M REV. D APRIL 2010 BMR-44 PARTS MANUAL

Transcription

1 M REV. D APRIL 00 BMR-44 PARTS MANUAL 9 Slauson Avenue. Santa Fe Springs, CA (800) 7-46 MAXON Lift Corp. 009

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3 LIFT CORP. CUSTOMER SERVICE: (56) (800) 7-46 FAX: (888) Slauson Ave. Santa Fe Springs, CA TECHNICAL SERVICE: (800) 8-MAXTEK (86-985) NOTE: Check with Customer Service Department for updated versions of Manuals on an annual basis. WARRANTY POLICY & PROCEDURE NEW LIFTGATE WARRANTY Term of Warranty: Years from Date of In-Service Type of Warranty: Full Parts and Labor MAXON agrees to replace any components which are found to be defective during the first years of service, and will reimburse for labor based on MAXON s Liftgate Warranty Flat Rate Labor Schedule. All claims for warranty must be received within 0 Days of the repair date, and include the following information:. Liftgate Model Number. Liftgate Serial Number. Description of Problem 4. Corrective Action Taken, and Date of Repair. 5. Parts used for Repair, Including MAXON Part Number(s). 6. MAXON R.G.A. # and/or Authorization # if applicable (see below). 7. Person contacted at MAXON if applicable. PURCHASE PART WARRANTY Term of Warranty: Year from Date of Purchase Type of Warranty: Part Replacement and Replacement Labor MAXON will guarantee all returned genuine replacement parts upon receipt, and inspection of parts and invoice. All Warranty repairs must be performed by an authorized MAXON warranty station. For major repairs, MAXON s Warranty Department must be notified, and an Authorization Number received. Major repairs would generally be considered repairs made to the structural assembly of the liftgate and/or repairs not outlined in the MAXON Liftgate Waranty Flat Rate Schedule. Major components (i.e. hydraulic pumps, cylinders, valves, or failed structural parts) must be returned, freight pre-paid, prior to the claim being processed. To ensure timely processing of these warranty claims, an R.G.A. (Returned Goods Authorization) number must be obtained from MAXON s Warranty Department prior to the return of any defective part. Defective Parts must be returned within 60 days of the claim date for consideration to: Warranty Dapartment, MAXON Lift Corp. 590 Alameda St., Huntington Park, CA MAXON s warranty policy does not include the reimbursement for travel time; towing; vehicle rental; service calls; fabrication of parts which are available from MAXON; oil; defects due to misuse or abuse; loss of income due to downtime. MAXON s Flat Rate Labor Schedule times takes into consideration time required for diagnosis of problem. Warranty and Technical Information is available by calling MAXON s Customer Service Department.

4 Table of Contents WARNINGS...PAGE 6 LIFTGATE TERMINOLOGY...PAGE 7 R.H. COLUMN ASSEMBLY...PAGE 8 L.H. COLUMN ASSEMBLY...PAGE 0 R.H. RUNNER ASSEMBLY...PAGE L.H. RUNNER ASSEMBLY...PAGE 4 R.H. CHAIN ASSEMBLY...PAGE 6 L.H. CHAIN ASSEMBLY...PAGE 7 -PC. PLATFORM ASSEMBLY...PAGE 8 PLATFORM ASSEMBLY, BMR-44...PAGE 9 FOLDOVER ASSEMBLY BMR-44...PAGE 0 TANDEM ASSEMBLY...PAGE SPRING GUARD MOUNTING...PAGE HYDRAULIC SECTION...PAGE PUMP 555 (994 TO JAN.997)...PAGE 4 PUMP (JAN.997 TO PRESENT)...PAGE 6 HYD. COMPONENTS, PUMP GRAVITY DOWN...PAGE 8 PUMP FITTINGS, PUMP GRAVITY DOWN...PAGE 0 PUMP FITTINGS, PUMP POWER DOWN...PAGE HYD. COMPONENTS, PUMP POWER DOWN...PAGE HYD. COMPONENTS, PUMP GRAVITY DOWN...PAGE 4 PUMP FITTINGS, PUMP GRAVITY DOWN...PAGE 6 ELECTRICAL SECTION...PAGE 9 CONTROL BOX GRAVITY DOWN (NEW STYLE)...PAGE 40 CONTROL BOX GRAVITY DOWN (OLD STYLE)...PAGE 4

5 CONTROL BOX POWER DOWN (NEW STYLE)...PAGE 4 CONTROL BOX POWER DOWN (OLD STYLE)...PAGE 4 WIRING, PUMP GRAVITY DOWN...PAGE 44 WIRING, PUMP POWER DOWN...PAGE 46 WIRING, PUMP GRAVITY DOWN...PAGE 48 WIRING, PUMP POWER DOWN...PAGE 50 OPTIONAL SECTION...PAGE 5 HAND PUMP KIT...PAGE 54 BOTTOM STOP ASSEMBLY...PAGE 56 FIXED RAMP, 6 &...PAGE 57 ALUMINUM RETENTION RAMP...PAGE 58 CART STOP RAMP...PAGE 60 DUAL CART STOP RAMP...PAGE 6

6 WARNINGS WARNING PAGE 6

7 LIFTGATE TERMINOLOGY LH COLUMN LH CHAIN ASSY. RH COLUMN RH CHAIN ASSY. PLATFORM ASSY. FOLDOVER ASSY. PAGE 7

8 R.H. COLUMN ASSEMBLY P/N , 5,6 4a PAGE 8

9 R.H. COLUMN ASSEMBLY P/N 5577 ITEM QTY. PART NO. DESCRIPTION BOLT, /4-0 x /4" WASHER, /4" LOCK WASHER, /4" FLAT 64 COVER, (-LIGHT COLUMN) 4 COVER WELD'T (-LIGHT 5767 COLUMN) 5 46 PIN, ROLL /8" x " LONG PIN, " x 5-7/8" LONG COLUMN WELDMENT, RH ( LIGHT) COLUMN WELDMENT, RH (- 55 LIGHT) MAXON VERTICAL PLATE " x 0" RIVET, /6 POP 0 55 LIGHT, CLEAR (For -Lgt. Col. Only) 55 LIGHT, STOP/TAIL/TURN, SEALED 64 LIGHT KIT, LED, STOP/TAIL/TURN 5590 PIN, " x 4-/4" LONG 55 CYL., LIFT, DBL. ACT. x6x ROD CLOSING CYLINDER ASSEMBLY 4a 5657 BEARING, SELF LUBE, x PIN, " x -/" LONG PIN, ROLL /4" x " LONG SWITCH PLATE RUBBER SEAL, SWITCH COVER WELDMENT, RH COLUMN RUNNER ASSEMBLY, RH LOCKING PLATE x -/" RH 600 LIGHT MOUNT BRACKET (-LIGHT) LIGHT MOUNT BRACKET (-LIGHT) PAGE 9

10 L.H. COLUMN ASSEMBLY P/N , PAGE 0

11 L.H. COLUMN ASSEMBLY P/N 5578 ITEM QTY. PART NO. DESCRIPTION BOLT, /4-0 x /4" WASHER, /4" LOCK WASHER, /4" FLAT 4 64 COVER, (-LIGHT COLUMN) 5767 COVER WLDM'T (-LIGHT COLUMN) 5 46 PIN, ROLL /8" x " LONG PIN, " x 5-7/8" LONG COLUMN WELDMENT, LH ( LIGHT) COLUMN WELDMENT, LH (- 550 LIGHT) MAXON VERTICAL PLATE " x 0" RIVET, /6 POP 0 55 LIGHT, CLEAR (For -Lgt Col. Only) 55 LIGHT, STOP/TAIL/TURN SEALED 64 LIGHT KIT, STOP/TAIL/TURN, LED 5590 PIN, " x 4-/4" LONG 55 CYL., LIFT, DBL. ACT. x6x ROD RUNNER ASSEMBLY, LH COVER WELDMENT, LH COLUMN LOCKING PLATE x -/" LH LIGHT MOUNT BRACKET (-LIGHT) LIGHT MOUNT BRACKET (-LIGHT) PAGE

12 R.H. RUNNER ASSEMBLY P/N 556 5, ,7,, PAGE

13 R.H. RUNNER ASSEMBLY P/N 556 ITEM QTY. PART NO. DESCRIPTION BOLT, /8-6 x WASHER, LOCK / UPPER PAD SUPPORT ASSEMBLY RUNNER WELDMENT R.H PAD POLY,.5" x 8" RIVET POP, /6 x PAD.8 DIA LOWER PAD SUPPORT ASSEMBLY BOLT, /4-0 x -/" PIN COLLAR x /" NUT, NYLON LOCK 5/ BEARING, SELF-LUBE PIN BOLT, 5/6-8 x WASHER, FLAT, /4" BUMPER COUPLING, INSIDE WELDMENT BEARING x /4" TORSION SPRING COUPLING, OUTSIDE WELDMENT 5596 BEARING, SELF-LUBE TANDEM ASSEMBLY BOLT, /4-0 x /4" WASHER, LOCK, /4" CHAIN BRACKET WELDMENT PAGE

14 L.H. RUNNER ASSEMBLY P/N , ,7,, PAGE 4

15 L.H. RUNNER ASSEMBLY P/N 5565 ITEM QTY. PART NO. DESCRIPTION BOLT, /8-6 x WASHER, LOCK / UPPER PAD SUPPORT ASSEMBLY RUNNER WELDMENT L.H PAD POLY,.5" x 8" RIVET POP, /6 x PAD.8 DIA LOWER PAD SUPPORT ASSEMBLY BOLT, /4-0 x -/" PIN COLLAR x /" NUT, NYLON LOCK 5/ BEARING, SELF-LUBE PIN BOLT, 5/6-8 x WASHER, FLAT, /4" BUMPER PIN COLLAR x -/4" BEARING SELF-LUBE x PIN COLLAR WELDMENT TANDEM ASSEMBLY BOLT, /4-0 x /4" WASHER, LOCK, /4" 564 CHAIN BRACKET WELDMENT PAGE 5

16 R.H. CHAIN ASSEMBLY a b ITEM QTY. DESCRIPTION 5,7 6,7 (4 x 4 Only) 4" x 4" " x 0" PAGE 6 0 4,7 8,9 PLATFORM SIZE (ASSEMBLY PART NUMBER) 6" x 6" " x 4" " x 0" " x 48" ( Pc) 65- TEAR DROP ASSY. RH a BRNG, SELF-LUBE x / b BRNG, SELF-LUBE / x / 554 DOUBLE CLEVIS CHAIN SLEEVE 4-/4" LONG N/A 4 SLEEVE " LONG N/A N/A SLEEVE 0" LONG N/A N/A 5 SLEEVE 6-/" LONG N/A SLEEVE 5-/4" LONG N/A N/A N/A 6 SLEEVE -/4" LONG N/A N/A SLEEVE " LONG N/A N/A 7 6 TIE WRAP (NOT SHOWN) CLEVIS PIN COTTER PIN N/A 0 OPENER ASSEMBLY (RH)

17 L.H. CHAIN ASSEMBLY a 8,9 b ITEM QTY. DESCRIPTION 4,7 0 4" x 4" " x 0" 65-0 PAGE 7 5,7 6,7 PLATFORM SIZE (ASSEMBLY PART NUMBER) 6" x 6" " x 4" " x 0" " x 48" ( Pc) 65- TEAR DROP ASSY. LH a BRNG, SELF-LUBE x / b BRNG, SELF-LUBE / x / 554 DOUBLE CLEVIS CHAIN SLEEVE 4-/4" LONG N/A 4 SLEEVE " LONG N/A N/A SLEEVE 0" LONG N/A N/A 5 SLEEVE 6-/" LONG N/A SLEEVE 5-/4" LONG N/A N/A N/A 6 SLEEVE -/4" LONG N/A N/A SLEEVE " LONG N/A N/A 7 6 TIE WRAP (NOT SHOWN) CLEVIS PIN COTTER PIN N/A 0 OPENER ASSEMBLY (LH)

18 -PC. PLATFORM ASSEMBLY (REF. RH RUNNER) PIN (P/N 5586) BOLT, /- x -/4 (P/N ) LOCKNUT, / (P/N ) (REF. LH RUNNER) BOLT, /4-0 x (P/N ) WASHER, LOCK /4 (P/N 00575) WASHER, LOCK /4 (P/N 00575) (See Table) PAGE 8 PIN (P/N 5586) BOLT, /4-0 x -/4 Small Hex (P/N 608) ITEM QTY. DESCRIPTION 4" DEEP 48" DEEP PLATFORM, 96" WIDE VEHICLE PLATFORM, 0" WIDE VEHICLE

19 PLATFORM ASSEMBLY, BMR-44 (REF. RH RUNNER) PIN (P/N 5586) BOLT, /4-0 x (P/N ) BOLT, /- x -/4 (P/N ) LOCKNUT, / (P/N ) (REF. LH RUNNER) BUMPER (P/N 556) BOLT, /8-6 x -/4 (P/N 6056) (See Table) WASHER, /8 (P/N 00556) PIN (P/N 5586) BOLT, /4-0 x -/4 Small Hex (P/N 608) BEARING (P/N 5657) ITEM QTY. DESCRIPTION 0" DEEP 6" DEEP 4" DEEP PLATFORM, 96" WIDE VEHICLE PLATFORM, 0" WIDE VEHICLE PAGE 9

20 FOLDOVER ASSEMBLY BMR-44 PIN, P/F & F/S (P/N 5587) ROLL PIN, /8 x LG. (P/N 46) BUMPER (P/N 578-0) PLATFORM (REF.) LOCKNUT, 5/6-8 (P/N ) (See Table) CHAIN ASSY. (REF.) WASHER, /4 (P/N 00564) BOLT, 5/6-8 x (P/N 0009) ITEM QTY. DESCRIPTION 4" DEEP 0" DEEP 6" DEEP 4" DEEP FOLDOVER, 96" WIDE VEHICLE FOLDOVER, 0" WIDE VEHICLE PAGE 0

21 ROLLER ASSY. (P/N ) WASHER,.5 OD x.78 ID (P/N 68) ROLLER BRACKET (P/N ) TANDEM ASSEMBLY P/N 55-0 ROLLER BRACKET (P/N ) WASHER,.5 OD x.78 ID (P/N 68) WASHER, 5/8 FLAT (P/N 0057) NUT, 5/8-8 (P/N 6940) NUT, /-0 (P/N 90008) WASHER,.8 OD x.56 ID (P/N 9004) WASHER,.5 OD x.78 ID (P/N 68) BRACKET x -/ (P/N 5569) WASHER,.5 OD x.78 ID (P/N 68) ROLLER AXEL (P/N ) ROLLER AXEL (P/N 5509) NOTE: This Tandem Assembly Supercedes all previous Assemblies and is fully compatable PAGE

22 SPRING GUARD MOUNTING 6054 Ref. Electrical Schematic 6059 Ref. Electrical Schematic 574 Ref. Hydraulic Schematic 6099 SCREW, FLT. HD. /4-0 UNC x NUT, NYLON / SPRING GUARD BOLT, /4-0 x LONG Ref. RH Runner Assembly 605 Ref. Electrical Schematic SPRING GUARD NUT, NYLON / RD. TUBE.5OD x.94 LG. PAGE

23 HYDRAULIC SECTION PAGE

24 PUMP 555 (994 TO JAN.997) 5 5b 5c a 8 5f 7 5e 6,6 5d PAGE 4

25 PUMP 555 (994 TO JAN.997) ITEM QTY. PART NO. DESCRIPTION 5009 HEAVY DUTY MOTOR, VDC 6076 VALVE, SOLENOID 4-WAY *a 6595 O-RING KIT, 4-WAY VALVE 55 VALVE, SOLENOID -WAY *a 6594 O-RING KIT, -WAY VALVE MANIFOLD BLOCK ASSEMBLY RELIEF VALVE KIT 5a 600 STEEL BALL 5b 60 SPRING 5c 605 O-RING 5d 604 VALVE CAP 5e 60 ADJUSTING SCREW 5f 60 SPRING GUIDE RESERVOIR,.5 GAL FILLER/BREATHER CAP FILTER PUMP ASSEMBLY O-RING 6074 DRIVEPLATE ASSEMBLY, 5" 606 OIL SEAL 900 COUPLING BUS BAR SOLENOID SWITCH * CAPSCREW, HEX HD. WASHER * NOT SHOWN PAGE 5

26 PUMP (JAN.997 TO PRESENT) a c b d f 8, 8a 9 8, 8a 7 4,5 e ,6a PAGE 6

27 PUMP (JAN.997 TO PRESENT) ITEM QTY. PART NO. DESCRIPTION 609 RELIEF VALVE KIT a 604 VALVE CAP b 605 O-RING c 60 ADJUSTING SCREW d 60 SPRING e 60 SPRING GUIDE f 600 STEEL BALL FILLER-BREATHER CAP 606 RESERVOIR,.5 GAL FILTER PUMP ASSEMBLY O-RING DRIVEPLATE ASSEMBLY 5" OIL SEAL COUPLING BUS BAR 699 SOLENOID, PRESTOLITE 5009 HEAVY DUTY MOTOR, VDC 674 MANIFOLD BLOCK ASSEMBLY 4 60 CONTROL, NEEDLE VALVE O-RING, NEEDLE VALVE VALVE, SOLENOID, 4-WAY 6a 6595 O-RING KIT, 4-WAY VALVE STR. UNION, SAE #8 x JIC #8 M-M 8 55 VALVE, SOLENOID, -WAY 8a 6594 O-RING KIT, -WAY VALVE VALVE, RELIEF PAGE 7

28 HYD. COMPONENTS, PUMP GRAVITY DOWN 4 7,8, LH CYLINDER ,5 7,8,9 5 RH CYLINDER 5 6 See Pump Fittings- Pump, Gravity Down 0 Closing Cylinder Assy. (Ref. #5975) PAGE 8

29 HYD. COMPONENTS, PUMP GRAVITY DOWN ITEM QTY. PART NO. DESCRIPTION 6090 SPIN-ON FILTER & BLOCK a 64 FILTER ELEMENT 4 57 ELBOW, JIC#8 x SAE#6 ADJUST. 575 HOSE, /8HP JIC#8 F-F x -5/8" TEE, /4" STR. FTG. /4 TUBE x /4 NPT (M) RETURN LINE HOSE /4" x 0"LG STR. BULKHEAD JIC# NUT, BULKHEAD JIC# WASHER, FLAT -/4" x /4" ELBOW, /4 TUBE x /4 NPT (M) 8008 BUSHING, /8 NPT (M) x /4 NPT (F) 607 ELBOW, /" TUBE x /4"NPT 57 STR. THD. SAE#6 X JIC# FLOW DIVIDER HOSE, /8HP JIC#8 M-F x 40-/6" HYD. LOCK VLV. W/MAN. OVERRIDE FTG. /"TUBE x /4" NPT (M) VALVE, PRESSURE COMP. GPM ELBOW, SAE#6 (M) x /4 NPT (M) HOSE, /8HP JIC#8 M-F (SW) x 8" 470- HOSE, PLASTIC /4" x 87" LONG HOSE, PLASTIC /4" x 77" LONG 5706 STR. THD. SAE#8 X JIC# HOSE, /8HP JIC#8 F-F x -5/8" PAGE 9

30 PUMP FITTINGS, PUMP GRAVITY DOWN TO FILTER TO FILTER 6068 STR. UNION, JIC#8 x /4 NPT (M) 5706 STR. UNION, JIC#8 (M) x SAE#8 (M) TO FLOW DIVIDER TO CLOSING CYLINDER 6096 PLUG SAE#8 FROM LIFT CYLINDERS 0406 ELBOW, /4 TUBE x /4 NPT (M) 0406 ELBOW, /4 TUBE x /4 NPT (M) PAGE 0

31 PUMP FITTINGS, PUMP POWER DOWN 6068 STR. UNION, JIC#8 x /4 NPT (M) 5706 STR. UNION, JIC#8 (M) x SAE#8 (M) TO FLOW DIVIDER TO CLOSING CYLINDER TO FILTER 5706 STR. UNION, JIC#8 (M) x SAE#8 (M) TO FILTER FROM LIFT CYLINDERS PAGE

32 HYD. COMPONENTS, PUMP POWER DOWN 7,8, LH CYLINDER ,5,8,9 6,8,9 5 RH CYLINDER See Pump Ftgs. Pump, Power Down Closing Cylinder Assy. (Ref. #5975) PAGE

33 HYD. COMPONENTS, PUMP POWER DOWN ITEM QTY. PART NO. DESCRIPTION 6090 SPIN-ON FILTER & BLOCK a 64 FILTER ELEMENT 4 57 ELBOW, JIC#8 x SAE#6 ADJUST HOSE, /8HP JIC#8 F-F x -5/8" TEE, JIC#8 BULKHEAD ELBOW, M JIC#8 x F SWVL. JIC# ELBOW, BULKHEAD JIC# STR. BULKHEAD JIC# NUT, BULKHEAD JIC# WASHER, FLAT -/4" x /4" 0 55 FLOW DIVIDER 607 ELBOW, /" TUBE x /4"NPT 5779 HOSE, /8HP JIC#8 M-M x 4-/8" 57 STR. THD. SAE#6 X JIC# HOSE, /4HP JIC#5 xjic#6 x 4-/4" HOSE, /8HP JIC#8 M-F x 40-/6" HYD. LOCK VLV. W/MAN. OVERRIDE FTG. /"TUBE x /4" NPT (M) VALVE, PRESSURE COMP. GPM ELBOW, SAE#6 (M) x /4 NPT (M) HOSE, /8HP JIC#8 M-F (SW) x 8" 5706 STR. THD. SAE#8 X JIC# HOSE, /8HP JIC#8 F-F x -5/8" PAGE

34 HYD. COMPONENTS, PUMP GRAVITY DOWN L.H. CYL R.H. CYL See Pump Fittings- Pump, Gravity Down PAGE 4 Closing Cylinder Assy. (Ref. #5975)

35 HYD. COMPONENTS, PUMP GRAVITY DOWN ITEM QTY. PART NO. DESCRIPTION 6090 SPIN-ON FILTER & BLOCK a 64 FILTER ELEMENT 570 STR. UNION MALE, JIC#8 x SAE #6 57 ELBOW, JIC#8 x SAE#6 ADJUST HOSE, /8HP JIC#8 F-F x -5/8" TEE, JIC#8, (M) x (F SWIVEL) x (M) HOSE, /8HP JIC#8 F-F x " HOSE, /8HP JIC#8 M-F x 40-/6" 8 57 STR. THD. SAE#6 X JIC# HOSE, PLASTIC /4" x 77" LONG FTG. /"TUBE x /4" NPT (M) 5745 VALVE, PRESSURE COMP. GPM 6064 ELBOW, SAE#6 (M) x /4 NPT (M) 594 HYD. LOCK VLV. W/MAN. OVERRIDE ELBOW, /" TUBE x /4"NPT HOSE, /8HP JIC#8 M-F (SW) x 8" ELBOW, JIC#8 M x JIC#8 F (SW) NUT, BULKHEAD JIC# FLOW DIVIDER STR. UNION JIC#8 (M) BULKHEAD STR. THD. SAE#8 X JIC# HOSE, PLASTIC /4" x 87" LONG PAGE 5

36 PUMP FITTINGS, PUMP GRAVITY DOWN TO FLOW DIVIDER 7 6 TO FILTER TO FILTER PUMP TO FILTER 5 4 PUMP 9 7, PAGE 6

37 PUMP FITTINGS, PUMP GRAVITY DOWN ITEM QTY. PART NO. DESCRIPTION 575 HOSE ASSY. /8 HP JIC#8 (F-F) x " 5700 HOSE ASSY. /8 HP JIC#8 (F-F) x " 6078 HOSE ASSY. /8 HP JIC#8 (F-F) x 40" ELBOW, 90 /8 NPT(M) x JIC#8 (M) ELBOW, 90 /4 NPT(M) x /4 TUBE TEE, /4 NPT (F) BUSHING, /8 NPT(M) x /4 NPT(F) NIPPLE, CLOSE /4 NPT (SCH. 80) HOSE, PLASTIC /4" x 87" LG HOSE, PLASTIC /4" x 77" LG DUAL PUMP, VDC 6068 STR. UNION /4 NPT(M) x JIC#8 (M) UNION SAE#8 (M)x JIC#8 SWIVEL (M) UNION /8NPT (M)x JIC#8 SWIVEL (F) VALVE, NEEDLE /8 NPT (F) TEE, JIC#8(M)x /8 NPT(M)x JIC#8(M) TEE, /8 NPT(M)x JIC#8(M)x JIC#8(M) PAGE 7

38 THIS PAGE INTENTIONALLY LEFT BLANK PAGE 8

39 ELECTRICAL SECTION PAGE 9

40 CONTROL BOX GRAVITY DOWN (NEW STYLE) P/N 667 UP, OWN FOLD UNF 4, FOLD & UNFOLD FOLD UP DOWN UNFOLD UNF FOL 5 6,7 ITEM QTY. PART NO. DESCRIPTION BRACKET, MTG. SWITCH CNTRL BOX 4849 SWITCH, TOGGLE, 6 TERMINAL 597 SWITCH, TOGGLE POS. DBL. POLE BOX, COVER CONTROL BOX RECEPTACLE ASSY, FEMALE 5 POLE NUT, /" RECEPTACLE ASSY, FEMALE POLE 9 68 NUT, /4" 8,9 7, RECEPTACLE ASSY, FEMALE 4 POLE BOOT, SWITCH RUBBER SEAL PAGE 40

41 CONTROL BOX GRAVITY DOWN (OLD STYLE) P/N ,0 4 5 FOLD & UNFOLD FOLD UP DOWN UNFOLD UP OWN FOLD UNF UNF FOL 6 7 8,0 ITEM QTY. PART NO. DESCRIPTION BRACKET, MTG. SWITCH CNTRL BOX 4849 SWITCH, TOGGLE, 6 TERMINAL 597 SWITCH, TOGGLE POS. DBL. POLE BOX, COVER NUT, /" WATERTIGHT FITTING CONTROL BOX SPACER, SMALL BOX 8 6 CONNECTOR, WATERTIGHT CABLE ASSY. 5 POLE x 6FT BOOT, SWITCH RUBBER SEAL PAGE 4

42 CONTROL BOX POWER DOWN (NEW STYLE) P/N UP, OWN FOLD UNF 4, FOLD & UNFOLD FOLD UP DOWN UNFOLD UNF FOL 5 6,7 ITEM QTY. PART NO. DESCRIPTION BRACKET, MTG. SWITCH CNTRL BOX 4849 SWITCH, TOGGLE, 6 TERMINAL 597 SWITCH, TOGGLE POS. DBL. POLE BOX, COVER CONTROL BOX RECEPTACLE ASSY, FEMALE 5 POLE NUT, /" RECEPTACLE ASSY, FEMALE POLE 9 68 NUT, /4" 8,9 7, RECEPTACLE ASSY, FEMALE 4 POLE BOOT, SWITCH RUBBER SEAL PAGE 4

43 CONTROL BOX POWER DOWN (OLD STYLE) P/N , UP DOWN FOLD & UNFOLD FOLD POWER DOWN UNFOLD UP OWN 5 POWER DOWN FOLD UNF UNF FOL 6,7, ITEM QTY. PART NO. DESCRIPTION BRACKET, MTG. SWITCH CNTRL BOX 4849 SWITCH, TOGGLE, 6 TERMINAL 597 SWITCH, TOGGLE POS. DBL. POLE BOX, COVER, 8,9 7, CONTROL BOX & COVER REWORKED RECEPTACLE ASSY, FEMALE 5 POLE NUT, /" 8 67 RECEPTACLE ASSY, MALE POLE 9 68 NUT, /4" RECEPTACLE ASSY, FEMALE 4 POLE BOOT, SWITCH RUBBER SEAL 60 SWITCH, TOGGLE POS. SGL. POLE PAGE 4

44 WIRING, PUMP GRAVITY DOWN 5 PIN CONNECTOR P/N 5687 NUT, WATERTIGHT P/N PIN CONNECTOR P/N 5684 NUT, WATERTIGHT P/N 590 LOCK W/MANUAL OVERRIDE P/N 594 SOLENOID D VALVE P/N 6045 SOLENOID A VALVE P/N 55 LOCKING BLOCK P/N 6045 SOLENOID B VALVE P/N 55 PAGE 44 MOTOR SOLENOID P/N 699 SOLENOID C VALVE P/N 6076 SOLENOID E VALVE P/N 6076

45 WIRING, PUMP GRAVITY DOWN Gnd. To Mtr. Solenoid Mtg. Screw -Pole Splitter P/N 5698 D BRN 5 Pin Conn. P/N Pin Conn. P/N 5684 Mtr. Solenoid Mtg. Screw LT BLU Connector P/N 0049 Shrink Tubing P/N (Typ. -Plcs.) D WHT RED ORG BLK RED BLK WHT Mtr. Solenoid Pin # Fuse Holder P/N Fuse P/N 6468 ORG BLK RED GRN To Mtr. Solenoid Pin # Terminal Ring P/N Ga. Wire x Lg. P/N (Typ. Plcs.) A B C E To Mtr. Solenoid Pin # Shrink Tubing P/N To Mtr. Solenoid Pin # Terminal Ring P/N Ga. Wire x Lg. P/N (Typ. 4 Plcs.) Gnd. To Mtr. Solenoid Mtg. Screw To Power Supply Mtr. Solenoid Pin # Cable x 6 Lg. P/N 587- Circuit Breaker P/N 76 PAGE 45

46 WIRING, PUMP POWER DOWN 5 PIN CONNECTOR P/N 5687 NUT, WATERTIGHT P/N PIN CONNECTOR P/N 5684 NUT, WATERTIGHT P/N 590 LOCK W/MANUAL OVERRIDE P/N 594 SOLENOID D VALVE P/N 6045 SOLENOID A VALVE P/N 55 LOCKING BLOCK P/N 6045 SOLENOID B VALVE P/N 55 PAGE 46 MOTOR SOLENOID P/N 699 SOLENOID C VALVE P/N 6076 SOLENOID E VALVE P/N 6076

47 WIRING, PUMP POWER DOWN Gnd. To Mtr. Solenoid Mtg. Screw -Pole Splitter P/N 5698 D BRN 5 Pin Conn. P/N Pin Conn. P/N 5684 Mtr. Solenoid Mtg. Screw LT BLU Connector P/N 0049 Shrink Tubing P/N (Typ. -Plcs.) D WHT RED ORG BLK RED BLK WHT Mtr. Solenoid Pin # Fuse Holder P/N Fuse P/N 6468 ORG BLK RED GRN To Mtr. Solenoid Pin # Terminal Ring P/N Ga. Wire x Lg. P/N (Typ. Plcs.) A B C E To Mtr. Solenoid Pin # To Mtr. Solenoid Pin # Terminal Ring P/N Ga. Wire x Lg. P/N (Typ. 4 Plcs.) Gnd. To Mtr. Solenoid Mtg. Screw To Power Supply Mtr. Solenoid Pin # Cable x 6 Lg. P/N 587- Circuit Breaker P/N 76 PAGE 47

48 WIRING, PUMP GRAVITY DOWN 5 PIN CONNECTOR P/N 5687 NUT, WATERTIGHT P/N PIN CONNECTOR P/N 5684 NUT, WATERTIGHT P/N 590 LOCK W/MANUAL OVERRIDE P/N 594 SOLENOID D VALVE P/N 6045 SOLENOID A VALVE P/N 55 LOCKING BLOCK P/N 6045 SOLENOID B VALVE P/N 55 MOTOR SOLENOID P/N 699 SOLENOID C VALVE P/N 6076 SOLENOID E VALVE P/N 6076 PAGE 48

49 WIRING, PUMP GRAVITY DOWN 5-Pin Conn. P/N Pin Conn. P/N 5684 GND BRN -Pole Splitter P/N 5698 D 5 4 To Pump Solenoid Pin Connector P/N 0049 Shrink Tubing P/N (Typ. 6-Plcs.) 4 LT. BLU D WHT RED GRN ORG BLK GRN RED BLK WHT Cable Assy. P/N 607 LT. BLU WHT ORG GRN BLK To Mtr. Solenoid Pin Shrink Tubing P/N ORG ORG WHT BLK RED ELEC. SWITCH BOX Switch P/N 6049 RED WHT BLK ORG WHT BLK RED PUMP PUMP RED RED BLK ORG WHT A B C E E C B A Gnd. To Pump Solenoid Mtg. Screws Gnd. To Pump Solenoid Mtg. Screws Cable Assy. P/N To Pump Solenoid Pin Switch P/N 8754 Cable Assy. P/N 0570 Solenoid Mtg. Screws Solenoid Pin Cable 6 P/N-587- To Pump Solenoid Pin Solenoid Pin Solenoid Pin PUMP PUMP Solenoid Pin PAGE 49

50 WIRING, PUMP POWER DOWN 5 PIN CONNECTOR P/N 5687 NUT, WATERTIGHT P/N PIN CONNECTOR P/N 5684 NUT, WATERTIGHT P/N 590 LOCK W/MANUAL OVERRIDE P/N 594 SOLENOID D VALVE P/N 6045 SOLENOID A VALVE P/N 55 LOCKING BLOCK P/N 6045 SOLENOID B VALVE P/N 55 MOTOR SOLENOID P/N 699 SOLENOID C VALVE P/N 6076 SOLENOID E VALVE P/N 6076 PAGE 50

51 WIRING, PUMP POWER DOWN 5-Pin Conn. P/N Pin Conn. P/N 5684 GND BRN -Pole Splitter P/N 5698 D 5 4 To Pump Solenoid Pin Connector P/N 0049 Shrink Tubing P/N (Typ. 6-Plcs.) 4 LT. BLU D WHT RED GRN ORG BLK GRN RED BLK WHT Cable Assy. P/N 607 LT. BLU WHT ORG GRN BLK ORG ORG WHT BLK RED To Mtr. Solenoid Pin ELEC. SWITCH BOX Switch P/N 6049 RED WHT BLK ORG WHT BLK RED PUMP PUMP RED RED BLK ORG WHT A B C E E C B A Gnd. To Pump Solenoid Mtg. Screws Gnd. To Pump Solenoid Mtg. Screws Cable Assy. P/N To Pump Solenoid Pin Switch P/N 8754 Cable Assy. P/N 0570 Solenoid Mtg. Screws Solenoid Pin Cable 6 P/N-587- To Pump Solenoid Pin Solenoid Pin Solenoid Pin PUMP PUMP Solenoid Pin PAGE 5

52 THIS PAGE INTENTIONALLY LEFT BLANK PAGE 5

53 OPTIONAL SECTION PAGE 5

54 HAND PUMP KIT P/N ,,,,4 9 0,5,6, SHOWN IN POWER DOWN CONFIGURATION. GRAVITY DOWN REPLACES THIS HOSE AND FITTINGS WITH A PLUG IN THE MANIFOLD PAGE 54

55 HAND PUMP KIT P/N 6604 ITEM QTY. PART NO. DESCRIPTION NIPPLE CLOSE PIPE, / NEEDLE VALVE, /8 NPT FTG. SWIVEL ELBOW TABULATED HOSE ASSEMBLY, 4" HOSE ASSY. HP 4" HOSE CLAMP, SCREW ELBOW, 90 /4"M x /8 BARB BRACKET, HAND PUMP KIT PIN, ROLL /6" x " HAND PUMP 008 FITTING, NIPPLE, /4 x -/ TEE, /4 NPT (F) 6057 ELBOW, JIC#8 x /4" NPT HOSE, /8"LP x 0" LG DECAL, SGL. PLUMB. ASSY ELBOW, 90 /8"NPT x JIC#8 (M) ELBOW, 90 /8"NPT x JIC#8 (F) TEE, /8" M x /8" (F-F) HOSE, /8"HP (F-F) x -5/8" LG STR. SWVL. /8NPT (M) x JIC#8 (F) * NUT, HEX 5/6-8 * SCREW, CAP 5/6-8 x " LG. * WASHER FLAT 5/6 x /6 * WASHER, LOCK 5/6 x 5/64 * NUT, NYLON LOCK /4-0 * BOLT, HEX /4-0 x -/" * WASHER, FLAT /4" * NOT SHOWN PAGE 55

56 BOTTOM STOP ASSEMBLY P/N BOTTOM STOP ASSY. LH (OPPOSITE) BOTTOM STOP ASSY. RH (SHOWN) PART NUMBER ITEM QTY DESCRIPTION HOOK, BOTTOM STOP BLOCK, BOTTOM STOP LH BLOCK, BOTTOM STOP RH WASHER, FLAT " BLOCK, ROTATING WELDMENT LH BLOCK, ROTATING WELDMENT RH PIN, ROLL /4" x " SPRING, TORSION, LH SPRING, TORSION, RH PAGE 56

57 FIXED RAMP, 6 & FOLDOVER ASSEMBLY (REF.) FIXED RAMP (SHOWN) 6 FIXED RAMP (NOT SHOWN) VEHICLE BODY WIDTH RAMP 90" 96" 0" 6" DEEP " DEEP PAGE 57

58 ALUMINUM RETENTION RAMP ASSEMBLY 90" WIDE VEHICLE 96" WIDE VEHICLE 0" WIDE VEHICLE PART NO ITEM QTY. PART NUMBER DESCRIPTION 555 HINGE ASSEMBLY R.H WASHER, FLAT /8" LOCKNUT, /8-6 UNC BUMPER ALUMINUM RAMP HINGE ASSEMBLY L.H. BOLT, /8-6 UNC x -/4" FLAT HD. BOLT, /8-6 UNC x -/" FLAT HD PIPE, /4" SCH. 80 x 60" LG. PAGE 58 5

59 ALUMINUM RETENTION RAMP R.H. HINGE ASSEMBLY, P/N ITEM QTY PART NUMBER DESCRIPTION 46 ROLL PIN /8" x " 55 LOCK & BUSHING WELDMENT 554 BEARING, SELF-LUBE " DIA. x " LG BUSHING x /4" PIN WELDMENT HINGE ARM WELDMENT R.H TORSION SPRING LOCKING ARM ASSEMBLY PIN WELDMENT PAGE 59

60 CART STOP RAMP SEE BREAKDOWN ON NEXT PAGE. ASSEMBLY 90" W IDE VEHICLE 96" W IDE VEHICLE PAGE " W IDE VEHICLE PART NO ITEM QTY. PART NUMBER DESCRIPTION RAMP, POP-UP CART STOP 554 BEARING, SELF-LUBE / x / PIN, 4.8" LG CART STOP, /8" DIAMOND PLATE BOLT, /8-6 x -/4" NUT, LOCK, / WASHER, FLAT /8" LOCKING HOOK R.H TORSION SPRING PIN, LOCKING HOOK SUPPORT BOLT, /4-0 x " LG WASHER, FLAT /4" 5460 TORSION SPRING NUT, LOCK, / LOCKING CAM, R.H PIN, 7." LG RETAINING RING,.5 x.5

61 CART STOP RAMP 5 5,6, ,7 0 PAGE 6

62 DUAL CART STOP RAMP SEE BREAKDOWN ON NEXT PAGE. 9 4 PAGE 6

63 DUAL CART STOP RAMP (RH ASSY. SHOWN, LH OPPOSITE) 5,0 5,6,7 4 9,8 8, 6,7 0 PAGE 6