DMF ROTO-180 Quick start guide

DIVERSIFIED METAL FABRICATORS, INC.
DMF  665 Pylant Street  Atlanta, Georgia 30306
Parts [phone] Parts Fa [phone] [e-mail]
Service Department [phone] [e-mail]
Phone [phone]  Fa [phone] [e-mail]
http://www.dmfatlanta.com
Installation and
Parts & Servi e Manual
ROTO 180
September 2017
SERIAL NUMBER ________________________
NOTE:
Please refer to the serial numbers when ordering parts or
inquiring about warranty items.

DIVERSIFIED METAL FABRICATORS, INC. ROTO - 180
© 2017 DMF, Inc. All Rights Reserved.
Message from DMF
Thank you for choosing DMF ROTO-180. We make every effort to provide quality, safe and
rugged products for the railroad. We hope you'll find 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 our website listed below.
Contact:
Diversified Metal Fabricators
665 Pylant St. NE
Atlanta, GA 30306
[phone]
[phone] Fa
[phone] Parts
http://www.dmfatlanta.com
[e-mail]
Ship to:
668 Drewry St. NE
Atlanta, GA 30306

DIVERSIFIED METAL FABRICATORS, INC. ROTO 180
© 2017 DMF, Inc. All Rights Reserved.
T ABLE OF C ONTENTS
SECTION 1.0 GENERAL INFORMATION
1.1 General Description ..........................................................1-2
1.2 pecifications ..................................................................1-3
SECTION 2.0 OPERATIONS
2.1 Operations – HydraForce Manifold ......................................2-2
2.2 Operations – PVG Valves In Cab .........................................2-5
2.3 Operations – PVG Valves Wireless Remote ...........................2-10
2.4 Operations – PVG Valves Manual Operation .........................2-13
2.5 Operations – Post Dump Travel ..........................................2-16
SECTION 3.0 ROUTINE MAINTENANCE & TROUBLESHOOTING
3.1 Inspection and Maintenance ...............................................3-2
3.2 Lubrication pecification ....................................................3-3
3.3 Troubleshooting – HydraForce Manifold ...............................3-5
3.4 Troubleshooting – PVG Valves ............................................3-10
SECTION 4.0 ROTO 180 INSTALLATION
4.1 Pre-Installation ................................................................4-2
4.2 ubframe Mounting Procedure ...........................................4-5
4.3 Hydraulic ystem Connection – HydraForce Manifold.............4-8
4.4 Electrical Installation – HydraForce Manifold ........................4-10
4.5 Initial Operation – HydraForce Manifold ...............................4-12
4.6 Hydraulic ystem Connection – PVG Valves .........................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 Options ..........................................................5-4
5.4 Dump Body Options Continued ...........................................5-5
5.5 Dump Body Ladder Options ...............................................5-6
5.6 Dump Body pare Tire Carrier Assembly .............................5-7
5.7 Optional Vibrator ..............................................................5-8
5.8 Trailer Hitch Options .........................................................5-9
5.9 Fender Assembly ..............................................................5-10
5.10 Rubber tep Assembly LH ide ..........................................5-11
5.11 Rubber tep Assembly RH ide ..........................................5-12
SECTION 6.0 ROTO 180 H DRAULICS
6.1 HydraForce Manifold, Hydraulic chematic ...........................6-2
6.2 12’ ubframe, HydraForce Manifold, Hydraulic chematic ......6-3
6.3 14’ ubframe, HydraForce Manifold, Hydraulic chematic ......6-4
6.4 HydraForce Valve Manifold, Hydraulic chematic ..................6-5
6.5 Parker Manifold, Hydraulic chematic ..................................6-6
6.6 Parker Valve Manifold, Hydraulic chematic .........................6-7
6.7 5 ection PVG Valves, Hydraulic chematic..........................6-8
6.8 3 ection PVG Valves, Hydraulic chematic..........................6-9
6.9 12’ ubframe, PVG Valves, Hydraulic chematic ...................6-10
6.10 14’ ubframe, PVG Valves, Hydraulic chematic ...................6-11
6.11 2015 N/ pec, PVG Valves, Hydraulic chematic .................6-12

DIVERSIFIED METAL FABRICATORS, INC. ROTO 180
© 2017 DMF, Inc. All Rights Reserved.
6.12 HOC Hydraulic chematic ..................................................6-13
6.13 Hydraulic wing Cylinder, RH .............................................6-14
6.14 Hydraulic wing Cylinder, LH .............................................6-15
6.15 Hydraulic Tailgate Cylinder ................................................6-16
6.16 Cylinder Assembly Production Procedure .............................6-17
6.17 JIC Fitting Installation Procedure ........................................6-18
6.18 O-Ring Fitting Installation Procedure ...................................6-19
6.19 Pipe Fitting Installation Procedure .......................................6-20
SECTION 7.0 ROTO 180 ELECTRICAL
7.1 HydraForce Manifold, Electrical chematic, 3 Proximity
witches .........................................................................7-2
7.2 In Cab Control, 3 Proximity witches ..................................7-3
7.3 HydraForce Manifold ubframe, Electrical chematic, 3
Proximity witches ...........................................................7-4
7.4 Parker Manifold, Electrical chematic ..................................7-5
7.5 PVG Valves, Electrical chematic, Tarp, Vibrator & Wireless ...7-6
7.6 PVG Valves ubframe, Electrical chematic, Tarp & Vibrator ..7-7
7.7 PVG Valves, N/ ’15 Electrical chematic, Diamond
Logic & Plus 1 ..................................................................7-8
7.8 PVG Valves, Electrical chematic, Tarp & Vibrator .................7-9
7.9 Joystick for HydraForce Manifold ........................................7-10
7.10 Proximity witch Kit ..........................................................7-11
7.11 Limit witch Kit ................................................................7-12

DIVERSIFIED METAL FABRICATORS, INC. ROTO 180
© 2017 DMF, Inc. All Rights Reserved.
L IST OF F IGURES /T ABLES
Figure 2.1 HydraForce Mani old Dashboard Mounted Controls ................... 2-2
Figure 2.1.4.A Center Lock Pin Engaged ...................................................... 2-3
Figure 2.1.4.B Engaging the Center Lock Pin ................................................ 2-4
Figure 2.2.1.A PVG Joystick Assembly ......................................................... 2-6
Figure 2.2.1.B Keypad Top View ................................................................. 2-6
Figure 2.2.2 Keypad Top View & LED Locations.......................................... 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 o PVG Valves ............................................ 2-14
Figure 3.4.2 Keypad LED Identi ication ..................................................... 3-10
Figure 4.2.A Sub rame Mounting Location ................................................. 4-5
Figure 4.2.B Sub rame Component Location .............................................. 4-6
Figure 4.3.1 Sub rame Hydraulic Connections ........................................... 4-8
Figure 4.4 ROTO 180 Controls Cable ..................................................... 4-10
Figure 4.6.1.A 3 Section PVG Valves – Port Locations .................................... 4-13
Figure 4.6.1.B Sub rame Hydraulic & Electrical Connections ........................... 4-14
Figure 4.7 Joystick/Keypad Mount Wiring ............................................... 4-16
Figure 4.8 Joystick Movement............................................................... 4-19

DIVERSIFIED METAL FABRICATORS, INC. ROTO 180
© 2017 DMF, Inc. All Rights Reserved. 1-1
SECTION 1.0 GENERAL 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
1.2.2Hydraulic Requirements................................................................................. 1-3
1.2.3Rotating Sub-frame & Hoist............................................................................ 1-3
1.2.4Safety Features ............................................................................................ 1-3

DIVERSIFIED METAL FABRICATORS, INC. ROTO 180
1-2 © 2017 DMF, Inc. All Rights Reserved.
1.1 GENERAL DESCRIPTION
The DMF ROTO 180 system is a rotating dump body that allows the operator to deposit its load
anywhere within a 180° arc. Between the dump body and the truck chassis lays the
hydraulically actuated subframe. This two-piece structure contains a ball bearing that lets the
dump body rotate about the truck frame. Within the subframe are the hydraulic cylinders used
to lift and rotate the dump body. The standard ROTO 180 has a 12' long, 10-12 cubic yard
dump body; however there are also options for 10' long, 5-7 cubic yard and 14' long, 12-14
cubic yard models. Two control options are offered for the ROTO 180 system. See the following
sections for a description 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 solenoid valves to control the operation of
the manifold. The manifold controls the lift, rotation and tailgate functions of the dump body.
1.1.2 PVG Valve ROTO 180 System Controls
The PVG Valve ROTO 180 system uses a PVG valve block, mounted to the exterior of the
subframe, to control the hydraulic system. Proportional valves are used to smooth out the
movement of the lift cylinder and the rotation of the dump body. The system is controlled from
a keypad and joystick within the cab of the truck. It can also be controlled externally through
an optional wireless remote. All signals from these devices are routed through a PlusOne
control module. All major electronics and hydraulics are mounted outside of the subframe for
easy access and serviceability.

DIVERSIFIED METAL FABRICATORS, INC. ROTO 180
© 2017 DMF, Inc. All Rights Reserved. 1-3
1.2 SPECIFICATIONS
1.2.1 Standard Dump Body
•12’ subframe weight: 2180 lbs.
•Standard 12’ dump body: 6100 lbs.
•14’ subframe weight: 2690 lbs.
•Standard 14’ dump body: 6290 lbs.
•12’ dump body is 144” long and 40” high walls with optional side board pockets. See
Section 5 for other body options.
•14’ dump body is 168” long and 46” high walls with optional side board pockets. See
Section 5 for other body options.
•Apron – 30” long and full width of body, ¼” thk steel, fixed side plates and hinged to
dump body
•Inside width – 85”
•Tailgate height - varies
•Floor thickness – ¼”
•Side walls – 10 gauge 50,000 PSI yield steel
•Side braces – 10 gauge steel
•Tailgate – high tensile steel with formed top rail and boxed reinforcements
•Cross members – 3” x 2” x 11 gauge rectangular tubing
•Longitudinal members – 6” x 2” x ¼” rectangular tubing
1.2.2 Hydraulic Requirements
Power Source: PTO/pump 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 Height Above Frame Rail: 19" for 14’ Body, 18.5” for 12’ Body
Dump Angle: 40°
Hoist Cylinder: Telescoping (3 Stage Single Acting)
Hoist Cylinder Bore/Stroke: 6-5-4 x 111”
Turning Speed: 1/2 RPM
Swing Actuator: Hydraulic Cylinders
Thrust Bearing: Diameter -- 43"
Max. Moment Load -- 120,000 ft.-lbs.
Hydraulic Valves: Manifold/PVG Valve Block
1.2.4 Safety Features
The ROTO 180 system has built in safety features to keep personnel safe and equipment
functioning properly. The tailgate is set to automatically release at 22° to prevent sudden
shifts in load that could tip over the truck. This function may be overridden by the operator at
any time however at their own risk. The dump body is restricted to a 40° lift angle to prevent
overextending the hoist cylinder and damaging the rear of the truck and rear Railgear. A swing
alarm sounds whenever the dump body is rotated. A safety strut is provided for use when
servicing the dump body.

DIVERSIFIED METAL FABRICATORS, INC. ROTO 180
© 2017 DMF, Inc. All Rights Reserved. 2-1
SECTION 2.0 O PERATIONS
2.1 OPERATIONS – HYDRAFORCE MANIFOLD ........................................................ 2-2
2.1.1 Enable S stem.............................................................................................. 2-2
2.1.2 Disable S stem ............................................................................................. 2-2
2.1.3 Raising Bod – H draForce Manifold ................................................................ 2-2
2.1.4 Lowering Bod – H draForce Manifold ............................................................. 2-3
2.1.5 Swinging Bod – H draForce Manifold ............................................................. 2-4
2.2 OPERATIONS – PVG VALVES IN CAB ............................................................... 2-5
2.2.1 PVG Valves – In Cab Controls ......................................................................... 2-5
2.2.2 Enable S stem – Within Truck Cab .................................................................. 2-6
2.2.3 Disable S stem ............................................................................................. 2-7
2.2.4 Operator Presence Switch .............................................................................. 2-7
2.2.5 Raising Bod – In Cab Operation ..................................................................... 2-7
2.2.6 Lowering Bod – In Cab Operation .................................................................. 2-8
2.2.7 Swinging Bod – In Cab Operation .................................................................. 2-9
2.3 OPERATIONS – PVG VALVES WIRELESS REMOTE .......................................... 2-10
2.3.1 Enable S stem - Wireless Operation .............................................................. 2-10
2.3.2 Disable S stem – Wireless Operation ............................................................. 2-10
2.3.3 Raising Bod – Wireless Operation ................................................................ 2-11
2.3.4 Lowering Bod – Wireless Operation .............................................................. 2-11
2.3.5 Swinging Bod – Wireless Operation .............................................................. 2-12
2. OPERATIONS – PVG VALVES MANUAL OPERATION ....................................... 2-13
2.4.1 Raising Bod – Manual Operation .................................................................. 2-13
2.4.2 Lowering Bod – Manual Operation ............................................................... 2-14
2.4.3 Swinging Bod – Manual Operation ............................................................... 2-15
2.5 OPERATIONS – POST DUMP TRAVEL ............................................................. 2-16

DIVERSIFIED METAL FABRICATORS, INC. ROTO 180
2-2 © 2017 DMF, Inc. All Rights Reserved.
2.1 OPERATIONS – HYDRAFORCE MANIFOLD
The H draForce manifold is located within the ROTO 180 s stem subframe. The manifold is
controlled from a set of toggle switches mounted to the dashboard of the truck, see Figure 2.1.
If equipped, a vibrator toggle switch ma be included on this mount and a tarp control switch
mounted to the dashboard.
Figure 2.1 - HydraForce Manifold Dashboard Mounted Controls
2.1.1 Enable System
1. Engage the PTO as outlined in the PTO Operations Manual provided with the truck.
2. If the truck is equipped with a h draulic selector valve, shift it to activate the ROTO 180
s stem.
3. PULL out or toggle the “SYSTEM ENABLE” switch, to enable the s stem. The red light will
come on to indicate that the s stem is operational.
2.1.2 Disable System
1. PUSH in or toggle the switch, to disable the s stem. The red light will turn off to indicate
the end of the task.
2. Disengage the PTO as outlined in the PTO Operations Manual provided with the truck.
2.1.3 Raising Body – HydraForce Manifold
NOTE
Operation of the ROTO 180 s stem with the bod turned awa from the center position
requires the use of either manual or h draulic Raildogs to stabilize the truck. For
operation of Raildogs, refer to the separate “Raildog” manual.