is in operation. Never reach into the hopper while the tipper is in operation. Do not lift broken carts or bulk items with the tipper. Do not operate the tipper faster than 6 seconds per cycle. Do not lift over-loaded carts. They can break and fall or be thrown or dropped after breaking. Do not lift carts that your tipper is not designed to operate with. Do not perform maintenance on the tipper unless it is properly secured. Inspect the tipper daily before use for anything in need of repair or service. SSP II Cart Tipper 2-4 2008 McNeilus Truck and Manufacturing, Inc.
WARNING Safety decals must be replaced anytime they are damaged, missing, or cannot be read clearly. Failure to have proper decals in place can result in serious injury or death. If you require safety decals, please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 for no charge replacement safety decals. WARNING This product may contain materials with chemicals or byproducts of chemical processes known in the State of California to cause cancer or birth defects or other reproductive harm (California Proposition 65). WARNING Follow ALL Lockout Procedures as defined in this manual, as well as all lockout procedures defined by OSHA or other regulatory bodies, including your employer. WARNING Never operate the hydraulic system if a leak is present. Serious injury may result. WARNING Hydraulic systems operate under very high pressure. Hydraulic fluid escaping from a pressurized system can penetrate unprotected body tissue. NEVER inspect for hydraulic leaks with bare hands or other exposed body parts. At a minimum, wear leather gloves prior to inspecting for leaks and use cardboard or wood. If leaks are present, relieve pressure and allow system to cool prior to servicing. If injured by escaping hydraulic oil, contact a physician immediately. Serious complications may arise if not treated immediately. If you have questions regarding inspecting for hydraulic leaks, please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 prior to servicing. Safety WARNING Hydraulic hoses and tubing must be inspected on a daily basis for leaks, cuts, abrasions, damage, aging, improper clearance, and along the frame for hidden damage. If you find hoses with any such adverse conditions or damage, they must be replaced before the vehicle is returned to service! Failure to properly inspect and maintain your vehicle may result in serious personal injury or death. 2 WARNING Hydraulic systems are hot. DO NOT TOUCH! Serious personal injury or death may result from hot oil. When you have completed working on the hydraulic systems, thoroughly clean any spilled oil from the equipment. Do not spill any hydraulic fluid on the ground. Clean any hydraulic fluid from your skin as soon as you have completed your maintenance and repairs. Dispose of used oil and filters as required by law. 2008 McNeilus Truck and Manufacturing, Inc. 2-5 SSP II Cart Tipper
2 Safety WARNING Correct hoses, fittings, and adapters with the correct SAE rating must be used when replacing hoses to prevent possible serious injury. Always replace hoses, fittings, and adapters with replacements that have a proper, suitable working pressure rating. Replacement hoses must be of correct length and must comply with the hose manufacturer s installation guidelines and recommendations. Hydraulic hoses have the SAE ratings marked on the hose to assist you in selecting the correct hose. Any replacement hydraulic hoses and fittings assemblies must be supplied by the same manufacturer. As an example: Brand A hose and brand B fitting will not normally be compatible. No twist is allowed in the hydraulic hoses. Twist may result in premature hose failure. WARNING The hydraulic cylinders can be holding a function in a certain position when the engine is OFF. An example of this would be a function being held in the lift or partial lift position by the cylinders. If a hydraulic line is removed or the hydraulic circuits or controls are being worked on, gravity may allow the function being held in position to drop. All workers and personnel must remain clear of these areas when working on or operating the McNeilus equipment. Block and secure all applicable devices and functions before beginning work or operation. Failure to comply with this can result in serious injury or death. WARNING Any hydraulic tubing which is replaced must conform to SAE J1065 specifications. If incorrect hydraulic tubing is installed, the hydraulic system may fail, causing serious injury. Damaged or leaking tubing must be replaced before the Packer is returned to service. Please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 for assistance. WARNING Do not heat hydraulic tubing. The carbon content of this steel tube is such that if heated for bending, and either water or air is quenched, the tubing may lose its ductility and thereby be subject to failure under high pressure or hydraulic shock conditions. Serious injury can result. Damaged or leaking tubing must be replaced before the Packer is returned to service. Please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you require assistance or have questions. WARNING All hydraulic pressure must be relieved from the hydraulic system prior to removing any components from the system. To relieve the hydraulic pressure from the hydraulic system, turn off the truck engine and operate the control panel in the cab with the key in the ON position. This will allow the spools to shift and expend the hydraulic pressure. Failure to comply can result in serious injury. If you have any questions concerning relieving the hydraulic pressure from the system, please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278. SSP II Cart Tipper 2-6 2008 McNeilus Truck and Manufacturing, Inc.
WARNING Hydraulic components can be heavy. Use caution while lifting these components. Serious personal injury can be avoided with proper handling of the components. WARNING All hydraulic pressure must be relieved from the hydraulic system prior to removing any components from the system to prevent oil from spraying or functions and systems from failing. Failure to follow this procedure can result in serious injury. Call McNeilus Truck and Manufacturing, Inc. at (507) 374-6321 for information concerning the hydraulic pressures. WARNING Hydraulic systems operate under high pressure. Only qualified, experienced people properly trained in hydraulic system maintenance should attempt repairs or troubleshoot hydraulic systems. Use the proper tools and equipment when servicing the hydraulic system. Failure to comply can cause serious injury. Please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you require assistance. WARNING When performing hydraulic test procedures, use the proper hydraulic gauges. Installing an incorrect test gauge could result in serious injury if the gauge fails. Use properly rated hydraulic hoses to allow the test gauge to be read away from moving parts and functions. Please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you require assistance. Safety WARNING Increasing hydraulic pressure beyond the recommendations may result in serious damage to the Packer or serious personal injury may void the Packer Warranty. If you have questions concerning hydraulic pressures or testing procedures, please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 before attempting the test procedures or making adjustments. WARNING The Packer must not be modified in any way without authorization from McNeilus Truck and Manufacturing, Inc. Modifications may not comply with safety standards, including ANSI safety standards, and may result in serious personal injury. Please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you require assistance. WARNING Always keep hands and feet and other parts of your body clear of revolving or moving parts. Failure to comply can cause serious injury. WARNING Do not wear watches, rings, and jewelry while working with electrical and mechanical equipment. These items can be hazardous and can cause serious and painful injuries if they come into contact with electrical wires, moving parts, or hydraulic equipment. 2 2008 McNeilus Truck and Manufacturing, Inc. 2-7 SSP II Cart Tipper
2 Safety 4.0 Safety Decals The following safety decals are found on your Cart Tipper and warn of hazards related to the use of this equipment. Read and understand all safety decals before operating this equipment. NOTE Depending on the Packer configuration and optional equipment, the actual location of decals and/or placards may vary slightly from the examples shown. If any safety decals on this equipment are not clearly readable, call McNeilus Street Smart Parts and Service at 888-686-7278 or www.streetsmartparts.com for replacements free of charge. The following table contains part numbers for the individual Cart Tipper safety decals as shown in Figure 2, Figure 3, and Figure 4. NOTE Specifications, appearance, and part numbers for safety decals are subject to change without notice. 4.1 Safety Decal Identification Item Part Number Qty. Description 1 1324541 1 Warning: Stand clear when tipper is in motion. 2 1324543 1 Caution: Never operate tipper faster than a six second cycle time. 1 2 Figure 2 SSP II Cart Tipper 2-8 2008 McNeilus Truck and Manufacturing, Inc.
Safety 2 Figure 3 Figure 4 2008 McNeilus Truck and Manufacturing, Inc. 2-9 SSP II Cart Tipper
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Specifications Specifications 3 Table of Contents 1.0 FEATURES...3 2.0 PERFORMANCE...3 3.0 DIMENSIONS...4 2008 McNeilus Truck and Manufacturing, Inc. 3-1 SSP II Cart Tipper
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Specifications 1.0 Features Designed for compact installation. Compatible with all standard 2-Bar U.S. carts. Bronze or spring bushings at all pivot points with grease fittings. Generous 17-1/2" ground clearance. Break-away feature to minimize damage. Welded cylinder with replaceable seals and built-in PO check to prevent drifting. Adjustable dump angle up to 50 degrees. 6-8 second cycle time. Generous lift capacity. Rugged, solid hook drive mechanism automatically secures cart throughout the dump cycle. No Packer blade interference. Powder-coated finish for durability. 2-year Limited Warranty. Optional tap-in kits available including diverter valve, hand valve, hoses and fittings. 2.0 Performance Cart Compatibility: ANSI Z245.60-1996 Type B Containers Lift Capacity: 400 lbs @1800 PSI Working Pressure: 1800 PSI Maximum Pressure: 2500 PSI Hydraulic Flow: 1-1/2-2 GPM Cycle Time: 6-8 Seconds 3 1141074 Single Tap-In Kit 1148515 Dual Tap-In Kit 2008 McNeilus Truck and Manufacturing, Inc. 3-3 SSP II Cart Tipper
3.0 Dimensions Specifications 3 Figure 1 SSP II Cart Tipper 3-4 2008 McNeilus Truck and Manufacturing, Inc.
Specifications 3 Figure 2 2008 McNeilus Truck and Manufacturing, Inc. 3-5 SSP II Cart Tipper
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Installation Installation Table of Contents 1.0 LOCKOUT/TAGOUT PROCEDURES...3 2.0 INSTALLATION GUIDELINES...3 4 2008 McNeilus Truck and Manufacturing, Inc. 4-1 SSP II Cart Tipper
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1.0 LOCKOUT/TAGOUT Procedures Installation of the Cart Tipper must be performed by skilled service personnel. Safety and safe working procedures must be followed at all times. OSHA LOCKOUT/TAGOUT procedures must be followed when performing installation on this equipment. Refer to the safety section of this manual. 1 Installation 2.0 Installation Guidelines The Cart Tipper is compatible with ANSI Standard Z245.60-1996 for type B containers. The correct installation of the Cart Tipper is required to properly lift carts. When installing the Cart Tipper, the installation height and level are very important. For proper dimensions when mounting Cart Tipper, see Figure 1. 4 When mounting the Cart Tipper, the distance from the top of the mounting plate to the ground must be 36 1/8". The most important dimension to check after mounting is the distance from the ground to the top face of the saddle as shown in Figure 1, Item 1. When the face plate is perpendicular to the ground. Using a tape measure, the distance from the saddle to the ground should be 34". Before installing the Cart Tipper, the Packer body must be empty and the chassis parked on a smooth and level surface. Never cut into the original structural member across the sill of the tailgate. If the Packer body has container locks, the sill extension can be modified to recess the Cart Tipper. Figure 1 In-line flow controls are not required in the hydraulic lines. The Cart Tipper cylinder has a built-in orifice to provide the correct cycle time. If this is a new installation, installation instructions and details regarding the hydraulics are included with the available tap in kits. 1141074 Single Tap-In Kit 1148515 Dual Tap-In Kit The Cart Tipper can be mounted on many different Packer bodies, which may require special fabrication for installation. Contact McNeilus Street Smart Parts and Service for assistance. 2008 McNeilus Truck and Manufacturing, Inc. 4-3 SSP II Cart Tipper
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Preventive Maintenance Preventive Maintenance Table of Contents 1.0 LOCKOUT/TAGOUT PROCEDURES...3 2.0 DESIGN...3 3.0 DAILY INSPECTION (10 HOURS)...3 3.1 LATCH ASSEMBLY...4 3.2 BREAK-AWAY FASTENERS...4 3.3 HYDRAULIC SYSTEM AND COMPONENTS...4 3.4 HYDRAULIC HOSES, TUBES, AND PIPES...4 4.0 WEEKLY LUBRICATION (50 HOURS)...5 4.1 LUBRICATION POINTS...5 4.1.1 Grease Fittings and Bushings...5 4.2 COMPONENT INSPECTION...5 4.2.1 Proper Adjustment...5 5 2008 McNeilus Truck and Manufacturing, Inc. 5-1 SSP II Cart Tipper
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1.0 Lockout/Tagout Procedures All maintenance procedures must be performed by skilled service personnel. Safety and safe working procedures must be followed at all times. OSHA LOCKOUT/TAGOUT procedures must be followed when performing maintenance on this equipment. See the safety section of this manual. Preventive Maintenance 2.0 Design The Cart Tipper is designed to provide exceptional performance and value while requiring a minimum amount of maintenance. Performing Preventive Maintenance on your Cart Tipper will prolong the life of the Cart Tipper, help prevent expensive downtime, and minimize the potential for problems arising on the route. 3.0 Daily Inspection (10 Hours) Daily, before placing the Cart Tipper in service, a thorough and complete inspection for damage, loose hardware, missing break-away fasteners, and oil leaks is required. Inspect the Cart Tipper and all components for binding, damage, and loose or missing parts. Also inspect all cap screws and nuts to verify that none are loose or missing. Cycle the Cart Tipper several times before leaving the yard to verify the Cart Tipper is operating properly. Observe the Cart Tipper for looseness and wear in the bearings. Repair as necessary any deficiencies found during the inspection and check procedure. 5 NOTE If the Packer is operated more hours per day or double-shifted, the maintenance interval must be adjusted accordingly. 2008 McNeilus Truck and Manufacturing, Inc. 5-3 SSP II Cart Tipper
Preventive Maintenance 1 2 3.3 Hydraulic System and Components Inspect the hydraulic system and components for leaks and damage. Inspect around all fittings and connections. Look for any fresh puddles or drips under the Packer and tipper. 5 3 Ensure that all components are securely mounted and that all bolts and nuts are in place and secure. Inspect for cracks or other damage to the mounting brackets. 3.4 Hydraulic Hoses, Tubes, and Pipes Inspect hydraulic hoses, tubes, and pipes for damage and proper clearance with other components. Figure 2 shows some examples of hydraulic hose damage to inspect for: Bulging (Item 1) Cracks (Item 2) Cuts (Item 3) Abrasion (Item 4) Twisting (Item 5) Bending (Item 6) 3.1 Latch Assembly Figure 1 Inspect the latch assembly and weldment (Figure 1, Item 1 and Item 2) for any damage. Also inspect the tie rods, specifically, verify that the tie rods and latch assembly are not bent or damaged. 3.2 Break-Away Fasteners Inspect to verify that both break-away fasteners (Figure 1, Item 2) are in place and not damaged. The face plate is attached to two (2) tangs with two (2) break-away fasteners. To minimize damage to the Cart Tipper, the fasteners are designed to break if the Cart Tipper is bottomed-out on route. 3 1 2 4 5 If replacement of a break-away fastener is required, installing with the proper torque is very critical. Torque the locknuts to 18-20 ft-lb (216-240 in-lb). Two (2) additional break-away fasteners (Figure 1, Item 3) are stored on the tipper for emergency use when on route. NOTE Proper torquing of the break-away fasteners is critical. If over-torqued, the break-away fastener will break or fail prematurely. Figure 2 6 SSP II Cart Tipper 5-4 2008 McNeilus Truck and Manufacturing, Inc.
4.0 Weekly Lubrication (50 Hours) Lubrication is required weekly or every 50 hours, whichever occurs first. Inspect bushings and bearings for wear or damage. 4.1 Lubrication Points Figure 3 Identifies the lubrication points for the Cart Tipper. 1 2 3 4 Preventive Maintenance 4.2 Component Inspection Inspect the Cart Tipper and all components (Figure 4) for binding, damage and loose or missing parts. Also inspect all cap screws and nuts to verify that none are loose or missing. 4.2.1 Proper Adjustment The Cart Tipper is designed for reliable operation while requiring minimal maintenance. To ensure this, proper adjustment and maintenance is critical. There are two critical points to reference when performing the adjustment procedure as shown in Figure 4. 1. Proper tie rod length adjustment (Figure 4, Item 1). The tie rod assembly must be set to a length of 15-5/8 between the centers of the rod ends. 2. Proper tie rod gap (Figure 4, Item 3). This adjustment prevents interference between the tie rod assembly and the pivot when the face plate is fully raised. To eliminate interference or increase gap clearance, adjust the trunnion (Figure 4, Item 2) as needed. 5 5 1 6 7 15 5/8 2 Figure 3 4.1.1 Grease Fittings and Bushings 3 Lubricate all of the lubrication points with a highquality EP No. 2 lithium grease. Clamp Weldment (Figure 3, Item 2) 2 Grease Fittings, 2 Bronze Bushings LH and RH Tangs (Figure 3, Item 4) 4 Grease Fittings, 4 Spring Bushings Face Plate Pivot (Figure 3, Item 5) 2 Grease Fittings, 4 Spring Bushings Cylinder Mounts (Figure 3, Item 7) 2 Grease Fitting, 3 Bronze Bushings Cycle the Cart Tipper by raising and lowering several times. Observe the Cart Tipper for looseness and wear in the bearings. Figure 4 Refer to the Tie Rod Assembly Adjustment Procedure in the Service Procedures section of this manual for more detailed adjustment information. 2008 McNeilus Truck and Manufacturing, Inc. 5-5 SSP II Cart Tipper
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Service Procedures Service Procedures Table of Contents 1.0 LOCKOUT/TAGOUT PROCEDURES...3 2.0 TROUBLESHOOTING GUIDELINES...4 3.0 TIE ROD ASSEMBLY ADJUSTMENT PROCEDURE...4 4.0 CART TIPPER CYLINDER TRUNNION INSPECTION...5 5.0 CART TIPPER CYLINDER TRUNNION ADJUSTMENT...6 6 2008 McNeilus Truck and Manufacturing, Inc. 6-1 SSP II Cart Tipper
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1.0 LOCKOUT/TAGOUT Procedures This section of the manual describes procedures that may be required for proper maintenance of the Cart Tipper. All maintenance procedures must be performed by skilled service personnel. See the safety section of this manual. Service Procedures 2.0 Troubleshooting Guidelines When a problem or malfunction occurs, the following procedures will help isolate the problem and often permit a quick repair. If further assistance is required, refer to the applicable section of this manual or contact your McNeilus Street Smart Parts and Service location listed in the Foreword of this manual. NOTE Isolate the problem before taking any remedial action. 6 2008 McNeilus Truck and Manufacturing, Inc. 6-3 SSP II Cart Tipper
Service Procedures 3.0 Tie Rod Assembly Adjustment Procedure 6 1. Rotate the tipper face completely to the RAISED position. 2. Inspect to verify there is a gap (Figure 1, Item 2) between the tie rod assembly and the face plate pivot. 3. If a gap is not present, lower the face plate until a gap is present. 4. Apply LOCKOUT/TAGOUT procedure to the Packer. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures. 5. Measure the length of the tie rod assembly between the center of rod ends. The distance should be 15-5/8 (Figure 1) 6. If the tie rod requires adjustment, loosen the jam nuts (Figure 1 Item 1) on both ends of the tie rod. Turn the tie rod to lengthen or shorten as required. Tighten both jam nuts. 7. If the face plate was lowered to provide a gap, remove LOCKOUT/TAGOUT procedure from the Packer. 8. Rotate the tipper face completely to the RAISED position. 2 1 15-5/8 Figure 1 SSP II Cart Tipper 6-4 2008 McNeilus Truck and Manufacturing, Inc.
4.0 Cart Tipper Cylinder Trunnion Inspection 1. Apply LOCKOUT/TAGOUT procedure to the Packer. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures. 2. Measure the distance from the top of the cylinder gland to the center of the cylinder trunnion (Figure 2). The specified distance should measure 8-5/8 ±1/16. 3. If the measurement does not meet the specified distance, the dump angle of the tipper face will be affected relative to the measurement. The dump angle increases as the measurement increases and vice versa. Service Procedures 8-5/8 ± 1/16 Fully Extended 6 Figure 2 2008 McNeilus Truck and Manufacturing, Inc. 6-5 SSP II Cart Tipper
Service Procedures 5.0 Cart Tipper Cylinder Trunnion Adjustment 6 1. If the distance does not meet the specified measurement, inspect the rod gap between the tie rod assembly and the pivot. 2. If a gap is present between the tie rod assembly and pivot, no adjustment is required. NOTE If the measurement does not meet the specified distance and interference between the tie rod assembly and pivot exists, adjust the cylinder trunnion as required. Adjust the trunnion on the cylinder rod to the specified distance of 8-5/8, ±1/16. 3. Disassembly is required to adjust the position of the trunnion on the cylinder rod. 4. Safely secure the face plate (Figure 3, Item 1) with a come-along or strap so that it cannot fall. CAUTION Use caution when lifting face plate to avoid potential pinch point between roller yoke and mounting plate. Failure to heed this warning may result in personal injury or damage to property or equipment. Figure 3 1 2 3 4 5 5. Support the cylinder (Figure 3, Item 5) and remove both cylinder pins (Figure 3, Item 4) retaining the cylinder. 6. Rotate the cylinder up to provide access to the trunnion jam nut (Figure 3, Item 2). 7. Loosen the trunnion jam nut. 8. With a wrench, use the flat on the cylinder rod (Figure 3, Item 3) to adjust the position of the trunnion on the rod. Adjust the rod length to 8-5/8 ±1/16 as shown in Figure 2. 9. Tighten the trunnion jam nut. 10. Rotate the cylinder down and re-install both cylinder pins. 11. Unsecure the come-along or strap used to secure the face plate. 12. Remove the LOCKOUT/TAGOUT procedure from the Packer. 13. Rotate the face plate to the DOWN position. SSP II Cart Tipper 6-6 2008 McNeilus Truck and Manufacturing, Inc.
Illustrations and Parts List Illustrations and Parts Lists Table of Contents 1.0 HOW TO USE...3 2.0 CART TIPPER ASSEMBLY...4 3.0 CART TIPPER CYLINDER...6 4.0 TIE ROD ASSEMBLY...8 7 7 2008 McNeilus Truck and Manufacturing, Inc. 7-1 SSP II Cart Tipper
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1.0 How To Use Illustrations and Parts Lists The majority of the pages in this section are arranged so that the illustrations and parts lists are on facing pages. The pages are prioritized in order with the assembly first, followed by the serviceable components. Where applicable, descriptions are indented to indicate when the component is part of an assembly. The information in the following table is sample information only and represents how the parts list tables are built. Item Description Footnote Qty. MTM Part No. SSP Cart Tipper Assembly 1 1325031 1 1/2-13 UNC x 1.25 BHCS, ZP F1 2 1332139 2 Torque Arm Retainer 2 1331920 3 Torque Arm Weldment 2 1339155 4 1/4-28 UNF x 0.38 Set Screw 2 1328563 5 Master Cylinder Assembly 1334084 Master Cylinder Rod Assembly (Includes Items 2, 5, 6 and 9) 1 1332656 2 Rod End Mount 1 NSS 5 Cylinder Rod 2 NSS 6 Cam Roller, 1 OD 1 NSS 9 Dowel Pin, 5/16 x 1-1/4 1 NSS F1 Apply Loctite grade 271 or equivalent and torque to 65-75 ft-lb (780-840 in-lb) 1. Item: Refers to callout and leader on corresponding illustration. 2. Description: Provides a description of item to identify size, type or application. 3. Footnote: A footnote is used when specific information is required for an item. A footnote is indicated by an F accompanied by a number such as F1. Additional sequential numbers are used when more than one footnote is used. 4. Qty: Quantity of the part in the assembly. 5. MTM Part No.: The McNeilus part number to use when ordering replacement parts. When a component part is not available, a Not Serviced Separately (NSS) designation is used to indicate that the part is not serviced separately. 7 2008 McNeilus Truck and Manufacturing, Inc. 7-3 SSP II Cart Tipper
Illustrations and Parts List 2.0 Cart Tipper Assembly 26 2 1 24 25 3 23 5 21 22 4 2 7 6 20 19 12 8 7 19 2 1 13 11 11 10 9 18 11 2 6 15 14 7 17 16 Figure 1 SSP II Cart Tipper 7-4 2008 McNeilus Truck and Manufacturing, Inc.
Illustrations and Parts Lists Item Description Notes Qty. MTM Part No. SSP II Break-Away Cart Tipper Assembly with Heavy Duty Latch 1 1147480 1 Nylok Lock Nut, 3/8-16 UNC 8 1147465 2 Flat Washer, 3/8 Zinc 14 0120277 3 Plate, Base, SSP II 1 1147460 4 Frame, Base, Weldment, SSP II 1 1147455 5 Pin, Upper Pivot, SSP II 2 1147453 6 Hex Head Cap Screw, 3/8-16 UNC x 1-1/4 G8 Zinc F3 7 1136593 7 Spring Lock Washer, 3/8 Zinc 8 0621024 8 Pin, Cylinder, SSP II 2 1147454 9 Hex Nut, 1/2-20 UNF G5 Zinc F4 8 0120354 10 Spring Lock Washer, 1/2 Zinc 8 1147466 11 Flat Washer, 1/2 Zinc 11 0120279 12 Tang, Right-Hand, SSP II 1 1147458 13 Latch hook, SSP II, Heavy-Duty 1 1147451 14 Block, Latch Hook Mounting, SSP II 2 1147459 15 Bronze Journal, 5/8" ID 2 1426863 16 Face Plate, SSP II 1 1147456 17 Button Head Cap Screw, 3/8-16 UNC x 1-1/4 F2 4 1147467 18 Saddle 1 0621016 19 Spring Bushing, 1 ID (Mulitple locations in assembly drawing.) 10 1332241 20 Cylinder, SSP II Cart Tipper 1 1147462 21 Tie Rod Assembly, SSP II (With Two 1147477 Spherical Rod Ends) 2 1147452 22 Hex Jam Nut F4 4 1250235 23 Break-Away Fastener, with Notch (Standard) F1 4 1147478 Kit, Break-Away Fastener with Notch - Standard (Includes Qty. 2 each of 1147478 and Items 1 and 2) 1147461 23 Break-Away Fastener, without Notch (Heavy-Duty) F1 1238209 Kit, Break-Away Fastener without Notch - Heavy-Duty (Includes Qty. 2 each of 1238209 and Items 1 and 2) 1238208 24 Tang, Left-Hand, SSP II 1 1147457 25 External Snap Ring, 1" Shaft 2 1165037 26 Long Stud, 1/2-20 UNF x 1-3/4 F5 6 1147463 7 F1 F2 F3 F4 Grease Fitting, 1/4-28 UNF, Straight F6 1245544 Apply loctite grade 243 or equivalent and torque to 18-20 ft-lb (216-240 in-lb). Apply loctite grade 243 or equivalent and torque to 20-25 ft-lb (240-300 in-lb). Apply loctite grade 243 or equivalent and torque to 40-45 ft-lb (480-540 in-lb). Apply loctite grade 243 or equivalent and torque to 60-75 ft-lb (720-900 in-lb). F5 Apply loctite grade 243 or equivalent to the threaded holes of base plate, item 3, before installing long studs. Long studs must not protrude past the back of base plate. F6 Item not shown in illustration. 2008 McNeilus Truck and Manufacturing, Inc. 7-5 SSP II Cart Tipper
Illustrations and Parts List 3.0 Cart Tipper Cylinder 7 Figure 3 SSP II Cart Tipper 7-6 2008 McNeilus Truck and Manufacturing, Inc.
Illustrations and Parts Lists ITEM Description Notes Qty. MTM Part No. SSP II Cart Tipper Cylinder 1147462 Kit, Seal, Cart Tipper SSP II (Includes Items 1 through 14) 1 1323138 1 Square Ring 1 NSS 2 Backup Ring, Dynamic 2 NSS 3 O-Ring 1 NSS 4 Precision Wearband 1 NSS 5 TFE Buffer Seal 1 NSS 6 Deep Z-Seal 1 NSS 7 HD Rod Wiper, Sealed OD 1 NSS 8 O-Ring 1 NSS 9 Locking Insert 1 NSS 10 Backup Ring 1 NSS 11 O-Ring 1 NSS 12 Piston Ring, Cast Iron 1 NSS 13 Piston Seal, Square Section TFE 1 NSS 14 Wearband 1 NSS 15 Check Valve, P.O. 1 1328016 16 Orifice Plug 1/16 Diameter 1 1328017 17 Connector, #6 O-Ring Boss 37 JIC (Retract) 1 1328018 18 90 Elbow, #6 O-Ring Boss 37 JIC (Extend) 1 1328019 7 2008 McNeilus Truck and Manufacturing, Inc. 7-7 SSP II Cart Tipper
Illustrations and Parts List 4.0 Tie Rod Assembly Figure 3 Item Description Notes Qty. MTM Part No. SSP II Tie Rod Assembly 2 1147452 1 Tie Rod without Rod Ends 2 1364186 2 Hex Jam Nut, 1/2-20 UNF G5 Zinc 4 1250235 3 Rod End, Spherical Threaded 4 1147477 7 SSP II Cart Tipper 7-8 2008 McNeilus Truck and Manufacturing, Inc.
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