600/700 SERIES PIVOT SQUEEZE

Transcription

1 00/00 SERIES PIVOT SQUEEZE -09

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3 Thank you for purchasing a DewEze Flatbed. TO THE OWNER OR OPERATOR: As with all Harper products, the 00 and 00 Series Flatbeds have been thoroughly tested and built to provide a sturdy, dependable product. The Flatbed is equipped with live hydraulics, which allows it to be used for a wide range of lifting and hauling tasks. This manual is written as an aid to operating and maintaining the DewEze Flatbed. Read and understand the manual thoroughly before operation to avoid damage to the unit or injury to the operator or bystanders. A Flatbed can present hazards to an operator who follows unsafe procedures in either the operation or maintenance of the unit. Therefore, SAFETY WARNINGS are present at certain locations in the text. Harper Industries is not responsible for accidents or injuries that result from the misuse or lack of maintenance of the Flatbed. SYMBOL: SAFETY WARNING! MEANING: Failure to understand and obey this warning may result in injury to you or others. Whenever this symbol is used, please pay very close attention to the information presented, and make sure you fully understand. If you do not, contact your dealer or Harper Industries for clarification. E. HWY. 0 Harper, KS 0 (0) 9- Fax (0) 9-9 Toll Free info@deweze.com Website 09 Harper Industries, Inc. The Harper and DewEze names and the ATM logo are registered trademarks of Harper Industries, Inc. All other brand and productnames are trademarks or registered trademarks of their respective companies.

4 Statement of Warranty Harper Industries, Inc. (HII) warrants to each purchaser of a new DewEze Flatbed from an authorized dealer or representative, that such equipment is free of manufacturer s defects in workmanship and materials which appear while in normal service for a period of TWO YEARS commencing with delivery to the original user. The Flatbed hydraulic and electrical systems are warranted for a period of ONE YEAR. The obligation of HII under this warranty is expressly limited, at our option, to replacement or repair at a service facility designated by Harper Industries or at the manufacturing plant in Harper, KS. A part will be replaced after inspection discloses it to have been defective. This warranty does not apply to defects caused by damage or unreasonable use (including failure to provide reasonable and necessary maintenance, or by performing functions without genuine DewEze Flatbed accessories) while in the possession of the consumer. Warranty is limited to parts, labor and ground freight delivery of replacement parts. Labor for repair to hydraulic and electrical power systems from HII installed with bed purchase/ installation is covered under this warranty. HII shall not be liable for the consequential damages of any kind, including but not limited to consequential labor costs or transportation charges in connection with replacement or repair of defective parts. This warranty does not apply to parts subjected to misuse, abuse, alteration, improper or inadequate maintenance, or normal wear. Harper Industries makes no warranty with respect to trade accessories. They are subject to the warranties of their respective manufacturers. ANY IMPLIED OR STATUTORY WARRANTIES, INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. HII makes no other express warranty, nor is anyone authorized to make any on behalf of HII. For further information please contact your nearest DewEze Flatbed dealer. RECORDS Date of Purchase / / Dealer s Name Dealer s Phone Serial Number Bed Serial Number Pump

5 Table of Contents OPERATOR SECTION To the Owner or Operator... Warranty Statement... Table of Contents... Specifications... Feature Identification... Safety Guidelines General Equipment Safety... Flatbed Operation Safety... Hydraulic Safety... Operating Instructions Beginning Operation... Loading... Extending (option)... Unloading... Unrolling... Storing the arms... Turning System Off... Maintenance Check Daily or Before Use... Lubrication... Hydraulic Oil... Hydraulic System... GatorHyde Protective Coating... Remote Control... Power Unit... Troubleshooting PARTS SECTION Standard Parts 00/00 Common Parts... Dual Lift Standard Parts... Parts Crosstube and Arms... XRM Crosstube and Arms... Hydraulics Hydraulics... XRM Hydraulics... Hydraulic Reservoir Assy... Valve and Filter... Gen. Valve Service Parts... Gen. Valve Service Parts... Electrical RF Control & Manual Switches... Hand Control Option... Switch, Clutch Control Assy... Lights and Harness... Appendices I GatorHyde Repair... II Remote Control... -Bank Wiring - Kar-Tech Remote... -Bank Wiring - Kar-Tech Remote... -Bank - Gen - Kar-Tech Remote... -Bank - Gen - Kar-Tech Remote... III Heavy Duty E/H Power Kit Install... HD E/H Kit... IV Independent Arm Control Hydraulics Replacements & Accessories Decals, Safety and Operation /00 Decals.... Cargo Lights.... Swingout Lights Toolbox & Fender Skirts Toolbox.... Toolbox.... Toolbox (fits 0 mounting) Toolbox....9 Across the Bed Toolbox....0 Spinners and Risers.... Other Accesssories.... Front Skirt Toolbox Replacement

6 Specifications DewEze flatbeds are specifically designed to transport and feed round hay bales. Model Specifications MODEL 0 9 WIDTH 9 9 LENGTH WEIGHT 00# 0# # 0# 0# 0# 0# # 0# MODEL 0 WIDTH LENGTH WEIGHT 0# 0# 0# 0# 0# 90# 0# * Length of all flatbeds includes for crosstube. Hydraulic System Specifications HYDRAULIC SYSTEM Powered by engine driven pump SYSTEM PRESSURE 0 psi OIL RESERVOIR CAPACITY 0 gallons OIL FILTER DewEze 00, WIX (0 micron) CYLINDER, LIFT ().0 x. CYLINDER, SQUEEZE.00 x.00. x.00 Rephasing Protective Coating Specifications PAINT GATORHYDE Heat-cured, polyurethane based paint Long-lasting, textured polyurea surface

7 Feature Identification A O B C N D E J I F M L G K H A. Headache Rack protects the rear pickup window. The hydraulic oil tank and valve are located in the headache rack. B. Across-the-bed Toolbox (optional) measures wide,. tall and. deep and has a shelf mounted inside. C & D. Spinners & Risers (optional) used to unroll hay. The risers allow the hugger arms to lie flat on the bed with the spinners attached. E. Hugger Arms squeeze together to grip the bale and lift it onto the flatbed. When the arms are stored they serve as side rails for the flatbed. F. Crosstube houses the squeeze cylinder and guides the hugger arms. G. Hitch Plate allows for a square receiver hitch and has holes for hitch pins. H. Safety Chain Loops always use safety chains when towing. I. Gooseneck Hitch located under a cover plate in the middle of the bed. J. Safety Chain Loops always use safety chains when towing. K. Lights LED lighting for stop-tail-turn has long life and low current draw. L & M. Skirts & Toolboxes (optional) mount under front of bed on both sides. The Electric/Hydraulic Power unit mounts inside the left toolbox. N. Dummy Arms serve as side rail along with hugger arms. O. Swing Lights (optional) lights can be pivoted out wider than the bale when working at night.

8 Specifications A. Valve Compartment houses the hydraulic control valve, hydraulic oil filter and the radio frequency receiver. B. Pioneer Couplers connect hydraulic hoses to the squeeze cylinder may also be used to connect to implements. C. Hydraulic Oil Fill & Dipstick check hydraulic oil level with dipstick fill here when necessary. Remote Control Transmitter operates all functions of the flatbed uses two AA batteries. SAFETY WARNING! Do not stand under the hugger arms when operating the bale pickup unit, even when arms are empty. Operator safety is of upmost concern when designing and developing a new piece of equipment. Designers and manufacturers build in as many safety features as possible. However, every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment. Most accidents can be avoided by observing the precautions in this section. To avoid personal injury, study the safety warnings and cautions listed in this manual and follow them. General Equipment Safety This equipment can be dangerous to children and persons unfamiliar with its operation. The operator should be a responsible adult familiar with farm machinery and trained for this unit. Do not attempt to operate equipment under the influence of drugs or alcohol. Do not allow persons to operate or assemble this unit until they have read this manual and have developed a thorough understanding of the safety precautions and how the unit works. Review the safety warnings and cautions with all users annually. If you have any questions not answered in this manual or require additional copies, contact your dealer or Harper Industries. Flatbed Operation Safety Replace any CAUTION, WARNING, DANGER or instruction decal that is not readable or is missing. Make sure all safety pins are in place and flatbed mounting bolts are secure to the truck frame. Make sure hinges, joints, and sliding parts are well greased, especially during off season to prevent rusting and binding.

9 Check with truck dealer for any load limits, additional suspension or tire requirements. The flatbed s lifting capability may exceed the truck s load capacity in some instances. Hydraulic Safety Do not operate the hydraulic system with the hood open. Do not activate the electric clutch unless the truck engine is at idle. Operating the clutch at road speeds can damage the hydraulic system. Lift the bale onto the truck. Release the bale and repeat the operation for the second bale. CAUTION: When hauling one bale, make sure it is held tightly and rests on the bed. When hauling two bales make sure the second bale is as far forward as possible (Fig. ). Carrying a bale behind the bed, as show in Fig, places excessive stress on the cylinder, linkage, and pins. SAFETY WARNING! Hydraulic system operates under high pressure and escaping fluid can penetrate the skin. Operating Instructions Beginning Operation Turn the pump switch on the dash to the ON position. (Red light will indicate that pump is on). CAUTION: In cold weather, let engine idle for -0 minutes with pump on before operating arms to warm oil. Neglecting to do so may cause hydraulic pump failure. Press and hold the power button on the transmitter until both LEDs turn on, then release. The green LED will flash rapidly when the communication has been established. If the receiver is off, the red LED will flash slowly. Press the corresponding buttons on the transmitter keypad to turn on and off each of the outputs. Loading Back truck against bale with the arms wide apart and tilted slightly upward. Squeeze arms firmly against the bale. CAUTION: Do not exceed GVRW rating of truck when loading. Two bales can easily exceed the GVRW on a ¾ ton truck. A typical ¾ ton truck can haul,00 lbs. of payload in addition to the flatbed. Extending (option) Always squeeze the bale with the arms in the retracted position. Extend the arms and release the bale. Fully retract the arms before laying them on the bed. CAUTION: Squeezing the bale when the arms are extended puts excessive force on the arms and cross-tube and may result in bending the unit. Unloading To unload, do the reverse of the loading operation. Spinners may sometimes be needed to grip the front bale for unloading. Unrolling (option) Use risers and spinners to unroll a bale. Position the arms over the bale so the spinners are at the center of the bale.

10 To unroll, lower the bale to the ground. Turn the pump off and push the FLOAT switch on the remote control. Slowly drive STRAIGHT forward. The bale will gradually unroll. CAUTION: Turning while unrolling a bale may cause hugger arms to bend. CAUTION: Failure to use FLOAT while unrolling may damage flatbed frame or lift cylinder. The FLOAT switch on the remote transmitter stays on until it is pressed a second time or another switch is activated. To avoid power loss, always deactivate the FLOAT when not in use. Storing the Arms Close the arms partially and lay them on the flatbed. Open the arms until they are flush with the side of the bed. They now function with the dummy arms as side rails. Turning System Off Turn the pump off when it is not in use. The remote control turns itself off automatically after 0 minutes. CAUTION: Operating truck at road speeds or above,000 RPM with pump engaged may cause hydraulic pump failure. Maintenance Lubrication Grease the locations indicated in the illustrations below once per week while the unit is in use and at the end of each season (same locations on right and left).. Lift cylinder rod end. Cross-tube hinge. Idler arm base. Idler link pin SAFETY WARNING! Use extreme caution when greasing the flatbed. Completely lower arms to expose rear zerks and turn off ignition.. Pivot. Riser (option) Check Daily or Before Use Check the hydraulic oil level. Keep the level to FULL on the dipstick. Check the belt, belt tensioner and idler pulleys on engine clutch pump system. Examine the hydraulic hoses for leaks with an object such as cardboard. SAFETY WARNING! Hydraulic fluid escaping under pressure can penetrate the skin and may cause death if not treated immediately.

11 Hydraulic Oil Hydraulic fluid selection will affect the performance of the hydraulic system. For easy hookup of the couplers, turn the pump switch off and activate the control valve switches with the ignition on. This will release pressure in the lines. GatorHyde Protective Coating In the event that damage should occur to the GatorHyde protective coating, repair materials are available from your DewEze dealer to fix small areas. Follow the instructions provided in Appendix I. Consult your local oil supplier for help in selection of a hydraulic fluid appropriate for your area. Consideration will also need to be given as to whether the system is a clutch pump or electric over hydraulic. Change the hydraulic oil filter after the first 0 hours of use and then every 0 hours, or annually thereafter. Change the hydraulic oil if it becomes contaminated or turns milky in appearance. If other hydraulic equipment is connected to the system, the oil will intermix and cold weather viscosity may be lost. Hydraulic System If the quick-couplers leak, the o-rings may need to be replaced. High heat, 90 or greater, can be damaging to the hydraulic system. Feel various parts of the system to make sure there are no hot spots which may indicate a problem. In the off season, run the bed at least twice a month to prevent valve condensation. Remote Control The remote control transmitter has two LED indicators, the green TRANSMIT indicator and the red BATTERY / DIAGNOSTIC indicator. The green TRANSMIT indicator flashes rapidly whenever there is communication between the transmitter and the receiver. The red BATTERY / DIAGNOSTIC indicator starts blinking once every second when the battery voltage is low and requires replacement. It also blinks when there is a problem with the system in the form of an error code. Refer to the ERROR CODE CHART in Appendix II. To synchronize a new transmitter and receiver together, refer to the TEACH ID CODE instructions in Appendix II. Power Unit If the flatbed is powered with a DewEze Under-the-Hood hydraulic system, refer to the following chart when troubleshooting. See Appendix III if the flatbed is powered with the Electric/Hydraulic power unit. 9

12 Troubleshooting Problem Symptom Hydraulic Pump Hydraulic Pump Clutch Belt(s) Possible Solutions No Oil Flow CHECK OIL LEVEL IN RESERVOIR. If oil level is low, check for leaks in system then re-fill to FULL. CHECK BELT TENSION. Replace tensioner or tighten idlers if needed. Replace belt if worn. CHECK FOR SHEARED KEY ON PUMP SHAFT. Replace key. CHECK IF SUCTION HOSE COLLAPSES IN SUCTION. Locate and remove obstruction. CLUTCH NOT FUNCTIONING. See possible clutch solutions. INTERNAL PUMP DAMAGE. Seek assistance from dealer. No Oil Pressure Does Not Engage Jumps Off Pulley HYDRAULIC OIL LEAKS IN SYSTEM. Take safety precautions and check for leaks. Tighten fittings and replace damaged hoses. CHECK FOR MALFUNCTIONING SWITCH. Replace switches. BELT OR CLUTCH MAY BE SLIPPING. Replace tensioner or tighten idlers if needed. Replace belt if worn. VALVE NOT FUNCTIONING. Check for disconnected wires at solenoid or rusted ground wires. Seek assistance from dealer if valve continues to be unresponsive. PRESSURE RELIEF MAY BE SET TOO LOW OR BROKEN. Seek assistance from dealer. CAUTION: PRESSURE EXCEEDING,00 PSI CAN DAMAGE THE PUMP. PUMP IS WORN OR DAMAGED. Seek assistance from dealer. CHECK FOR BLOWN FUSE. Replace fuse. CAUTION: FUSE SHOULD NOT EXCEED 0 AMPS CHECK WIRE TO CLUTCH. Insure there are no breaks or shorts. CHECK FOR BAD SWITCHES IN SYSTEM. Replace switches. CLUTCH IS WORN OUT. Seek assistance from dealer. BELT(S) TOO LOOSE. Replace tensioner or tighten idler pulleys. CHECK FOR EXCESSIVE BELT WEAR. Replace worn belt(s). CHECK FOR LOOSE PUMP BRACKET. Tighten loose bolts. Replace broken bolts. CHECK CRANKSHAFT PULLEY FOR LOOSE OR BROKEN BOLTS. Tighten loose bolts. Replace broken bolts. CHECK ALIGNMENT OF IDLER PULLEYS AND CONDITION OF BEARINGS. Re-align idler pulleys or replace worn idler pulleys. CHECK ALIGNMENT OF CLUTCH AND CRANKSHAFT PULLEY. If misalignment is visible, seek assistance from dealer. SAFETY WARNING! Use extreme caution when inspecting an engine. Serious injury or death could result from getting too close! Remove key from ignition when servicing. 0

13 PIVOT SQUEEZE PARTS

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15 Table of Contents PARTS SECTION Standard Parts 00/00 Common Parts... Dual Lift Standard Parts..... Parts Crosstube and Arms... XRM Crosstube and Arms..... Hydraulics Hydraulics... XRM Hydraulics... Hydraulic Reservoir Assy... Valve and Filter... Gen. Valve Service Parts... Gen. Valve Service Parts... Electrical RF Control & Manual Switches... Hand Control Option... Switch, Clutch Control Assy... Lights and Harness... Appendices I GatorHyde Repair... II Remote Control... -Bank Wiring - Kar-Tech Remote... -Bank Wiring - Kar-Tech Remote... -Bank - Gen - Kar-Tech Remote... -Bank - Gen - Kar-Tech Remote... III Heavy Duty E/H Power Kit Install... HD E/H Kit... IV Independent Arm Control Hydraulics Replacements & Accessories Decals, Safety and Operation /00 Decals.... Cargo Lights.... Swingout Lights.... LED Cargo Lights.... LED Swingout Lights Toolbox & Fender Skirts Toolbox.... Toolbox....9 Toolbox (fits 0 mounting) Toolbox.... Across the Bed Toolbox.... Spinners and Risers.... Other Accesssories.... Front Skirt Toolbox Replacement

16 0 DUMMY ARM LEFT MUDFLAP, WIDE 0 -- MUDFLAP, NARROW 00 & 00 Series Common Parts DUMMY ARM RIGHT 9 0 //0.

17 00 & 00 Series Common Parts Dummy Arms Left & Right Part # ITEM QTY PART # Parts List WASHER, /" FLAT SAE BOLT, /- X. SHCS NUT, /- U-TYPE.L BOLT, /- X. BOLT, /- X, WIZ FLANGE NUT, /- WIZ FLANGE WASHER, /" FLAT STANDARD WASHER, /" LOCK WASHER, /" FLAT STANDARD NUT, /- U-TYPE.L NUT, /- GR Bolt, /- X in Carriage INSTALL HARDWARE HITCH BALL AND NUT VALVE COVER EDGE TRIM, VALVE COVER BALL WELL DOOR WELDMENT CENTER TAILBOARD DOOR WELDMENT, UPPER CENTER TAILBOARD, LOWER, ARM BED //0 ii.

18 0 9 Dual Lift Common Parts /9/0.

19 Dual Lift Common Parts Dual Lift Cylinders Production Part# 0 Seal Kit Part# 0 ITEM QTY 0 PART # Parts List BOLT, - X 0, GR BOLT, /- X 0., WIZ FLANGE WASHER, " LOCK ADAPTER, MJ-MJ-MJ ADAPTER, MJ-MB ROLL PIN, / X SPRING, " O.D. X " L X.0 WIRE IDLER ARM, MACHINE DWG. PUSH ARM ASSY, DUAL LIFT PIN WELDMENT, -/ X PIN WELDMENT, -/ X KEEPER, IN NUT, WELDMENT PIN WELDMENT, CROSSTUBE LINK COUPLER, PIONEER FEMALE HOSE ASSY, FLATBED DUAL LIFT HOSE ASSY, FLATBED SQUEEZE SHORT LIFT CYLINDER.0 X. MOUNT, HOSE SPRING GREASE ZERK, /- ST WITH GENERATION VALVES COMMON HOSES SQUEEZE HOSES SHORT LIFT HOSES SHORT RESERVOIR RETURN HYDRAULIC MTF - FJX / MP MK - FJX / FJX -0FJX / -MPX90 HOSE KIT # ea. ea. ea. 0 ( in.) 0 ( in.) 09 (. in.) 0 FLATBED LENGTH SQUEEZE HOSES LIFT HOSES MK - FJX / MJ MK - FJX / FJX ea. ea. 0 in. _0 0 (0 in.) 0 ( in.) 0 9 in. _ & _ 0 ( in.) 0 (99 in.) in. _ & _, _9 & _ 0 ( in.) 09 ( in.) 0 - in. _ & _ 0 ( in.) 090 ( in.) 0 /9/0 ii.

20 0 Dual Lift Common Hydraulics With Generation Valve 9 9 //0..

21 Dual Lift Common Hydraulics With Generation Valve Dual Lift Cylinders Production Part# 0 Seal Kit Part# 0 ITEM QTY 0 PART # Parts List BOLT, - X 0, GR BOLT, /- X 0., WIZ FLANGE WASHER, " LOCK ADAPTER, MJ-MJ-MJ ADAPTER, MJ-MB ROLL PIN, / X SPRING, " O.D. X " L X.0 WIRE IDLER ARM, MACHINE DWG. PUSH ARM ASSY, DUAL LIFT PIN WELDMENT, -/ X PIN WELDMENT, -/ X KEEPER, IN NUT, WELDMENT PIN WELDMENT, CROSSTUBE LINK COUPLER, PIONEER FEMALE HOSE ASSY, FLATBED DUAL LIFT HOSE ASSY, FLATBED SQUEEZE SHORT LIFT CYLINDER.0 X. MOUNT, HOSE SPRING GREASE ZERK, /- ST WITH GENERATION VALVES COMMON HOSES SQUEEZE HOSES SHORT LIFT HOSES SHORT RESERVOIR RETURN MTF - FJX / MP MK - FJX / FJX -0FJX / -FJX ea. ea. ea. HYDRAULIC HOSE KIT # 0 ( in.) 0 ( in.) 0 ( in.) 0 FLATBED LENGTH SQUEEZE HOSES LIFT HOSES MK - FJX / MJ MK - FJX / FJX ea. ea. 0 in. _0, _ 0 (0 in.) 0 ( in.) 0 9 &0 in. _, _ & _ 0 ( in.) 0 (99 in.) in. _ & _, _9 & _ 0 ( in.) 09 ( in.) 0 - in. _ & _ 0 ( in.) 090 ( in.) 0 //0 ii..

22 Crosstube & Arms 0 9 Parts List ITEM QTY PART # 0 BOLT, /- X 0., WIZ FLANGE 0 0 BOLT, /- X 0., WIZ FLANGE 000 ROLL PIN, / X 00 BUSHING,. X. X.0 SPLIT CG/ID 0 PIN WELDMENT, -/ X Weldment, Arm Left Weldment, Arm Right 9 Weldment, Pivot Pin 9 00 Shim Washer 0 00 Shield, Pivot Arm, Left 00 Shield, Pivot Arm, Right 0 0 GREASE ZERK, /- ST Crosstubes Bed Width Bed #'s Part #. 9.0 & 0 9. /9/0.

23 Crosstube & Arms Starting S/N's Parts List ITEM QTY PART # 0 BOLT, /- X 0., WIZ FLANGE 0 0 BOLT, /- X 0., WIZ FLANGE 000 ROLL PIN, / X 00 BUSHING,. X. X.0 SPLIT CG/ID 0 PIN WELDMENT, -/ X Weldment, Arm Left Weldment, Arm Right 9 Weldment, Pivot Pin 9 00 Shim Washer 0 0 Shield, Pivot Arm 0 0 GREASE ZERK, /- ST 0 Crosstubes Bed Width Bed #'s Part #. 0,,,, & 9 9.0,, & ,,,, & //0..

24 ITEM QTY //0 PART # Parts List BOLT, /- X 0., WIZ FLANGE BOLT, /- X 0., WIZ FLANGE Heavy JamHexNut _-0 UNC ROLL PIN, / X BUSHING,. X. X.0 SPLIT CG/ID CYLINDER PIN PIN WELDMENT, -/ X Weldment, Pivot Pin Weldment, XRM Arm Left Weldment, XRM Arm Right Weldment, Pivot Extension Arm, Left Weldment, Pivot Extension Arm, Right Shim Washer Spacer,. x., C'Sink Bushing,.0 x. x. Bolt, /-0 x.0 FH SCHS Shield, Pivot Arm GREASE ZERK, /- ST 9 XRM Crosstube & Arms 0 XRM Crosstubes Bed Width Bed #'s Part #. 0,,,, & 9 9.0,, & 9. 0,,,,, &.

25 ITEM.. QTY PART # Parts List ADAPTER, MJ-MB Pivot Cylinder,.0 x.0 Seal Kit Pivot Cylinder,. x.0 Seal Kit Shim Washer COUPLER, PIONEER MALE Hydraulics Hoses Hoses Crossover 0 (in) 0 (.in) 0 (in) Short 0 (in) 0 (0in) 0 (in) Long 0 (in) 0 (in) 0 (in) Kit number Crossover Long Short.. LEFT BIG RIGHT SMALL /9/0.

26 ITEM QTY PART # Parts List ADAPTER, MJ-MB90 SWITCH BOOT Valve, rd Bank add on (0) SWITCH, DPDT, M, PIN, PUSH ON PORT # RIGHT SIDE -BASE- PORT # LEFT SIDE -ROD- XRM Hydraulics ITEM QTY PART # Parts List ADAPTER, MJ-MJ ADAPTER, MJ-MB EXTENSION CYLINDER. EXTENSION CYLINDER.0 9//0.

27 XRM Hydraulics RIGHT BIG SMALL LEFT XRM Valve Hoses Hoses Pivot XRM Front to Back (ea) 0 ( in) 09 ( in) 0 ( in) 0 (in) Kit XRM Hoses Hoses XRM Crossover 0 ( in) 0 ( in) 0 ( in) XRM To Valve 0 (9 in) 0 ( in) 0 (0 in) Kit number //0 ii.

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29 HYDRAULIC ASSEMBLY RESERVOIR 0 & GALLON SYSTEM PART # QTY 09 ADAPTER, 0MB-0BH 00 HOSE CLAMP, #, & 9 GALLON SYSTEM PART # QTY 0 ADAPTER, MB-BH 0 ADAPTER, 0MB-FOR 00 HOSE CLAMP, #0 9 ITEM 9 0 PART # QTY Parts List NUT, /-0 WIZ FLANGE BOLT, /-0 X 0., WIZ FLANGE BOLT, /- X 0., WIZ FLANGE NUT, /", J-TYPE, CAGE,.C ADAPTER, BH-MP ADAPTER, MJ-MP ADAPTER, MJ-MB90 DIP STICK VENT HOSE FILTER TO RESERVOIR HOSE Reservoir, Flatbed, Remote Filter MOUNTING BRACKET, FILTER FITTING, PLUG /" PIPE FUEL FILTER //0.

30 ITEM 9 0 QTY PART # Parts List BOLT, /- X.0 NUT, /- WASHER, /" LOCK ADAPTER, MJ-MB90 ADAPTER, MJ-MB ADAPTER, MJ-MB90 ADAPTER, 0MJ-MB NUT, /-0 WIZ FLANGE BOLT, /-0 X 0., WIZ FLANGE ADAPTER, MJ-MP RESERVOIR RETURN MOUNTING BRACKET, FILTER FILTER HEAD FILTER, 0 MICRON 09 Valve, Check With.0 Orifice 0 Flatbed Valve, Small, Hydac Spade 9 9 Valve & Filter 0 SQUEEZE CYLINDER - OUT - LIFT CYLINDER - BASE - SQUEEZE CYLINDER - IN - LIFT CYLINDER - ROD - /9/0.

31 ITEM QTY PART # LIFT CYLINDER - ROD - ** CHECK VALVE 09 TO THIS PORT LIFT CYLINDER - BASE - Parts List BOLT, /- X.0 NUT, /- WASHER, /" LOCK ADAPTER, MJ-MB90 ADAPTER, MJ-MB ADAPTER, MJ-MB90 ADAPTER, 0MJ-MB NUT, /-0 WIZ FLANGE BOLT, /-0 X 0., WIZ FLANGE ADAPTER, MJ-MP MOUNTING BRACKET, FILTER FILTER HEAD FILTER, 0 MICRON HOSE, VALVE TO FILTER Valve, Check With.0 Orifice Flatbed Valve, Small, Monoblock Ver II SQUEEZE CYLINDER - IN - SQUEEZE CYLINDER - OUT - Valve & Filter Gen Double Poppet ** TO PORT # **** & Gallon System Adapter MJ-MB Also As Required 0 -- Adapter mj-fjx Adapter mj-fjx90 9//0..

32 GEN VALVE -0 HYDAC DUAL SPADE SERVICE PARTS Flatbed Valve, Small, Hydac Spade P/N 0 ITEM QTY PART # 00 O-Ring Plug, # /-0 00 Valve, Directional, -Way ITEM QTY PART # 00 Valve, Pressure Relief 0 BOLT, /- X.0 SHCS 00 Cartridge, # HYDAC Double Poppet 0 O'RING, -9, 90 DURO 0 Coil, # Hydac, Dual Spade 00 Valve, Poppet N.C. SOL VALVE 0 O-Ring Plug, # /- 09 COIL, #0 DUAL SPADE 09 COIL, #0 DUAL SPADE 0 Spool, #0 Valve VALVE, rd BANK ADD ON P/N 0 //0.

33 GEN VALVE -0 HYDAC DEUTSCH SERVICE PARTS Starting S/N's 0 Flatbed Valve, Small, Hydac Deutsch P/N 0 ITEM QTY PART # 00 O-Ring Plug, # /-0 00 Valve, Pressure Relief 00 Cartridge, # HYDAC Double Poppet 0 #0 SOLENOID, POSITION WAY 00 Coil, # Hydac, Deutsch DT0-P #0 E-COIL, VDC, DEUTSCH DT0-P 0 O-Ring Plug, # /- 0 Spool, #0 Valve Valve, rd Bank add on P/N 0 ITEM QTY PART # 0 BOLT, /- X.0 SHCS 0 O'RING, -9, 90 DURO 00 Valve, Poppet N.C. SOL VALVE #0 E-COIL, VDC, DEUTSCH DT0-P //0.

34 GEN VALVE -0 EATON DEUTSCH SERVICE PARTS Starting S/N's Late 0 Flatbed Valve, Small, Eaton Deutsch P/N 0 ITEM QTY PART # 00 O-Ring Plug, # /-0 00 Valve, Pressure Relief 0 #0 SOLENOID, POSITION WAY 0 Valve, # Eaton, Dbl Poppet 0 Coil, # Eaton, V, Deutsch DT0-P #0 E-COIL, VDC, DEUTSCH DT0-P 0 O-Ring Plug, # /- 0 Spool, #0 Valve Valve, rd Bank add on P/N 0 ITEM QTY PART # 0 BOLT, /- X.0 SHCS 0 O'RING, -9, 90 DURO 00 Valve, Poppet N.C. SOL VALVE #0 E-COIL, VDC, DEUTSCH DT0-P //0..

35 Flatbed Valve, Small, Hydac Deutsch P/N 0 ITEM QTY PART # 00 O-Ring Plug, # /-0 00 Valve, Pressure Relief 00 Cartridge, # HYDAC Double Poppet 0 #0 SOLENOID, POSITION WAY 09 Coil, # Hydac, DT0-P Suppressed 0 O-Ring Plug, # /- 0 Spool, #0 Valve 99 Coil, #0 Hydraforce, DT0-P Suppressed LIFT CYLINDER -ROD- CHECK VALVE 09 TO THIS PORT LIFT CYLINDER -BASE- Flatbed Valve -0 Hydac Deutsch Service Parts Starting S/N s Late 0 SQUEEZE CYLINDER -ROD- SQUEEZE CYLINDER -BASE- Valve, rd Bank add on P/N 0 ITEM QTY PART # 0 BOLT, /- X.0 SHCS 0 O'RING, -9, 90 DURO 00 Valve, Poppet N.C. SOL VALVE 99 Coil, #0 Hydraforce, DT0-P Suppressed /9/0..

36 RF Control & Manual Switches 9 0 ITEM 9 0 Parts List QTY PART # 09 NUT, 0- LOCK 0 BOLT, 0- X. STAINLESS, PHILLIPS 0 PLUG, /" BUTTON PLASTIC 0 Switch, Spst, Toggle.0 Tab 0 SWITCH BOOT Switch, Toggle, DPDT, (On)-OFF-(ON) 000 DECAL, SWITCH IDENTIFICATION 00 Transmitter & Receiver, Kar-Tech 00 Transmitter, Kar-Tech Two AA Batteries Part # Note: Optional Latching Switch On-Off-On is Available //0.

37 Hand Control 00 Flatbed Hand Control Options Bank Bank Wiring Diagram Switches Shown From Back Side Wiring Diagram Switches Shown From Back Side Hand Control 00 RETRACT EXTEND UNLOAD LOAD IN OUT UNLOAD LOAD IN OUT GREEN BLACK YELLOW BROWN BLUE RED BRN BLU GRN YEL RED BLK GREEN BLACK YELLOW BROWN BLUE RED Plug in Hand Control in Place of Receiver on Flatbed Valve Harness # 09 BRN GRN RED BLU YEL BLK RED GRN GRN /YEL Harness 0 PUR YEL BLU GRN/YEL ORG BLU 0 9 RED BRN YEL PUR GRN GRY WHY ORG BLU 0 9 RED BRN YEL PUR GRN RED GRN GRY Harness 0 PUR YEL BLU //0.

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40 Lights & Harness For S/N's after A0 Thru June 0 Wiring Harness Assemblies Harness Part # Front Marker 0 I.D. & License 09 Rear Tailboard 09 Headache Rack Left 0 Headache Rack Right 0 Body Harness Short 0 Body Harness Long (- & -) 0 ITEM QTY PART # Parts List GROMMET, " LIGHT, GROMMET OVAL LIGHT, OVAL LED, S/T/T LIGHT, OVAL LED, BACK-UP LIGHT, " ROUND LED, AMBER LIGHT, " ROUND LED, RED LIGHT, /" ROUND, LED, RED LIGHT, LICENSE PLATE, LED W/.0 BULLETS 9//0.

41 Lights & Harness For S/N's after June 0 Wiring Harness Assemblies Harness Part # Rear Tailboard, Female Pin Front Marker, Half Headache Rack Left, Headache Rack Right, 0 Body Harness Short Body Harness Long (- & -) ITEM QTY PART # 9 0 Parts List Grommet, " Oval, Grote Grommet, " Round, Grote Light, Oval, S/T/T, Male Pin, Grote Light, Oval, S/T/T, BackUp, Male Pin, Grote Light, " Round, Amber, Grote Light, " Round, Red, Grote Light, /" Round, Red, Grote 9 Light, License Plate, w/plug, Grote //0..

42 BOTH SIDES Decals Safety & Operation 000 INSIDE OF VALVE COVER BANK rd BANK PART # QTY 0000 DANGER DECAL, HORIZONTAL 00 BALE PIK-UP, SILVER SCRIPT 00 DANGER DECAL, VERTICAL 00 DEWEZE, SILVER OUTLINE 0090 REFLECTIVE DECAL 000 DECAL, SWITCH IDENTIFICATION 00 DECAL, WIRING DIAGRAM, KAR-TECH REMOTE 00 DECAL, rd BANK OPTION, KAR-TECH REMOTE 000 DECAL, PIVOT 00 DECAL, DOUBLE POPPET VALVE 0000 FEMA DECAL IT IS THE OWNER'S RESPONSIBILITY TO REPLACE MISSING OR DAMAGED WARNING DECALS. DECALS ARE AVAILABLE FROM YOUR DEALER OR FROM THE DEWEZE FACTORY //0.

43 BOTH SIDES Decals Safety & Operation 000 INSIDE OF VALVE COVER BANK rd BANK PART # QTY 0000 DANGER DECAL, HORIZONTAL 0 BALE PIK-UP, SCRIPT, WARM SILVER 00 DANGER DECAL, VERTICAL 0 DEWEZE, OUTLINE, WARM SILVER 0090 REFLECTIVE DECAL 000 DECAL, SWITCH IDENTIFICATION 00 DECAL, DOUBLE POPPET VALVE 00 DECAL, WIRING DIAGRAM, KAR-TECH REMOTE 00 DECAL, rd BANK OPTION, KAR-TECH REMOTE 0000 FEMA DECAL 000 DECAL, SHIELD REMOVED 0 0 IT IS THE OWNER'S RESPONSIBILITY TO REPLACE MISSING OR DAMAGED WARNING DECALS. DECALS ARE AVAILABLE FROM YOUR DEALER OR FROM THE DEWEZE FACTORY. 000 //0..

44 00 & 00 Series Decals Model # Decals Left & Right Part # Qty Decal Kit, -00 Series Part # 00 PART # QTY 0000 DANGER DECAL, HORIZONTAL 00 BALE PIK-UP, SILVER SCRIPT 00 DANGER DECAL, VERTICAL 00 DEWEZE, SILVER OUTLINE 0090 REFLECTIVE DECAL 000 DECAL, SWITCH IDENTIFICATION 00 DECAL, WIRING DIAGRAM, KAR-TECH REMOTE 00 DECAL, rd BANK OPTION, KAR-TECH REMOTE 0000 FEMA DECAL 000 DECAL, SHIELD REMOVED Left Right PIN STRIPE /" SILVER 00 PIN STRIPE /" BLACK 00 PIN STRIPE /" SILVER 00 //0.

45 0 Model # Decals Left & Right Part # Qty PIN STRIPE WARM SILVER & 00 Series Pivot Decals Decal Kit, -00 Series Part # 0 Part # Qty Description 0000 Decal, Danger Red On White 0 Decal, Bale Pik-up Script, Warm Silver 00 Decal, Danger Vertical 0 Decal, Deweze Outline, Warm Silver 0090 Decal, Red Reflector, Rectangle 009 ft. Decal, Pin Stripe, Warm Silver 0 Decal, Squeeze Arm, Left 0 Decal, Squeeze Arm, Right 0000 Decal, Fema 000 Decal, Shield Removed PIN STRIPE WARM SILVER 009 Left -- 0 Right -- 0 Left -- 0 Right PIN STRIPE WARM SILVER 009 //0..

46 ITEM QTY Cargo Light Assy, Part# 9 PART # LIGHT BRACKET, RIGHT LIGHT BRACKET, LEFT GROMMET, / ID X 9/ OD SCREW, / X. TEK SELF-TAP WORK LIGHT, LEFT WORK LIGHT, RIGHT NOT SHOWN Wire, ga, Black 000 Terminal, Scotch Lock 0 Switch, Spst, Toggle.0 Tab 0 Boot, / Toogle Switch Seal 00 Terminal, Ring, 0- Ga, / 000 Terminal, Butt Connector,- 000 Terminal, Ring, -ga, 0- Flatbed Accessories Cargo Lights /9/0.

47 9 Flatbed Accessories Swingout Lights 9 0 ITEM QTY 0' Swing Light Kit, Part# 00 PART # 000 BOLT, /- X., WIZ FLANGE 00 BOLT, /- X, WIZ FLANGE 0 NUT, /- LOCK NYLON INSERT 0 WASHER, /" FLAT STANDARD 0 WASHER, /" FLAT STANDARD 0 NUT, /- LOCK NYLON SWING LIGHT MOUNT, LEFT SWING LIGHT MOUNT, RIGHT SWING LIGHT ARM, LEFT SWING LIGHT ARM, RIGHT LIGHT MOUNT FRICTION MOUNTING PLATE FRICTION WASHER." SWING LIGHT, RUBBER SEAL 9 SWINGLIGHT EDGE TRIM 0 GROMMET, / ID X 9/ OD 0 SCREW, / X TEK SELF-TAP 00 WORK LIGHT, LEFT 00 WORK LIGHT, RIGHT NOT SHOWN 000 WIRE, GA BLACK 00 TERMINAL, RING, -GA /" 0 Switch, Spst, Toggle.0 Tab 0 Boot, / Toogle Switch Seal 000 TERMINAL, BUTT CONNECTOR, TERMINAL, RING, -GA. 0- /9/0.

48 Flatbed Accessories Cargo Lights LED 9 ITEM 9 0 QTY ft Cargo Light Kit, Part# 0 PART # 000 Wire, ga Black 0 SWITCH BOOT Light, LED, " Rect. Flood Switch, Toggle, SPST, On-Off Terminal, Butt Connector, -, Heat Shrink Terminal, Ring, -, /", Heat Shrink 9 Terminal, Multi-Wire Butt Connector, Heat Shrink 0 Bracket, Cargo Light 0 SCREW, / X TEK SELF-TAP Harness, Packard to Packard, Terminal //0.

49 Flatbed Accessories Swingout Lights LED ITEM QTY ft Swingout Light Kit, Part# 0 PART # 00 NUT, M X., LOCK NYLON 00 BOLT, /- X, WIZ FLANGE 0 NUT, /- LOCK NYLON INSERT 0 WASHER, /" FLAT STANDARD 000 Wire, ga Black 0 SWITCH BOOT Light, LED, " Rect. Flood Switch, Toggle, SPST, On-Off Terminal, Butt Connector, -, Heat Shrink Terminal, Ring, -, /", Heat Shrink 9 Terminal, Multi-Wire Butt Connector, Heat Shrink FRICTION WASHER." 9 SWINGLIGHT EDGE TRIM 0 Bracket, Swing Light, Base, Right 0 Bracket, Swing Light, Base, Left 0 Bracket, Swing Light, Arm, Right 0 Bracket, Swing Light, Arm, Left 0 SCREW, / X TEK SELF-TAP Harness, Packard to Packard, Terminal //0.

50

51 ITEM Toolbox Complete W/Step, Part# 00 QTY. ft PART # Traction Pad DECAL, CHIP GUARD STEP, TOOLBOX SHIELD, TOP & SIDE TOOLBOX ASSEMBLY, FLATBED BOLT PACKAGE 009 Washer, / X / Fender 0 Nut, /-, Cage,.-.t 0 Bolt, /- X /, Wiz Flng Gr Zinc 0 Bolt, /- X. Wiz Flng Gr Zinc 00 Nut, /-, Wiz Flng 0 Nut, /-, Wiz Flng 0 Washer, / Flat Standard 0 Washer, / Flat Standard, Zinc TOOLBOX COMPLETE, PART# 0 PART # QTY 0 Nut, /-0, Lock (-way) 0 Pushnut, Flat Round Type 09 Clevis Pin, / X / Zinc 000 Seal, Tool Box Lid 9 Mat, Toolbox 0" 00 Gasket, Tool Box Mount use DK Foam 0 Latch, Toolbox w/studs, Key & Gasket 0 Weldment, Tool Box Door & Hinge 0 Weldment, Tool Box & Hinge Flatbed Accessories 0" Toolbox Fender Skirts Fender Skirt Fender Skirts Kits Left Right 00 Series Short Long N/A Series Short Long N/A 00 Series Short Long Series Short Long //0.

52 ITEM 9 0 Toolbox Complete W/Step, 0" Part# 000 QTY PART # 0 NUT, /-0 LOCK -WAY 0 PUSH NUT, WASHER CAP STYLE 09 CLEVIS PIN, STD ZP / X / 000 DECAL, CHIP GUARD 000 SEAL, TOOLBOX LID (TRIM-LOK X-9) 00 BOLT PACKAGE 009 WASHER, / X.0 FENDER 0 NUT, /-, CAGE TINNERMAN 0 BOLT, /- X 0., WIZ FLANGE 0 BOLT, /- X 0., WIZ FLANGE 00 NUT, /- WIZ FLANGE 0 NUT, /- WIZ FLANGE 0 WASHER, /" FLAT STANDARD 0 WASHER, /" FLAT STANDARD 09 STEP, TOOLBOX 009 Traction Pad TOOLBOX MAT 0" 9 TOOLBOX CHIP GUARD 0" 00 GASKET, TOOLBOX MOUNT 0 Latch, Toolbox w/studs, Key & Gasket 0 Gasket, Toolbox Latch TOOLBOX & HINGE WELDMENT 0" TOOLBOX DOOR & HINGE WELDMENT 0" Flatbed Accessories 0" Toolbox 9 0 //0.

53 Flatbed Accessories " Toolbox Fits 0" Mounting Toolbox Complete W/Step, " Right (0) ITEM QTY PART # 0 NUT, /-0 LOCK -WAY 0 PUSH NUT, WASHER CAP STYLE 09 CLEVIS PIN, STD ZP / X / 000 DECAL, CHIP GUARD 000 SEAL, TOOLBOX LID (TRIM-LOK X-9) 00 BOLT PACKAGE 009 WASHER, / X.0 FENDER 0 NUT, /-, CAGE TINNERMAN 0 BOLT, /- X 0., WIZ FLANGE 0 BOLT, /- X 0., WIZ FLANGE 00 NUT, /- WIZ FLANGE 0 NUT, /- WIZ FLANGE 0 WASHER, /" FLAT STANDARD 0 WASHER, /" FLAT STANDARD 09 STEP, TOOLBOX. ft 009 Traction Pad 00 GASKET, TOOLBOX MOUNT 9 0 Latch, Toolbox w/studs, Key & Gasket 0 Gasket, Toolbox Latch 0 WELDMENT, TOOLBOX DOOR & HINGE, " 9 Weldment, " Right, Toolbox & Hinge 09 Toolbox Mat, " ITEM 9 0 Toolbox Complete W/Step, " Left (09) QTY PART # 0 NUT, /-0 LOCK -WAY 0 PUSH NUT, WASHER CAP STYLE 09 CLEVIS PIN, STD ZP / X / 000 DECAL, CHIP GUARD 000 SEAL, TOOLBOX LID (TRIM-LOK X-9) 00 BOLT PACKAGE 009 WASHER, / X.0 FENDER 0 NUT, /-, CAGE TINNERMAN 0 BOLT, /- X 0., WIZ FLANGE 0 BOLT, /- X 0., WIZ FLANGE 00 NUT, /- WIZ FLANGE 0 NUT, /- WIZ FLANGE 0 WASHER, /" FLAT STANDARD 0 WASHER, /" FLAT STANDARD 09 STEP, TOOLBOX. ft 009 Traction Pad 00 GASKET, TOOLBOX MOUNT 0 Latch, Toolbox w/studs, Key & Gasket 0 Gasket, Toolbox Latch WELDMENT, TOOLBOX DOOR & HINGE, " 9 Weldment, " Left, Toolbox & Hinge 09 Toolbox Mat, " //0.9

54 ITEM 9 0 Flatbed Accessories " Toolbox Fits 0" Mounting Toolbox Complete W/Step, " Left (00) QTY PART # 0 NUT, /-0 LOCK -WAY 0 PUSH NUT, WASHER CAP STYLE 09 CLEVIS PIN, STD ZP / X / 000 DECAL, CHIP GUARD 000 SEAL, TOOLBOX LID (TRIM-LOK X-9) 00 BOLT PACKAGE 009 WASHER, / X.0 FENDER 0 NUT, /-, CAGE TINNERMAN 0 BOLT, /- X 0., WIZ FLANGE 0 BOLT, /- X 0., WIZ FLANGE 00 NUT, /- WIZ FLANGE 0 NUT, /- WIZ FLANGE 0 WASHER, /" FLAT STANDARD 0 WASHER, /" FLAT STANDARD 09 STEP TOOL BOX. ft 009 Traction Pad TOOLBOX MAT " 00 GASKET, TOOLBOX MOUNT 0 Latch, Toolbox w/studs, Key & Gasket 0 Gasket, Toolbox Latch TOOLBOX DOOR & HINGE WELDMENT " WELDMENT, TOOLBOX " W/SKIRT, LEFT ITEM 9 0 Toolbox Complete W/Step, " Right (00) QTY PART # 0 NUT, /-0 LOCK -WAY 0 PUSH NUT, WASHER CAP STYLE 09 CLEVIS PIN, STD ZP / X / 000 DECAL, CHIP GUARD 000 SEAL, TOOLBOX LID (TRIM-LOK X-9) 00 BOLT PACKAGE 009 WASHER, / X.0 FENDER 0 NUT, /-, CAGE TINNERMAN 0 BOLT, /- X 0., WIZ FLANGE 0 BOLT, /- X 0., WIZ FLANGE 00 NUT, /- WIZ FLANGE 0 NUT, /- WIZ FLANGE 0 WASHER, /" FLAT STANDARD 0 WASHER, /" FLAT STANDARD 09 STEP TOOL BOX. ft 009 Traction Pad TOOLBOX MAT " 00 GASKET, TOOLBOX MOUNT 0 Latch, Toolbox w/studs, Key & Gasket 0 Gasket, Toolbox Latch TOOLBOX DOOR & HINGE WELDMENT " WELDMENT, TOOLBOX " W/SKIRT, RIGHT //0.0

55 Flatbed Accessories 0 Toolbox Fits "0" only 0 Toolbox Complete W/Step, 0 Right (00) ITEM QTY PART # 0 NUT, /-0 LOCK -WAY 0 PUSH NUT, WASHER CAP STYLE 09 CLEVIS PIN, STD ZP / X / 000 DECAL, CHIP GUARD 000 SEAL, TOOLBOX LID (TRIM-LOK X-9) 00 BOLT PACKAGE 009 WASHER, / X.0 FENDER 0 NUT, /-, CAGE TINNERMAN 0 BOLT, /- X 0., WIZ FLANGE 0 BOLT, /- X 0., WIZ FLANGE 00 NUT, /- WIZ FLANGE 0 NUT, /- WIZ FLANGE 0 WASHER, /" FLAT STANDARD 0 WASHER, /" FLAT STANDARD 09 STEP, TOOLBOX. ft 009 Traction Pad 00 GASKET, TOOLBOX MOUNT 9 0 Latch, Toolbox w/studs, Key & Gasket 0 Gasket, Toolbox Latch 0 WELDMENT, TOOLBOX & HINGE, 0 LEFT WELDMENT, TOOLBOX DOOR & HINGE, " 00 TOOLBOX SKIRT, 0, LEFT 00 TOOLBOX MAT 0, LEFT 0 ITEM 9 0 Toolbox Complete W/Step, 0 Left (00) QTY PART # 0 NUT, /-0 LOCK -WAY 0 PUSH NUT, WASHER CAP STYLE 09 CLEVIS PIN, STD ZP / X / 000 DECAL, CHIP GUARD 000 SEAL, TOOLBOX LID (TRIM-LOK X-9) 00 BOLT PACKAGE 009 WASHER, / X.0 FENDER 0 NUT, /-, CAGE TINNERMAN 0 BOLT, /- X 0., WIZ FLANGE 0 BOLT, /- X 0., WIZ FLANGE 00 NUT, /- WIZ FLANGE 0 NUT, /- WIZ FLANGE 0 WASHER, /" FLAT STANDARD 0 WASHER, /" FLAT STANDARD 09 STEP, TOOLBOX. ft 009 Traction Pad 00 GASKET, TOOLBOX MOUNT 0 Latch, Toolbox w/studs, Key & Gasket 0 Gasket, Toolbox Latch WELDMENT, TOOLBOX & HINGE, 0 RIGHT WELDMENT, TOOLBOX DOOR & HINGE, " 00 TOOLBOX SKIRT, 0, RIGHT 00 TOOLBOX MAT 0, RIGHT //0.

56 Flatbed Accessories Across the Bed Toolbox ITEM 9 0 Across the Bed Toolbox, Part# 09 QTY PART # 09 TOOLBOX WELD ASSEMBLY BUSHING,. X. X.0 FNG 0 NUT, /- LOCK NYLON INSERT 090 ALL THREAD SPRING/LATCH 000 Shock, Gas Filled 0000 DECAL, DEWEZE BLACK OUTLINE 0 NUT, /- WIZ FLANGE HANDLE WELD ASSY 09 SetScrew, /- X 0. WEAR PAD, PLASTIC TOOLBOX 0 /-0 X. FLAT C'SUNK SCREW 0 WASHER, /" LOCK 009 NUT, /-0 //0.

57 Riser, Offset Pair, Part# ITEM QTY PART # 0 BOLT, - X.0 00 NUT, - RISER WELD ASSY 0 GREASE ZERK, /- ST Riser, Offset Pair, Pivot XRM Part# 009 ITEM QTY PART # 0 BOLT, - X.0 00 NUT, - 0 Weldment, Riser, Pivot XRM 0 GREASE ZERK, /- ST Flatbed Accessories Spinners & Risers Spinner Assy, Swivel Pair Part# 00 ITEM QTY PART # 000 Pin, Lynch / x / LYNCH PIN GUARD Weldment, Spinner, Swivel //0.

58 OTHER ACCESSORIES Adapter Assy, ' Bale, Part# 09 ITEM QTY PART # 099 ' BALE ADAPTER 000 Pin, Lynch / x / RECEIVER HITCH P/N 00 Parallel Squeeze Lift Bar P/N 0 Lift Bar P/N 0 //0.

59 Front Skirt Toolbox Replacement Bolt Kit ea Required Per Fenderskirt Fits Straight Beds 00 & 00 Series 0" Toolbox Replacement Fits Tapered Beds 00 & 00 Series 0" Toolbox Replacement Fits Short Beds 0" Toolbox Replacement //0.

60

61 Appendix I GatorHyde Repair Instructions GatorHyde Repair Instructions Required items: x ml caulking gun (000) x ml cartridge set of GatorHyde Repair Material (00) ¼ x mixing wand (00) pair of rubber gloves wooden stick Instruction sheet and MSDS sheet MEK methyl ethyl ketone solvent (available at most hardware stores) small paint brush plastic cups SAFETY WARNING! Read the Master Safety Data Sheets (MSDS) on all chemicals before handling any chemical. See: Note: This repair is designed to easily fix small, damaged areas fast and with limited amount of effort. However this product is fast reacting so make sure to thoroughly read this instruction sheet before proceeding with repairs. Application Instruction: Step. Before you start, put on rubber gloves and safety glasses. Step. Place a piece of cardboard or newspaper next to the repair area prior to opening and mixing the material. Step. Cut back damaged area with a razor knife to make a square. Step. Sand area and feather edges with 0 grit sandpaper. Blow out sanded area to get rid of dust. Step. Clean area well with MEK solvent and allow to dry for 0 minutes. Step. Attach static mixing wand to x ml cartridge set, twist and lock in place. Insert cartridge into caulking gun. Step. Hold the caulking gun in an upright position in one hand, then set the two plastic cups on a flat surface side by side. Next point the static mixing wand into a cup and squeeze the trigger of the gun two times so a small amount of material is discharged into the cup. (Note! This material is to be discarded.) Immediately move the static mixing wand over and point it into the next cup and continue to discharge the remaining amount of material into this cup. Step. Allow the material to set in cup and gently stir with wooden stick for a period of to ½ minutes or until the GatorHyde becomes thicker and will stick to either a finger or wooden stick. Step 9. Once material has begun to gel, apply enough product to finger or a stick and immediately dab onto damaged area. Use the paint brush to dab the area in a vertical manner to make a textured surface. Cure time. Allow repaired area to cure for a period of hour prior to heavy impact loading. Clean-up. In order to clean up the area take a paper sack or plastic trash bag and place all the empty jars and remaining contents of the repair kit and dispose into a standard trash can or simply put everything back in the box and throw away. GatorHyde Protective Coatings, Inc., 0 South Highway 9, Wagoner, OK * (9) - *

62 Appendix II Remote Control Remote Control SYNCHRONIZING TRANSMITTER AND RECEIVER POWER To teach the transmitter ID code to the receiver, use the following procedure:. Make sure the receiver and transmitter are OFF. BUTTON. Press and hold transmitter's button and (as shown) then press Power button until both LEDs start blinking, then release buttons.. Apply power to the receiver.. Wait for ~ seconds or until the green LED on the transmitter starts blinking rapidly.. Teach complete. BUTTON.0 SYNCHRONIZING TRANSMITTER AND RECEIVER POWER To teach the transmitter ID code to the receiver, use the following procedure:. Make sure the receiver and transmitter are OFF. BUTTON. Press and hold transmitter's button and (as shown) then press Power button until both LEDs start blinking, then release buttons.. Apply power to the receiver.. Wait for ~ seconds or until the green LED on the transmitter starts blinking rapidly.. Teach complete. BUTTON. DEWEZE HARNESS 9 TO 0 VOLT 0 RED BLACK YELLOW PURPLE GREEN BROWN BLUE ORANGE WHITE GRAY GREEN/YELLOW 0.

63 ii.

64 Bank Wiring, Kar-Tech Remote Decal Part# 00 Harness Part# 0 POWER LOAD RED BATTERY DIAGNOSTIC GREEN TRANSMIT UNLOAD The Bed Has a Double Poppet Valve With Jumper Wires Between C & D (Green) E & F (Blue) SQUEEZE rd BANK EXTEND FLOAT COILS "C" & "D" UNSQUEEZE rd BANK RETRACT WORK LIGHTS PAGE OF //0.

65 SOLENOID FIRES LOAD UNLOAD OIL IN OIL OUT OIL OUT OIL IN SQUEEZE OIL IN OIL OUT OIL OUT OIL IN UNSQUEEZE PAGE OF //0 ii.

66 rd Bank Wiring, Kar-Tech Remote Decal Part# 00 Harness Part# 0 POWER RED BATTERY/DIAGNOSTIC GREEN TRANSMIT LOAD UNLOAD SQUEEZE rd BANK EXTEND FLOAT COILS "C" & "D" UNSQUEEZE rd BANK RETRACT WORK LIGHTS. //0.

67 SOLENOID FIRES FLOAT EXTEND RETRACT OIL IN OIL OUT OIL OUT OIL IN. //0 ii.

68 Bank Wiring, Kar-Tech Remote Gen Double Poppet, Deutsch Decal Part# 00 Harness Part# 09 POWER LOAD RED BATTERY DIAGNOSTIC GREEN TRANSMIT UNLOAD SQUEEZE rd BANK EXTEND FLOAT COILS "C" & "D" UNSQUEEZE rd BANK RETRACT WORK LIGHTS PAGE OF 9/9/0.

69 SOLENOID FIRES LOAD UNLOAD OIL IN OIL OUT OIL OUT OIL IN SQUEEZE OIL IN OIL OUT OIL OUT OIL IN UNSQUEEZE PAGE OF 9/9/0 ii.

70 rd Bank Wiring, Kar-Tech Remote Gen Double Poppet, Deutsch Decal Part# 00 Harness Part# 099 POWER RED BATTERY/DIAGNOSTIC GREEN TRANSMIT LOAD UNLOAD SQUEEZE rd BANK EXTEND FLOAT COILS "C" & "D" UNSQUEEZE rd BANK RETRACT WORK LIGHTS 9/9/0.

71 SOLENOID FIRES FLOAT EXTEND RETRACT OIL IN OIL OUT OIL OUT OIL IN 9/9/0 ii.

72 Appendix III Heavy Duty E/H Power Kit * Read all instructions first.. Attach adapters to E/H valve and install inside cavity on headache rack.. Attach valve harness per diagram on decal.. Attach return hose to valve and filter housing. Attach pressure hose from pump.. Attach / hoses from squeeze cylinder to valve ports # & #.. Attach / hoses from lift cylinder to valve ports # & #.. Use cover plate to locate cutout in right side toolbox.. Use access cover or edge molding to protect hoses.. Drill holes for / bolts as indicated and bolt pump to inside of toolbox. Back of Box.0.9 Front of Box.0...

73 9. Attach power harness as indicated. 0. Attach 0-amp fuse holder to positive terminal on battery, run wire through switch on dash and then to the red wire on the harness.. Attach suction hose and pressure hose to pump with adapters provided.. Attach suction hose to bottom of reservoir.. Run battery cables through hole in toolbox and attach to E/H motor as indicated.. Run battery cables along frame rail and attach black cable to negative terminal on battery.. Attach 00-amp fuse holder to positive battery terminal.. Insert 00-amp fuse.. Attach red cable from E/H ontop of ice cube fuse. Install rubber cap. If installing the 0 Switch Unit Read the E/H Hybrid specific instructions first. ii.

74 Back of Box n.9. Heavy Duty E/H 9.0 Front of Box.0. ITEM 9 0 QTY in PART # Parts List EDGE TRIM BOLT, /- X, WIZ FLANGE WASHER, /" LOCK WASHER, /" FLAT STANDARD NUT, /- GR ADAPTER, BH-0MB90 ADAPTER, MJ-MB90 ADAPTER, 0MB-FOR ADAPTER, BH-MB ACCESS COVER FRAME HOSE, SUCTION,. X Hose, Pressure HD E/H E/h Motor Pump/unit, Heavy Duty V Strap, Motor-Solenoid Connecting Solenoid, Post, VDC Contactor Shield, HD, E/H Access Cover, HD E/H CLAMP, HOSE #." SCREW, / X TEK SELF-TAP 0 /9/0.

75 ITEM Heavy Duty E/H, W/Remote Part# 0 QTY PART # 09 NUT, 0- LOCK 0 NUT, M X. WIZFLANGE 0 BOLT, 0- X. STAINLESS, PHILLIPS 0 BOLT, /- X.0 00 NUT, /- WIZ FLANGE 0 PLUG, /" BUTTON PLASTIC 0 ADAPTER, MJ-MB90 0 ADAPTER, MJ-MB 0 ADAPTER, MJ-MB90 0 ADAPTER, MJ-FJX90 09 ADAPTER, 0MJ-MB 00 FUSE HOLDER, ATC, GA., MINI 00 FUSE, MINI 0 AMP 0 SWITCH BOOT 0 Switch, Spst, Rocker Led 09 FUSE COVER, BUSS CFCOVER-R 09 FUSE HOLDER, BUSS CFBAR-MXSP 09 FUSE 00 AMP, BUSS MRBF-00 Switch, Toggle, DPDT, (On)-OFF-(ON) 000 DECAL, SWITCH IDENTIFICATION 00 Decal, Double Poppet Valve 00 Decal, Wiring Diagram, Double Poppet Deutsch 0 BATTERY CABLE, GA TWIN LEAD, " 09 Harness, Flatbed, Double Poppet Deutsch Harness, Flatbed Valve, E/H Control 0 Flatbed Valve, Small, Monoblock Ver II 00 Transmitter & Receiver, Kar-Tech Heavy Duty E/H Kit W/ Remote /9/0 ii.

76 Heavy Duty E/H, W/Hand Control Part# 0 ITEM QTY PART # 09 NUT, 0- LOCK 0 NUT, M X. WIZFLANGE 0 BOLT, 0- X. STAINLESS, PHILLIPS 0 BOLT, /- X.0 00 NUT, /- WIZ FLANGE 0 PLUG, /" BUTTON PLASTIC 0 ADAPTER, MJ-MB90 0 ADAPTER, MJ-MB 9 0 ADAPTER, MJ-MB ADAPTER, MJ-FJX90 09 ADAPTER, 0MJ-MB 00 FUSE HOLDER, ATC, GA., MINI 00 FUSE, MINI 0 AMP 0 SWITCH BOOT 0 Switch, Spst, Rocker Led 09 FUSE COVER, BUSS CFCOVER-R 09 FUSE HOLDER, BUSS CFBAR-MXSP 09 FUSE 00 AMP, BUSS MRBF-00 9 Switch, Toggle, DPDT, (On)-OFF-(ON) 0 00 Hand Control & Cable Assy, Bank 000 DECAL, SWITCH IDENTIFICATION 00 Decal, Double Poppet Valve 00 Decal, Wiring Diagram, Double Poppet Deutsch 0 Flatbed Valve, Small, Monoblock Ver II 0 BATTERY CABLE, GA TWIN LEAD, " 09 Harness, Flatbed, Double Poppet Deutsch 0 Harness, Adapter Bank, Hand Control Harness, Flatbed Valve, E/H Control 0 Heavy Duty E/H Kit W/ Hand Control /9/0.9

77 Flatbed Valve -0 Hydac Deutsch Service Parts LIFT CYLINDER -ROD- CHECK VALVE 09 TO THIS PORT LIFT CYLINDER -BASE- Flatbed Valve, Small, Hydac Deutsch P/N 0 ITEM QTY PART # 00 O-Ring Plug, # /-0 00 Valve, Pressure Relief 00 Cartridge, # HYDAC Double Poppet 0 #0 SOLENOID, POSITION WAY 09 Coil, # Hydac, DT0-P Suppressed 0 O-Ring Plug, # /- 0 Spool, #0 Valve 99 Coil, #0 Hydraforce, DT0-P Suppressed SQUEEZE CYLINDER -ROD- SQUEEZE CYLINDER -BASE- ITEM QTY Heavy Duty E/H Motor & Pump 09 E/H MOTOR & PUMP, HD V PART # 0 0 Strap, Motor-Solenoid Connecting Solenoid, Post, VDC Contactor Purple Switch Wire From Valve Harness - Pressure Port Positive Cable -0 Suction Port Ground Cable /9/0 ii.9

78 Controlling E/H Solenoid From Flatbed Harness Harness # To the Switch Post on the E/H Solenoid Fused and Switched Power Supply Here Red Wire from Valve Harness Here This Plug to B Coil on Valve Plug With Purple Wire From Valve Harness Here Make Sure the Purple & Black Wires Match /9/0 iii.9

79

80 Bank Wiring, Kar-Tech Remote Gen Double Poppet, Deutsch Decal Part# 00 Harness Part# 09 POWER LOAD RED BATTERY DIAGNOSTIC GREEN TRANSMIT UNLOAD SQUEEZE rd BANK EXTEND FLOAT COILS "C" & "D" UNSQUEEZE rd BANK RETRACT WORK LIGHTS PAGE O F 9/9/0 iv.9

81 SOLENOID FIRES LOAD UNLOAD OIL IN OIL OUT OIL OUT OIL IN SQUEEZE OIL IN OIL OUT OIL OUT OIL IN UNSQUEEZE PAGE OF 9/9/0 v.9

82 rd Bank Wiring, Kar-Tech Remote Gen Double Poppet, Deutsch Decal Part# 00 Harness Part# 099 POWER RED BATTERY/DIAGNOSTIC GREEN TRANSMIT LOAD UNLOAD SQUEEZE rd BANK EXTEND FLOAT COILS "C" & "D" UNSQUEEZE rd BANK RETRACT WORK LIGHTS 9/9/0 vi.9

83 SOLENOID FIRES FLOAT EXTEND RETRACT OIL IN OIL OUT OIL OUT OIL IN 9/9/0 vii.9

84 Appendix I V GatorHyde Repair Instructions Independent Arm Control Hoses GatorHyde Hoses Repair --0 Instructions Independent Squeeze Required Front to Back items: (ea) 0 (0in) 0 (in) 0 (in) 0 (in) Kit x ml caulking Pivot gun (000) Squeeze Hoses x Hoses ml cartridge set of - GatorHyde Repair - Material (00) -- Pivot ¼ x Squeeze mixing Short wand 0 (00) (in) 0 (0in) 0 (in) Pivot pair Squeeze of rubber Long gloves 0 (in) 0 (in) 0 (in) wooden Kit number stick Instruction rd Bank, sheet Independent and MSDS Arm sheet (0) ITEM MEK QTY methyl PART # ethyl ketone solvent (available at most SAFETY WARNING! Read the Master Safety Data Sheets hardware stores) 0 Valve, rd Bank add on (0) (MSDS) on all chemicals before small paint 0 brush ADAPTER, MJ-MB90 handling any chemical. plastic cups 099 Harness, Flatbed rd Bank, Deutsch See: Note: This repair is designed to easily fix small, damaged areas fast and with limited amount of effort. However this product is fast reacting so make sure to thoroughly read this instruction sheet before proceeding with repairs. Application Instruction: Step. Before you start, put on rubber gloves and safety glasses. Step. Place a piece of cardboard or newspaper next to the repair area prior to opening and mixing the material. Step. Cut back damaged area with a razor knife to make a square. Step. Sand area and feather edges with 0 grit sandpaper. Blow out sanded Long area to get rid of dust. Long Step. Clean area well with MEK Short solvent and allow to dry for 0 minutes. Short Step. Attach static mixing wand to x ml cartridge set, twist and lock in place. Insert cartridge into caulking gun. Step. Hold the caulking gun in an upright position in one hand, then set the two plastic cups on a flat surface side by side. Next point the static mixing wand into a cup and squeeze the trigger of the gun two times so a small amount of material is discharged into the cup. (Note! This material is to be discarded.) Immediately move the static mixing wand over and point it into the next cup and continue to discharge the remaining amount of material into this cup... Step. Allow the material to set in cup and gently stir with wooden stick for a period of to ½ minutes or until the GatorHyde becomes thicker and will stick to either a finger or wooden stick. Step 9. Once material has begun to gel, apply enough product to finger or a stick and immediately dab onto damaged area. Use the paint brush to dab the area in a vertical manner to make a textured surface. Cure time. Allow repaired area to cure for a period of hour prior to heavy impact loading. LEFT RIGHT Clean-up. In order to clean up the area BIG take a paper sack or plastic trash bag and place all the empty jars SMALL and remaining contents of the repair kit and dispose into a standard trash can or simply put everything back in the box and throw away. ITEM SWITCH BOOT SWITCH, DPDT, M, PIN, PUSH ON Decal, rd Bank, Double Poppet Deutsch Parts List QTY GatorHyde PART # Protective Coatings, Inc., 0 South Highway 9, Wagoner, OK * (9) - * 09 ADAPTER, MJ-MB Independent Arm Control 0 Pivot Cylinder,.0 x.0 0 Seal Kit 0 Pivot Cylinder,. x.0 Hydraulics 0 Seal Kit 00 Shim Washer 000 COUPLER, PIONEER MALE 9//0.0