& Operating Manual Document #: OM-NitroStinger-NitroSpreader-R1.doc Revision: 1 Date: 5/23/2007
& Operation Manual Page 2 Table of Contents Table of Contents... 2 Introduction... 3 Warnings / General Safety... 3 Features and Options... 5 Operation... 7 Attaching Stinger to Trailer Using a Crane or Forklift... 7 Attaching Stinger to Trailer without a Crane or Forklift... 7 To Attach a Pin-On Axle (NitroSpreader only)... 8 To Transfer Trailer Load to Stinger Axle:... 8 To Reduce Trailer Load on Stinger Axle:... 8 To Raise Stinger off Ground:... 9 Preventive Maintenance... 10 Troubleshooting... 12 Replacement Parts... 13 APPENDIX A: Electric Pump Specifications... 15 APPENDIX B: Air Pump Specifications... 16 APPENDIX C: Gas Engine Specifications... 18 APPENDIX D: Cylinder Control Valve Specifications... 19 APPENDIX E: Hydraulic Schematic... 20 APPENDIX F: Electrical Schematic... 21 REVISION HISTORY... 22
& Operation Manual Page 3 Introduction This manual provides instruction on the safe use of the NitroStinger, Tandem Axle NitroStinger and the NitroSpreader (hereafter collectively referred to as Stinger). It also provides suggested preventive maintenance, replacement parts and troubleshooting guidelines. If any other information is necessary, please contact the factory at: Warnings / General Safety Express Welding, Inc. 2525 14 th Avenue North Escanaba, MI 49829 906-786-8808 (Phone) 906-786-6165 (Fax) Before operating the Stinger, read this operating manual and become familiar with its safe operation. Before and during operation, all bystanders must stay a safe distance away from the Stinger. o There are pinch points on the Stinger. These may cause serious injury or death. o When the Stinger is lowered from its raised position, a person may become trapped underneath. This may cause serious injury or death. Stay alert while operating the Stinger. o Do not operate Stinger while under the influence of alcohol or other drugs, or if deprived of sleep. Do not operate Stinger if any of the wires, hoses or tubes are frayed, abraded, cut or otherwise damaged. o Damaged wires may cause an electrical short and create sparks. These sparks may ignite any oil in the area, causing a fire. o Damages hoses or tubes may burst. The high pressure fluid may cause the hose or tube to whip around and strike a bystander. This may cause serious injury or death. The high pressure fluid may also pierce the skin, injecting air or oil into the body. This may cause serious injury or death. Check operation of brakes daily. o Brakes are important. They control the Stinger while braking. Without brakes, the Stinger may not function as expected. Replace worn brake components before operating Stinger.
& Operation Manual Page 4 Check operation of all lights (including strobe lights) daily. o Lights are important. They help other drivers to see the Stinger. They also help by communicating to other drivers all turns and brakes. Replace non-functioning lights immediately. Check oil level before operating the Stinger. o With the cylinders fully retracted, the oil level should be 3 to 4 inches below the top of the oil tank. If oil level is low, the Stinger may not function properly. Before backing up, raise the Stinger off of the ground. o Make sure the locking pin is properly installed before raising the Stinger off the ground. o It is very difficult, if not impossible, to control the Stinger when it is on the ground while backing up. Doing so will cause damage to the Stinger and void the warranty. Do not load the Stinger with more than 25,000 pounds (50,000 pounds for tandem axle units). o The Stinger is designed for 25,000 pounds per axle. Applying more than 25,000 pounds per axle may cause damage to the Stinger. This may cause serious injury or death. Do not rest or tie down any part of the trailer load to the Stinger. o The Stinger must freely pivot with respect to the trailer. Resting or tying down part of the trailer load to the Stinger may cause the load to become unstable. This may cause serious injury or death. Do not travel with the Stinger raised off the ground. o The locking pin may shear, causing the Stinger to swing uncontrollably. This may cause serious injury or death. When traveling without a trailer load, either: 1) Remove Stinger and haul on trailer (Recommended). 2) Apply enough load to the Stinger to equalize weight on all axles. This load will reduce the road vibrations on the Stinger. Before traveling, do the following: o Raise landing gear as far as possible. This will reduce the chance of the landing gear striking an object on the road and becoming damaged. o Remove Locking pin from front pivot. If locking pin is installed, it will be sheared off. This may cause the pin to be thrown from the Stinger, striking a bystander. This may cause serious injury or death. Before servicing the Stinger, do the following: o Remove entire load from the Stinger. o Disconnect the air and electrical connections between the Stinger and the trailer. NitroSpreader shall only be used with a single Pin-on Axle
& Operation Manual Page 5 Features and Options 25,000 Pound GVWR (Single Axle), 50,000 Pound GVWR (Tandem Axle) Self-Contained Hydraulic System (Hydraulic Fluid is Dexron/Mecron III ATF) o Electric Motor/Hydraulic Pump, Powered by On-Board Battery (Standard on Single Axle, Not Available on Tandem Axle) o 6.5hp Gasoline Engine with Electric Start powered Hydraulic Pump, Powered by On-Board Battery (Standard on Tandem Axle, Optional on Single Axle) o Air Motor/Hydraulic Pump, NO On-Board Battery (Optional on Single Axle, Not Available on Tandem Axle) Nitrogen (N 2 ) Over Oil Accumulator 275/70R22.5 Tires (Standard) o 255/70R22.5 Tires (Optional) Steel Wheels (Standard) o Polished or Machine Finished Aluminum Wheels (Optional) Truck-Lite 7-Pin Wiring Harness (Standard) o Consult Factory for Other Harnesses LED Lights Built-in Rear Strobe Lights with Self Contained Circuitry o Powered by On-Board Battery on Gas and Electric Models o Powered by Running Lights on Air Model On-Board Battery is Charged with an on-board Charging Unit powered with ABS power (Blue wire) Heavy-Duty, Leg Landing Gear (One on Single Axle Unit, Two on Tandem Axle Unit) Manufactured with High-Strength Steel Painted Black (Standard) o Consult Factory for Other Paint Colors Will Couple to any Make of Trailer with Pin-On Axle Attachment Can be Raised off of Ground for Backing Up
& Operation Manual Page 6 25,000 Pound GVWR Self-Contained Hydraulic System (Hydraulic Fluid is Dexron/Mecron III ATF) o Air Motor/Hydraulic Pump, NO On-Board Battery (Standard) o Electric Motor/Hydraulic Pump, Powered by On-Board Battery (Optional)) Nitrogen (N 2 ) Over Oil Accumulator Truck-Lite 7-Pin Wiring Harness (Standard) o Consult Factory for Other Harnesses On-Board Battery is Charged with an on-board Charging Unit powered with ABS power (Blue wire) Manufactured with High-Strength Steel Painted Black (Standard) o Consult Factory for Other Paint Colors Will Couple to any Make of Trailer with Pin-On Axle Attachment Will Accept any Make of Pin-On Axle Can be Raised off of Ground for Backing Up
& Operation Manual Page 7 Operation Attaching Stinger to Trailer Using a Crane or Forklift 1) Drop locking pin into hole to prevent uncontrolled swinging of the Stinger when it is raised off the ground. a. Locking pin must drop down until its head is resting on the top plate. 2) Move CYLINDER CONTROL to middle position. 3) Remove the 4 pins from the front of the Stinger. 4) Lift Stinger by the two lifting ears on the main rail (4 ears on Tandem Axle). For the NitroSpreader, add a lift chain/strap around the tower section where the cylinder rod ends are attached. 5) Carefully line up either the top or bottom set of ears (whichever is more convenient) on the Stinger with the corresponding ears on the trailer. 6) Install the proper pins. 7) Either lower or raise the Stinger to align the other set of ears. 8) Install the other set of pins. 9) Unhook the Stinger from the crane or forklift. 10) Hook up the air and electrical connections to the trailer. 11) Check brakes and lights. Attaching Stinger to Trailer without a Crane or Forklift (Not Recommended for NitroSpreader) 1) Drop locking pin into hole to prevent uncontrolled swinging of the Stinger when it is raised off the ground. a. Head must drop down until the head is resting on the top plate. 2) Move CYLINDER CONTROL to middle position. 3) Remove the 4 pins from the front of the Stinger. 4) Using the Landing Gear, adjust the height of the Stinger so that the top or bottom ears (whichever is more convenient) are at the same height as the corresponding ears on the trailer. 5) Back up the trailer so that the appropriate ears are aligned. 6) Install the proper pins. 7) Hook up the air and electrical connections to the trailer. 8) Either lower or raise the Stinger using the hydraulic pump to align the other set of ears (instructions on Stinger operation follow). 9) Install the other set of pins. 10) Check brakes and lights.
& Operation Manual Page 8 To Attach a Pin-On Axle (NitroSpreader only) ***MUST BE DONE AFTER STINGER IS ATTACHED TO TRAILER*** 1) Remove the 4 pins from the pin-on axle. 2) Raise or lower Stinger until the top or bottom ears (whichever is more convenient) on the rear of the Stinger are at the same height as the corresponding ears of the pin-on axle. 3) Back up the trailer so that the appropriate ears are aligned. 4) Install the proper pins (top pins are smaller diameter than the bottom pins). 5) Hook up the air and electrical connections to the trailer. 6) Either lower or raise the Stinger using the hydraulic pump to align the other set of ears (instructions on Stinger operation follow). 7) Install the other set of pins. 8) Check brakes and lights. To Transfer Trailer Load to Stinger Axle: 1) Using the Load Chart on the control panel, determine the CYLINDER PRESSURE that corresponds to the desired load. 2) Set Master Valve to OPEN. 3) Turn hydraulic pump on or start engine. 4) Move CYLINDER CONTROL lever to LOAD and lock in place with spring latch. 5) Watch gauge. When desired pressure is reached, Move CYLINDER CONTROL to middle position. 6) Wait a moment for the pressure to settle. If necessary, Move CYLINDER CONTROL to LOAD until desired pressure is reached. 7) Turn off hydraulic pump or engine. 8) Move CYLINDER CONTROL lever to LOAD and lock in place with spring latch. 9) Set Master Valve to CLOSED. 10) Periodically check pressure by moving Master Valve to OPEN. Adjust pressure as necessary. 11) Move Master Valve to CLOSED before traveling. To Reduce Trailer Load on Stinger Axle: 1) Using the Load Chart on the control panel, determine the CYLINDER PRESSURE that corresponds to the desired load. 2) Set Master Valve to OPEN. 3) Slowly move CYLINDER CONTROL lever to LIFT. 4) After a few seconds, move CYLINDER CONTROL lever to LOAD and lock with LOAD LOCK.
& Operation Manual Page 9 5) If pressure is above desired pressure, repeat 3) & 4). 6) Follow the directions To Transfer Trailer Load to Stinger Axle:. To Raise Stinger off Ground: ***THIS MUST BE DONE BEFORE BACKING UP*** 1) Drop locking pin into hole to prevent uncontrolled swinging of the Stinger when it is raised off the ground. a. Head must drop down until the head is resting on the top plate 2) Set Master Valve to OPEN. 3) Slowly move CYLINDER CONTROL lever to LIFT. 4) When the oil can no longer be heard moving in system turn hydraulic pump on or start engine. 5) When Stinger is raised to desired height, turn pump off. 6) Move Master Valve to CLOSED before traveling.
& Operation Manual Page 10 Preventive Maintenance The following preventive maintenance should be done at least 2 times per month. Tires, Wheels & Hubs o Check tire pressure. Inflate tires to 115-120 psig. o Check for tire wear. Rotate, recap or replace tires as necessary. o Check tires for cuts, punctures, etc. Recap or replace tires as necessary. o Check torque on wheels lug nuts. Torque to 450 ft-lbf. o Check hubs for proper lubrication. Lubricate hubs as necessary. Wires, Hose & Tubing o Check for nicks, cuts, abrasions and other signs of wear. Replace as necessary o Check all fittings and connections for tightness. Tighten or replace as necessary Lights o Check all lights for proper function. Replace lights as necessary. Brakes o Lift Stinger off ground. o Spin wheels and then apply the brakes. The wheels must stop as soon as brakes are applied. Replace brakes as necessary. Emergency Brakes o Pressurize red supply line on Stinger. o When air tank is full, disconnect red supply line. Brakes should engage immediately. o Reconnect red supply line. Brakes should disengage immediately. Battery o Inspect battery for punctures and other signs of damage. Replace battery as necessary. o Inspect battery terminals for corrosion. Clean terminals as necessary. Spray terminals with anti-corrosion spray.
& Operation Manual Page 11 Electric Motor/Pump o Inspect solenoid for damage Replace solenoid as necessary (contact Express Welding). o Inspect pump for oil leaks. Replace pump as necessary (contact Express Welding). o Inspect solenoid and motor terminals for corrosion. Clean terminals as necessary. Spray terminals with anti-corrosion spray. Gas Engine o Check engine oil level o Check starter cable connections Tighten as needed o Check pump coupler bolts Tighten as needed Air Motor/Pump o Inspect pump for oil leaks. Replace pump as necessary. o Inspect motor exhaust for blockage. Clean as necessary. Pivot Points o Lubricate all grease points. 1 at bottom of Tower for horizontal pin 2 in coupler for vertical pin 2 on each cylinder
& Operation Manual Page 12 Troubleshooting Cylinders do not move. o CYLINDER CONTROL is in middle position. Lock CYLINDER CONTROL in LOAD position to increase load and to travel. Move CYLINDER CONTROL to LIFT position to reduce load and lift Stinger. o Master Valve is in the CLOSED position. Move Master Valve to OPEN position. Stinger will not lift off ground. o CYLINDER CONTROL is not in LIFT position Move CYLINDER CONTROL to LIFT position. Cylinder will not load Stinger. o CYLINDER CONTROL is not in LOAD position Move CYLINDER CONTROL to LOAD position. Wheels will not turn. o Brakes are applied Disengage brakes. o Supply line (red) has become disconnected with pressure in air tank. Reconnect supply line (red). o Brakes are damaged. Repair or replace brakes. Brakes do not work. o Supply line (red) has become disconnected with no pressure in air tank Reconnect supply line (red). o Brake signal line (blue) has become disconnected. Reconnect brake signal line (blue). Pressure drops to zero after setting. o Master Valve is in CLOSED position. THIS IS NORMAL. To check pressure, move Master Valve to OPEN position Front of Stinger does not turn. o Locking pin is installed. Remove locking pin. For other questions, please contact Express Welding.
& Operation Manual Page 13 Replacement Parts ***Consult Factory for Pricing and Availability*** ***Other parts may be available*** 255/70R22.5 Tire 275/70R22.5 Tire Accumulator Air Motor/Hydraulic Pump Air Motor Control Valve (Ball Valve) Air Tank Air Tank Drain Valve Axle Axle Hub Assembly Battery Battery Hold-Down Bracket Blue Brake Signal Line (Stinger to Trailer) Blue Nylon Tubing Bottom Pin (to trailer) Brake Can Brake Line (Valve to Can) Brake Slack Adjuster Brake Relay Valve Brake/Turn Signal Light Coupler (Front Section) Coupling Set (Gas Engine to Pump) Cylinder Control Valve Diode Set (old charging system) Electric Motor/Hydraulic Pump Gas Engine Gas Engine to Pump Bracket Large Light Grommet License Plate Light License Plate Light Bracket Lug Nuts (Wheels) Machined Aluminum Wheel Main Cylinder Main Electric Cable Master Valve (Ball Valve) Oil Tank Oil Tank Cap Polished Aluminum Wheel Pressure Gauge Pump (for Gas Engine) Quick Connect Air Coupling Quick Connect Air Nipple Rear Bunk Electric Harness
& Operation Manual Page 14 Rear ID Marker Light Rear Side Marker Light (Beehive) Red Nylon Tubing Red Pressure Supply Line (Stinger to Trailer) Rubber Suspension Spring Small Light Grommet Snapper Pin Steel Wheel Strobe Light Strobe Light/Electric Pump Power Switch Suspension Bolts Suspension Chain Suspension Nuts Switch Boot Thermal Breaker (old charging system) Top Pin (to trailer) Tower (Middle Section) Truck-Lite 7-Pin Harness Truck-Lite 7-Pin Receptacle
& Operation Manual Page 15 APPENDIX A: Electric Pump Specifications Battery operated Stingers and Spreader Bars use a Monarch Hydraulics 2500psi, 12VDC Power Unit to power the hydraulic system. For repair or replacement information, contact the Express Welding.
& Operation Manual Page 16 APPENDIX B: Air Pump Specifications Air operated Stingers and Spreader Bars use a Haskel AW-35, 1.5hp Liquid Pump to power the hydraulic system. Troubleshooting 1. Pump will not cycle and air exhausts continuously from air vent muffler. Remove air exhaust muffler and fitting located in the end cap. Pull out spool. Change all o-rings. Relubricate sleeve, spool and o-rings with Haskel Silicone Grease (P/N: 28442) and reassemble. Retest before further disassembly. If o-rings are swollen (most likely due to Phosphate Ester in the air compressor lubricant), replace with Haskel o-rings (P/N: 568017-7). Increase operating air pressure in system. 2. Pump will not cycle and air exhausts continuously from pilot vent. Check air cycling valve as in section 1. Replace the pilot stem(s) and seals Remove plugs (one in each end cap) (P/N: 16510). Remove springs and pilot stems (P/N: 27375) Inspect valve stem and seat. Replace if bent or damaged. Note: Replacement of the stem o-ring seals requires access from inside the air section of the unit. If replacement is required, care must be taken in installing the Tru-Arc retainer for seal and back-up concentricity. Use pilot stem valve (P/N: 27375) as a seating tool. Place the rubber valve face against the retainer and tap the top of the valve lightly to evenly bend the legs of the retainer. 3. False Cycling If pump will not cycle properly, the following test will determine which of the two pilot valves is faulty. Install a 160psi pressure gauge to show pilot pressure at the 1/8NPT port in the upper end cap. Apply air pressure to the air drive inlet to cycle against a load. Gauge will read zero pressure if lower pilot valve has not been actuated. Gauge will read full drive pressure after lower valve is actuated and before upper pilot valve has been actuated. Therefore, correct pilot valve action will cause gauge to sharply rise and fall from zero to drive pressure as pump cycles. During the push stroke, a slow increase in gauge reading indicates leakage past lower pilot valve seat. On the pull stroke, slow decrease in pressure indicates upper valve seat or pilot tube end seals are faulty. Repair as necessary. Also check for external leaks at all plugs and fittings.
& Operation Manual Page 17 4. Pump cycles but does not pump. Check inlet check valve parts for contamination or damage. 5. Pressure drops during suction stroke. Inspect outlet check valve parts. Repair as follows: Haskel check valves use either an internal snap ring to secure the retainer or stepped bore construction. All parts may be disassembled for individual replacement as necessary. After replacement of soft seat type checks, pump should be pressurized to approximately 2,000psig to seat the check valves. 6. Pumped fluid appears at vent muffler Replace high pressure seals as follows: Remove gland nut over inlet and outlet ports. Remove internal gland parts. Install new, lightly oiled gland parts into cavity in the order they were removed Replace gland nut, but leave loose. Carefully insert plunger through gland parts and tighten gland nut. Note: If any parts had Ø0.032 twisted safety wire, make sure to replace after reassembly. Replacement parts can be ordered from Haskel directly, or by contacting Express Welding. Haskel International, Inc., Industrial Technologies Division Headquarters: Burbank, CA 91502 818-843-4000 Haskel Controls Division: Burbank, CA 91502 818-843-4000 Haskel-Hogan Systems and Service Co.: Houston, TX 77061 713-910-9900 Factory Express Welding, Inc.: Escanaba, MI 49829 906-786-8808
& Operation Manual Page 18 APPENDIX C: Gas Engine Specifications The gas powered engine is 6.5hp Honda or Honda Equivalent engine with electric start. The pump is a 3000psi, 1.5gpm @ 1800RPM / 3.0gpm @ 3600RPM gear pump. Replacement engines, pumps, couplers and hardware are available from Express Welding.
& Operation Manual Page 19 APPENDIX D: Cylinder Control Valve Specifications The Cylinder Control Valve has a Pressure Release Detent for the LIFT position. There is also a Pressure Relief on the inlet side of the valve. The pressures are adjusted in the following ways: Pressure Release Detent: The adjustment for this is near the end of the valve on the opposite end as the shifting handle. There is an adjusting screw with a jam nut. To adjust the Detent Release Pressure: 1. Loosen the jam nut. 2. Turn the adjusting screw clockwise to increase the release pressure and counter-clockwise to decrease the release pressure. 3. Tighten the jam nut. NOTE: Pressure Relief: Jam nut must be tightened for the detent to work properly. The adjustment for this is near the end of the valve next to the shifting handle. There is an acorn nut with an adjusting screw underneath. To adjust the Relief Pressure: 1. Remove the acorn nut. 2. Turn the adjusting screw clockwise to increase the release pressure and counter-clockwise to decrease the release pressure. 3. Replace and tighten the acorn nut. NOTES: Do not back out the adjusting screw to the point where it falls out. Do not set the relief pressure higher than 2000psig without first consulting the factory.
& Operation Manual Page 20 APPENDIX E: Hydraulic Schematic MOTOR/PUMP HYDRAULIC TANK CYLINDER ACCUMULATOR A CYLINDER I O B N2
& Operation Manual Page 21 APPENDIX F: Electrical Schematic Main Wiring Harness Color Codes Wire Color Description Black Running Lights (common with Brown) Brown Running Lights (common with Black) White Ground Yellow Left Turn Signal Green Right Turn Signal Red Brake Lights Blue Charging System (Gas & Electric Only)
& Operation Manual Page 22 REVISION HISTORY Rev Date Rev Date Rev Date Rev Date Rev Date 1 5/24/2007