M REV. K SEPTEMBER Parts Manual Contains: Warranty Information Warnings Parts Ordering Information Exploded View Parts Breakdowns

Transcription

1 M-07- REV. K SEPTEMBER 03 Parts Manual Contains: Warranty Information Warnings Parts Ordering Information Exploded View Parts Breakdowns MAXON Lift Corp. 03

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3 LIFT CORP. 9 Slauson Ave. Santa Fe Springs, CA CUSTOMER SERVICE: TELEPHONE () TOLL FREE (800) 7- FAX: (888) NOTE: For latest version of all Manuals (and replacements), download the Manuals from Maxon s website at WARRANTY/ RMA POLICY & PROCEDURE LIFTGATE WARRANTY Type of Warranty: Term of Warranty: Full Parts and Labor Standard Liftgates - years from ship date or,000 cycles Premium Liftgates - years from ship date or 0,000 cycles This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift s specifi cations as set forth in MAXON Lift s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments, damage or malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this warranty does not cover equipment that has had unauthorized modifi cations or alterations made to the product. MAXON agrees to replace any components which are found to be defective during the fi rst years of service, and will reimburse for labor based on MAXON s Liftgate Warranty Flat Rate Schedule. (Copy of the Flat Rate is available at All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $00, including parts and labor, MAXON s Technical Service Department must be notifi ed and an Authorization Number obtained. All claims for warranty must be received within 30 Days of the repair date, and include the following information:. Liftgate Model Number and Serial Number. The End User must be referenced on the claim 3. Detailed Description of Problem. Corrective Action Taken, and Date of Repair. Parts used for Repair, Including MAXON Part Number(s). MAXON R.M.A. # and/or Authorization # if applicable (see below) 7. Person contacted at MAXON if applicable 8. Claim must show detailed information i.e. Labor rate and hours of work performed Warranty claims can also be placed online at Online claims will be given priority processing. All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON s Warranty Department within 30 days of repair date. All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior written approval from MAXON s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with original invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized returns will be refused and will become the responsibility of the returnee. Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in plain view, and returned freight prepaid. All returns are subject to a % handling charge if not accompanied by a detailed packing list. Returned parts are subject to no credit and returned back to the customer. Defective parts requested for return must be returned within 30 days of the claim date for consideration to: MAXON Lift Corp. 03 Greenleaf Ave., Santa Fe Springs, CA 9070 Attn: RMA# MAXON s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income due to downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered. MAXON s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem. All Liftgates returned are subject to inspection and a % restocking fee. Any returned Liftgates or components that have been installed or not returned in new condition will be subject to an additional reworking charge, which will be based upon the labor and material cost required to return the Liftgate or component to new condition. PURCHASE PART WARRANTY Term of Warranty: Year from Date of Purchase. Type of Warranty: Part replacement only. MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts and original invoice. All warranty replacements parts will be sent out via ground freight. If a rush shipment is requested, all freight charges will be billed to the requesting party.

4 TABLE OF CONTENTS WARNINGS... ORDERING PARTS... BMRSD LIFTGATE... 7 MAIN FRAME & ATTACHING HARDWARE - STEEL PLATFORM... 8 MAIN FRAME & ATTACHING HARDWARE - ALUMINUM PLATFORM... 0 RH COLUMN ASSEMBLY... RH RUNNER ASSEMBLY... CARRIER GUARD MOUNTING... 8 UPPER TANDEM ASSEMBLY, RH RUNNER... 9 TANDEM ASSEMBLY (LOWER - RH & LH RUNNERS)... 0 LH COLUMN ASSEMBLY... LH RUNNER ASSEMBLY... UPPER TANDEM ASSEMBLY, LH RUNNER... PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (STEEL)... 8 PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (STEEL) PLATFORM ASSEMBLY (STEEL)... 3 FLIPOVER WITH RETENTION RAMP (STEEL)... 3 FLIPOVER WITH FIX RAMP (STEEL)... 3 ALUMINUM RETENTION RAMP ASSEMBLY (FOR STEEL PLATFORM)... 3 LH CHAIN ASSEMBLY (FOR STEEL PLATFORM) RH CHAIN ASSEMBLY (FOR STEEL PLATFORM) PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (ALUMINUM)... 0 PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (ALUMINUM)... PLATFORM ASSEMBLY (ALUMINUM)... 8 FLIPOVER ASSEMBLY (ALUMINUM)... 0

5 TABLE OF CONTENTS - Continued FLIPOVER ASSEMBLY W/FIXED RAMP (ALUMINUM)... ALUMINUM RETENTION RAMP ASSEMBLY (FOR ALUMINUM PLATFORM)... LH CHAIN ASSEMBLY (FOR ALUMINUM PLATFORM)... RH CHAIN ASSEMBLY (FOR ALUMINUM PLATFORM)... 7 HYDRAULIC COMPONENTS SECTION... 8 DUAL PUMP ASSEMBLY... 8 SINGLE PUMP ASSEMBLY... VDC POWER UNIT... VDC POWER UNIT (PUMP, NO MANIFOLD)... 8 BOX ASSEMBLY FOR DUAL PUMPS BOX ASSEMBLY FOR SINGLE PUMP... 7 HYDRAULIC COMPONENTS... 7 ELECTRICAL COMPONENTS SECTION ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS - DUAL PUMP BOX ELECTRICAL COMPONENTS - SINGLE PUMP BOX... 8 ELECTRICAL COMPONENTS - BATTERY BOX... 8 BATTERY BOX ASSEMBLY... 8 BATTERY BOX...88

6 Comply with the following WARNINGS while maintaining Liftgates. WARNINGS WARNING Read and understand the instructions in Maintenance Manual before performing maintenance on the Liftgate. Disconnect Liftgate power cable from battery before repairing or servicing Liftgate. Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact with battery acid may injure unprotected eyes and skin. Be careful working by an automotive type battery. Make sure the work area is well ventilated and there are no fl ames or sparks near the battery. Never lay objects on the battery that can short the terminals together. If battery acid gets in your eyes, immediately seek fi rst aid. If acid gets on your skin, immediately wash it off with soap and water. Never perform unauthorized modifi cations on the Liftgate. Modifi cations may result in early failure of the Liftgate and may create hazards for Liftgate operators and maintainers. Use only Maxon Authorized Parts for replacement parts. Order replacement parts from: MAXON LIFT CORP. Customer Service 9 Slauson Ave., Santa Fe Springs, CA 9070 Phone: (800) 7- To order parts by , submit orders to cservice@maxonlift.com.! Remove all rings, watches and jewelry before doing any electrical work. Recommended practices for welding on steel parts are contained in the current AWS (American Welding Society) D. Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and personal injury can result from welds that are done incorrectly. Recommended practices for welding on aluminum parts are contained in the current AWS (American Welding Society) D. Structural Welding Code - Aluminum. Damage to Liftgate and/or vehicle, and personal injury can result from welds that are done incorrectly. ORDERING PARTS Provide Liftgate model and serial number information with your parts order. Need Technical Support? Send requests by to technicalsupport@maxonlift.com. For latest version Manuals (and replacements), download Manuals from Maxon s website at

7 BMRSD LIFTGATE REFER TO PLATFORM, FLIPOVER AND CHAIN ASSEMBLY REFER TO MAIN FRAME & ATTACHING HARDWARE BATTERY BOX (REFER TO ELECTRICAL COMPONENTS) PUMP BOX (REFER TO HYDRAULIC COMPONENTS) CONTROL SWITCH (REFER TO ELECTRICAL COMPONENTS) 7

8 MAIN FRAME & ATTACHING HARDWARE - STEEL PLATFORM REFER TO LH COLUMN ASSEMBLY ( PLACES) 3 (0 PLACES) REFER TO STEEL PLATFORM ASSEMBLY REFER TO LH COLUMN ASSEMBLY REFER TO STEEL PLATFORM ASSEMBLY 9 8 REFER TO STEEL PLATFORM ASSEMBLY REFER TO STEEL PLATFORM ASSEMBLY 7 (0 PLACES) REFER TO LH COLUMN ASSEMBLY 8 REFER TO STEEL PLATFORM ASSEMBLY 3 ( PLACES) REFER TO RH COLUMN ASSEMBLY 9 8

9 ITEM QTY. PART NO. DESCRIPTION FLANGE LOCK NUT, / FLAT WASHER, / CHANNEL (STAINLESS STEEL BRACKET) 80-0 CHANNEL (MILD STEEL BRACKET) FLAT WASHER, / NYLON LOCK NUT, / HEX HEAD SCREW, /8 - X -/ LG, GRADE EXTENSION PLATE, 9 UNIT (STAINLESS STEEL) EXTENSION PLATE, 0 UNIT (STAINLESS STEEL) 80- EXTENSION PLATE, 9 UNIT (MILD STEEL) 80- EXTENSION PLATE, 0 UNIT (MILD STEEL) SPACER, STAINLESS STEEL, /3 THICK HEX HEAD CAP SCREW, / -3 X -/ LG, GRADE 8 9

10 MAIN FRAME & ATTACHING HARDWARE - ALUMINUM PLATFORM REFER TO LH COLUMN ASSEMBLY ( PLACES) 3 (0 PLACES) 9 REFER TO ALUMINUM PLATFORM ASSEMBLY REFER TO LH COLUMN ASSEMBLY 8 REFER TO ALUMINUM PLATFORM ASSEMBLY REFER TO ALUMINUM PLATFORM ASSEMBLY 7 (0 PLACES) REFER TO LH COLUMN ASSEMBLY 8 REFER TO ALUMINUM PLATFORM ASSEMBLY 3 ( PLACES) REFER TO RH COLUMN ASSEMBLY 9 0

11 ITEM QTY. PART NO. DESCRIPTION FLANGE LOCK NUT, / FLAT WASHER, / CHANNEL (STAINLESS STEEL BRACKET) 80-0 CHANNEL (MILD STEEL BRACKET) FLAT WASHER, / NYLON LOCK NUT, / HEX HEAD SCREW, /8 - X -/ LG, GRADE EXTENSION PLATE, 9 UNIT (STAINLESS STEEL) EXTENSION PLATE, 0 UNIT (STAINLESS STEEL) 80- EXTENSION PLATE, 9 UNIT (MILD STEEL) 80- EXTENSION PLATE, 0 UNIT (MILD STEEL) SPACER, STAINLESS STEEL, /3 THICK HEX HEAD CAP SCREW, / -3 X -/ LG, GRADE 8

12 NOTE: Most hydraulic components not shown for clarity. Refer to HYDRAULIC COMPONENTS SECTION for hydraulic system parts. RH COLUMN ASSEMBLY 8 REFER TO RH RUNNER ASSEMBLY 3 3 REFER TO HYDRAULIC COMPONENTS 7 0 9

13 ITEM QTY. PART NO. DESCRIPTION COLUMN ASSEMBLY, RH, 3/ REF G COLUMN ASSEMBLY, RH, 3/ (GALVANIZED) COLUMN ASSEMBLY, RH, / G COLUMN ASSEMBLY, RH, / (GALVANIZED) 07 POP RIVET, 3/ X 7/ LG ROLL PIN, 3/8 X LG SWITCH PLATE 39 BUSHING 078 MAXON VERTICAL PLATE, 3 X 0-/8 LG COUPLING OUTSIDE 7 07 COUPLING INSIDE, CASTING COLUMN COVER, RH LED LIGHT, OVAL, RED STAINLESS STEEL FLANGE COLUMN WELDMENT, RH 889-0G COLUMN WELDMENT, RH (GALVANIZED) PIN, STAINLESS STEEL, O.D. X -3/ LG PIN, STAINLESS STEEL, O.D. X -7/8 LG PIN, STAINLESS STEEL, O.D. X -/ LG BOLT, HEX, / -0 X /8 LG, GRADE 8 3

14 RH COLUMN ASSEMBLY - Continued 30 8 ( PLACES) ( PLACES) 9 ( PLACES) 7 3 ( PLACES) 0 9 ( PLACES) ( PLACES)

15 ITEM QTY. PART NO. DESCRIPTION CAP SCREW, / -8 X / LG, GRADE CAP SCREW, HEX, 3/8 - X 3/ LG, GRADE CAP SCREW, HEX, 3/8 - X LG, GRADE FLAT WASHER, 3/ LOCK WASHER, / LOCK WASHER, /, GRADE LOCK WASHER, 3/ POP RIVET, 3/ X 9/ LG ROLL PIN, / X LG. 003 PLUG 8003 PIN, STAINLESS STEEL, -/ O.D. X 3 LG SOCKET HEAD CAP SCREW, / -0 X 3 LG, GRADE NYLON LOCK NUT, / FENDER WASHER, 3/ COLUMN COVER 87-0 COLUMN COVER (ZINC PLATED) BUTTON SOCKET CAP SCREW, 3/8 - X 7/8 LG COVER

16 RH RUNNER ASSEMBLY 3 UPPER TANDEM ASSEMBLY, RH RUNNER (REF) 8 (8 PLACES) TANDEM ASSEMBLY (LOWER) (REF) A 7 B 7 3 9

17 ITEM QTY. PART NO. DESCRIPTION REF RH RUNNER ASSEMBLY RH RUNNER ASSEMBLY (GALVANIZED) HEX HEAD CAP SCREW, 3/8 - X /8 LG, GRADE LOCK WASHER, 3/8 3 3 UPPER PAD SUPPORT ASSEMBLY A/R 3030 SPACER RH RUNNER RH RUNNER (GALVANIZED) A 3 CHAIN BRACKET WELDMENT B 3 GUSSET, CHAIN BRACKET HEX HEAD CAP SCREW, 3/8 - X 3/ LG, GRADE ARM WELDMENT CAP SCREW, / -0 X LG, GRADE PIN COLLAR NYLON LOCK NUT, / NYLON LOCK NUT, / RUBBER BUMPER FLAT WASHER, / BUTTON HEAD SCREW, / -8 X -/ LG. 3 LOWER PAD SUPPORT ASSEMBLY BEARING, SELF LUBE, -/ DIA. X -/8 LG BEARING, SELF LUBE, -/ DIA. X LG POP RIVET, 3/ X 7/ LG PAD 0 3 GREASE FITTING, / NOTE: A/R means As Required. 7

18 CARRIER GUARD MOUNTING RH COLUMN ASSEMBLY RH RUNNER ASSEMBLY 3 ITEM QTY. PART NO. DESCRIPTION 099 FLAT HEAD SCREW, / -0 X -/ LG CABLE/HOSE CARRIER HEX HEAD BOLT, / -0 X -/ LG, GRADE NYLON LOCK NUT, / -0 3 BUSHING, / DIA. X / LG. 3 CLAMP, #8 RUBBER LOOM 8

19 UPPER TANDEM ASSEMBLY, RH RUNNER (3 PLACES) 8 ITEM QTY. PART NO. DESCRIPTION REF UPPER TANDEM ASSEMBLY, RH RUNNER ROLLER AXLE 800 ROLLER BRACKET FLAT WASHER,.7 I.D. X -/ O.D. STAINLESS STEEL ROLLER 8003 ROLLER BRACKET 900 FLAT WASHER, /8 I.D. X -3/8 O.D LOCK NUT, THIN HEAD, / ROLLER COVER GREASE FITTING, DRIVE-IN, 3/ 9

20 TANDEM ASSEMBLY (LOWER - RH & LH RUNNERS) 8 3 ( PLACES) ITEM QTY. PART NO. DESCRIPTION REF 88-0 TANDEM ASSEMBLY (LOWER) ROLLER AXLE 800 ROLLER BRACKET 3 8 FLAT WASHER,.7 I.D. X -/ O.D. STAINLESS STEEL ROLLER 8003 ROLLER BRACKET 900 FLAT WASHER, /8 I.D. X -3/8 O.D LOCK NUT, THIN HEAD, / GREASE FITTING, DRIVE-IN, 3/ 7 0

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22 ( PLACES) ( PLACES) LH COLUMN ASSEMBLY 3 ( PLACES) NOTE: Most hydraulic components not shown for clarity. Refer to HYDRAULIC COMPONENTS SECTION for hydraulic system parts. REFER TO HYDRAULIC COMPONENTS 8 ( PLACES) REFER TO RH RUNNER ASSEMBLY 0 ( PLACES) 7 ( PLACES)

23 ITEM QTY. PART NO. DESCRIPTION COLUMN ASSEMBLY, LH, 3/ REF 888-0G COLUMN ASSEMBLY, LH, 3/ (GALVANIZED) COLUMN ASSEMBLY, LH, / 888-0G COLUMN ASSEMBLY, LH, / (GALVANIZED) 07 POP RIVET, 3/ X.0 LG ROLL PIN, 3/8 X LG PIN COLLAR, -3/ LG. 078 MAXON VERTICAL PLATE, 3 X 0-/8 LG. 3 COLUMN COVER 87-0 COLUMN COVER (ZINC PLATED) 80-0 COLUMN WELDMENT, LH 80-0 COLUMN WELDMENT, LH (GALVANIZED) PIN, STAINLESS STEEL, O.D. X -3/ LG PIN, STAINLESS STEEL, O.D. X -7/8 LG COUPLING LH, MACHINED COLUMN COVER, LH CAP SCREW, HEX, 3/8 - X 3/ LG, GRADE CAP SCREW, HEX, 3/8 - X LG, GRADE FLAT WASHER, 3/ LOCK WASHER, 3/ POP RIVET, 3/ X. LG. 003 PLUG LED LIGHT, OVAL, RED STAINLESS STEEL FLANGE SOCKET HEAD SCREW, / -0 X 3 LG, GRADE FENDER WASHER, 3/ PIN, STAINLESS STEEL, -/ O.D. X 3 LG BUTTON SOCKET CAP SCREW, 3/8 - X 7/8 LG PLATE W/ DECAL POP RIVET, /8 X 3/8 LG. 3

24 LH RUNNER ASSEMBLY 9 (8 PLACES) UPPER TANDEM ASSEMBLY, LH RUNNER (REF) B A 7 0 TANDEM ASSEMBLY (LOWER) (REF) 0

25 ITEM QTY. PART NO. DESCRIPTION REF LH RUNNER ASSEMBLY LH RUNNER ASSEMBLY (GALVANIZED) HEX HEAD CAP SCREW, 3/8 - X 3/ LG, GRADE LOCK WASHER, 3/8 3 3 UPPER PAD SUPPORT ASSEMBLY A/R 3030 SPACER LH RUNNER LH RUNNER (GALVANIZED) A 3 CHAIN BRACKET WELDMENT B 3 GUSSET, CHAIN BRACKET HEX HEAD CAP SCREW, 3/8 - X /8 LG, GRADE ARM WELDMENT CAP SCREW, / -0 X LG, GRADE PIN COLLAR NYLON LOCK NUT, / NYLON LOCK NUT, / RUBBER BUMPER FLAT WASHER, / BUTTON HEAD SCREW, / -8 X -/ LG. 3 LOWER PAD SUPPORT ASSEMBLY BEARING, SELF LUBE, -/ DIA. X -/8 LG BEARING, SELF LUBE, -/ DIA. X LG PAD POP RIVET, 3/ X 7/ LG. 0 3 GREASE FITTING / NOTE: A/R means As Required.

26 UPPER TANDEM ASSEMBLY, LH RUNNER (3 PLACES) ITEM QTY. PART NO. DESCRIPTION REF 88-0 UPPER TANDEM ASSEMBLY, LH RUNNER ROLLER AXLE 800 ROLLER BRACKET FLAT WASHER,.7 I.D. X -/ O.D. STAINLESS STEEL ROLLER 8003 ROLLER BRACKET 900 FLAT WASHER, /8 I.D. X -3/8 O.D LOCK NUT, THIN HEAD, / ROLLER COVER GREASE FITTING, DRIVE-IN, 3/ 7

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28 PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (STEEL)! CAUTION MAXON recommends replacing LH & RH platform support chains as a set. Possible harm to users or bystanders and/or equipment damage could result if chains are only replaced one at a time. 0 ( PLACES) B 8 REFER TO LH CHAIN ASSEMBLY FOR STEEL PLATFORM 9 REFER TO STEEL FLIPOVER WITH RETENTION RAMP ASSEMBLY C A D 9 0 ( PLACES) 7 3D 8 7 3A REFER TO STEEL PLATFORM ASSEMBLY 3C 3B 3 REFER TO RH CHAIN ASSEMBLY FOR STEEL PLATFORM 8

29 ITEM QTY. PART NO. DESCRIPTION 8 FLAT WASHER, 3/ I.D. STAINLESS STEEL 9-0G OPENER ASSEMBLY LH (GALVANIZED), * 9-03G OPENER ASSEMBLY LH (GALVANIZED), * 9-0G OPENER ASSEMBLY LH (GALVANIZED), + * 9-07G OPENER ASSEMBLY LH (GALVANIZED), 3 + * 9-09G OPENER ASSEMBLY LH (GALVANIZED), + 30 * A CLEVIS PIN, / X -7/8 LG, GRADE 8 B COTTER PIN, /8 X LG. C 80-0 ANCHOR SHACKLE D BEARING, SELF LUBE, 3/ DIA. X -3/8 LG. 9-0G OPENER ASSEMBLY RH (GALVANIZED), * 9-0G OPENER ASSEMBLY RH (GALVANIZED), * 3 9-0G OPENER ASSEMBLY RH (GALVANIZED), + * 9-08G OPENER ASSEMBLY RH (GALVANIZED), 3 + * 9-0G OPENER ASSEMBLY RH (GALVANIZED), + 30 * 3A CLEVIS PIN, / X -7/8 LG, GRADE 8 3B COTTER PIN, /8 X LG. 3C 80-0 ANCHOR SHACKLE 3D BEARING, SELF LUBE, 3/ DIA. X -3/8 LG U-BOLT ROLL PIN, 3/ X -/ LG PIN, STAINLESS STEEL -/ LG. 7 ROLL PIN, 3/8 X LG NUT, / NYLON LOCK NUT, / FLAT WASHER, / * PLATFORM + FLIPOVER DEPTH 9

30 PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (STEEL)! CAUTION MAXON recommends replacing LH & RH platform support chains as a set. Possible harm to users or bystanders and/or equipment damage could result if chains are only replaced one at a time. 3 ( PLACES) C A B REFER TO STEEL FLIPOVER WITH FIX RAMP ASSEMBLY D REFER TO LH CHAIN ASSEMBLY FOR STEEL PLATFORM 7 3 ( PLACES) 7 3D 3A REFER TO STEEL PLATFORM ASSEMBLY 3C 3B 3 REFER TO RH CHAIN ASSEMBLY FOR STEEL PLATFORM 30

31 ITEM QTY. PART NO. DESCRIPTION 8 FLAT WASHER, 3/ I.D. STAINLESS STEEL 9-09G OPENER ASSEMBLY LH (GALVANIZED), + 30 * A CLEVIS PIN, / X -7/8 LG, GRADE 8 B COTTER PIN, /8 X LG. C 80-0 ANCHOR SHACKLE D BEARING, SELF LUBE, 3/ DIA. X -3/8 LG G OPENER ASSEMBLY RH (GALVANIZED), + 30 * 3A CLEVIS PIN, / X -7/8 LG, GRADE 8 3B COTTER PIN, /8 X LG. 3C 80-0 ANCHOR SHACKLE 3D BEARING, SELF LUBE, 3/ DIA. X -3/8 LG U-BOLT ROLL PIN, 3/ X -/ LG PIN, STAINLESS STEEL -/ LG. 7 ROLL PIN, 3/8 X LG CLEVIS PIN, / X -7/8 LG, GRADE COTTER PIN, /8 X LG ANCHOR SHACKLE NUT, / 9000 NYLON LOCK NUT, / FLAT WASHER, / * PLATFORM + FLIPOVER DEPTH 3

32 8 PLATFORM ASSEMBLY (STEEL)

33 ITEM QTY. DESCRIPTION PART NO. 30 DEEP 3 DEEP DEEP PLATFORM, 9 WIDE VEHICLE (BMR-A -) PLATFORM,0 WIDE VEHICLE (BMR-A -) REF PLATFORM, 9 WIDE VEHICLE (BMR-A 3-) PLATFORM, 0 WIDE VEHICLE (BMR-A 3-) PLATFORM, 9 WIDE VEHICLE (GALVANIZED) G G G PLATFORM, 0 WIDE VEHICLE (GALVANIZED) 8883-G 8883-G G BEARING, SELF LUBE, DIA. X LG. 37 BEARING, SELF LUBE, -/ DIA. X -/ LG NYLON LOCK NUT, 3/ RUBBER BUMPER 3 FLAT WASHER, 3/ HEX HEAD BOLT, 3/8 - X -/ LG, GRADE NYLON LOCK NUT, / HEX HEAD SCREW, /8 - X -/ LG FLANGE LOCK NUT, 3-, PL FLAT WASHER, / SOCKET SCREW, / -3 X -/ LG, GRADE

34 FLIPOVER WITH RETENTION RAMP (STEEL) REFER TO ALUMINUM RETENTION RAMP ASSEMBLY (FOR STEEL PLATFORM) ITEM QTY. PART NO. DESCRIPTION FLIPOVER, 80 W X D (BMRSD 3-, 9 WIDE VEHICLE) FLIPOVER, 80 W X D (BMRSD -, 9 WIDE VEHICLE) 80-03G FLIPOVER, 80 W X D (GALVANIZED) 80-3 FLIPOVER, 8 W X D (BMRSD 3-, 0 WIDE VEHICLE) 80-3 FLIPOVER, 8 W X D (BMRSD -, 0 WIDE VEHICLE) 80-3G FLIPOVER, 8 W X D (GALVANIZED) 78-0 BUMPER FLAT WASHER, / BUTTON HEAD SCREW, / -8 X -/ LG NYLON LOCK NUT, / NYLON LOCK NUT, / FLASHING SAFETY LIGHT BUTTON SCREW, / -0 X -/ 8 7 3

35 FLIPOVER WITH FIX RAMP (STEEL) 3 7 REF 7 ITEM QTY. PART NO. DESCRIPTION FLIPOVER, 80 W X 30 D + FIX RAMP (BMR-A 3-, 9 WIDE VEHICLE) FLIPOVER, 80 W X 30 D + FIX RAMP (BMR-A -, 9 WIDE VEHICLE) G FLIPOVER, 80 W X 30 D + FIX RAMP (GALVANIZED) REF FLIPOVER, 8 W X 30 D + FIX RAMP (BMR-A 3-, 0 WIDE VEHICLE) FLIPOVER, 8 W X 30 D + FIX RAMP (BMR-A -, 0 WIDE VEHICLE) G FLIPOVER, 8 W X 30 D + FIX RAMP (GALVANIZED) 78-0 BUMPER FLAT WASHER, / BUTTON HEAD SCREW, / -8 X -/ LG NYLON LOCK NUT, / NYLON LOCK NUT, / FLASHING SAFETY LIGHT BUTTON SCREW, / -0 X -/ LG. 3 3

36 ALUMINUM RETENTION RAMP ASSEMBLY (FOR STEEL PLATFORM) (3 PLACES) 3 (3 PLACES) (3 PLACES) 3 (3 PLACES) 0 3 (3 PLACES) 8 8 (3 PLACES) 7 C B D A 9 9 3

37 ITEM QTY. PART NO. DESCRIPTION REF AL RET. RAMP ASSEMBLY, (9 WIDE VEH) (GALVANIZED) AL RET. RAMP ASSEMBLY, (0 WIDE VEH) (GALVANIZED) 97-0 ALUMINUM RAMP X 77 LG. (9 WIDE VEH) ALUMINUM RAMP X 83 LG. (0 WIDE VEH) 3-0 HINGE ASSEMBLY, LH (GALVANIZED) FLAT WASHER, 3/ NYLON LOCK NUT, 3/ RUBBER BUMPER SCREW, FLAT SOCKET HEAD, 3/8 - X -/ LG SCREW, FLAT SOCKET HEAD, 3/8 - X -/ LG. 9 8 PIN WELDMENT HINGE ASSEMBLY, RH (GALVANIZED) ROLL PIN, / X -/ LG. 38 PIN WELDMENT 3 3 BEARING, SELF LUBE, DIA. X LG ROLL PIN, 3/8 X LG. 77 PIN WELDMENT, / LG LOCKING ARM ASSEMBLY A 3 BEARING, SELF LUBE, / DIA. X / LG. B BOLT, 3/8 - X -/ GRADE 8 C 900- HEX NUT, 3/8 - D NORD-LOCK WASHER, 3/8 - M TORSION SPRING, LH ROLL PIN, /8 X LG BEARING, SELF LUBE, 3/ DIA. X LG. 37

38 LH CHAIN ASSEMBLY (FOR STEEL PLATFORM) 3 3A ITEM QTY. DESCRIPTION PART NO. * + * + 30 REF CHAIN ASSEMBLY LH CHAIN (GALVANIZED) CLEVIS PIN, / X -7/8 LG TEAR DROP ASSEMBLY, LH A BEARING, SELF-LUBE 0078 COTTER PIN, /8 X -/ LG KEEP HANDS CLEAR (PLATE) (SEE DECAL SEC) REF POP RIVET, 3/ X.0 LG. REF! CAUTION MAXON recommends replacing LH & RH platform support chains as a set. Possible harm to users or bystanders and/ or equipment damage could result if chains are only replaced one at a time. * PLATFORM + FLIPOVER DEPTH 38

39 RH CHAIN ASSEMBLY (FOR STEEL PLATFORM) 3A 3! ITEM QTY. DESCRIPTION CAUTION MAXON recommends replacing LH & RH platform support chains as a set. Possible harm to users or bystanders and/ or equipment damage could result if chains are only replaced one at a time. PART NO. * + * + 30 REF CHAIN ASSEMBLY RH CHAIN (GALVANIZED) CLEVIS PIN, / X -7/8 LG TEAR DROP ASSEMBLY, RH A BEARING, SELF-LUBE 0078 COTTER PIN, /8 X -/ KEEP HANDS CLEAR (PLATE) (SEE DECAL SEC) REF POP RIVET, 3/ X.0 LG. REF * PLATFORM + FLIPOVER DEPTH 39

40 PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (ALUMINUM)! CAUTION MAXON recommends replacing LH & RH platform support chains as a set. Possible harm to users or bystanders and/or equipment damage could result if chains are only replaced one at a time. REFER TO LH CHAIN ASSEMBLY FOR ALUMINUM PLATFORM 7 B D 0 C A REFER TO FLIPOVER ASSEMBLY (FOR ALUMINUM PLATFORM) 8 REFER TO PLATFORM ASSEMBLY (ALUMINUM) 3 ( PLACES) 0 A D C B REFER TO RH CHAIN ASSEMBLY FOR ALUMINUM PLATFORM 0

41 ITEM QTY. PART NO. DESCRIPTION 000 NYLON LOCK NUT, / -3 3 RUBBER BUMPER BOLT, 3/ -0 X -/8 LG HEX HEAD SCREW, /8 - X -/ LG. 9-0G OPENER ASSEMBLY LH (GALVANIZED), * 9-03G OPENER ASSEMBLY LH (GALVANIZED), * 9-0G OPENER ASSEMBLY LH (GALVANIZED), + * A CLEVIS PIN, / X -7/8 LG, GRADE 8 B COTTER PIN, /8 X LG. C 80-0 ANCHOR SHACKLE D BEARING, SELF LUBE, 3/ DIA. X -3/8 LG. 9-0G OPENER ASSEMBLY RH (GALVANIZED), * 9-0G OPENER ASSEMBLY RH (GALVANIZED), * 9-0G OPENER ASSEMBLY RH (GALVANIZED), + * A CLEVIS PIN, / X -7/8 LG, GRADE 8 B COTTER PIN, /8 X LG. C 80-0 ANCHOR SHACKLE D BEARING, SELF LUBE, 3/ DIA. X -3/8 LG PIN HINGE PIN CONNECTOR BAR WELDMENT 9 (GALVANIZED) 8-03 CONNECTOR BAR WELDMENT 0 (GALVANIZED) U-BOLT 30-0 LINK SPACER, LG. 30- LINK SPACER, / LG FLANGE LOCK NUT, /8 - * PLATFORM + FLIPOVER DEPTH

42 PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (ALUMINUM) - Continued ( PLACES) 7 ( PLACES) ( PLACES) 3 ( PLACES) 8 9

43 ITEM QTY. PART NO. DESCRIPTION HEX HEAD BOLT, 3/8 - X -/ LG, GRADE HEX HEAD CAP SCREW, / -3 X -/ LG, GRADE SOCKET SCREW, / -3 X -/ LG, GRADE FLAT HEAD SOCKET SCREW, 3/8 - X -/ NYLON NUT, 3/ NYLON LOCK NUT, / NUT, / FLAT WASHER, 3/ FLAT WASHER, / FLAT WASHER, 3/ FLAT WASHER, / LOCK WASHER, 3/ FLAT WASHER, / ROLL PIN, 3/ X LG ROLL PIN, / X -/ LG BEARING, SELF LUBE, -/ I.D. X -/ LG. 3

44 PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (ALUMINUM)! CAUTION MAXON recommends replacing LH & RH platform support chains as a set. Possible harm to users or bystanders and/or equipment damage could result if chains are only replaced one at a time. REFER TO LH CHAIN ASSEMBLY FOR ALUMINUM PLATFORM 7 B D 0 C A REFER TO FLIPOVER W/FIX RAMP ASSEMBLY (FOR ALUMINUM PLATFORM) 8 REFER TO PLATFORM ASSEMBLY (ALUMINUM) 3 ( PLACES) 0 A D C B REFER TO RH CHAIN ASSEMBLY FOR ALUMINUM PLATFORM

45 ITEM QTY. PART NO. DESCRIPTION 000 NYLON LOCK NUT, / -3 3 RUBBER BUMPER BOLT, 3/ -0 X -/8 LG HEX HEAD SCREW, /8 - X -/ LG. 9-0G OPENER ASSEMBLY LH (GALVANIZED), * 9-03G OPENER ASSEMBLY LH (GALVANIZED), * 9-0G OPENER ASSEMBLY LH (GALVANIZED), + * A CLEVIS PIN, / X -7/8 LG, GRADE 8 B COTTER PIN, /8 X LG. C 80-0 ANCHOR SHACKLE D BEARING, SELF LUBE, 3/ DIA. X -3/8 LG. 9-0G OPENER ASSEMBLY RH (GALVANIZED), * 9-0G OPENER ASSEMBLY RH (GALVANIZED), * 9-0G OPENER ASSEMBLY RH (GALVANIZED), + * A CLEVIS PIN, / X -7/8 LG, GRADE 8 B COTTER PIN, /8 X LG. C 80-0 ANCHOR SHACKLE D BEARING, SELF LUBE, 3/ DIA. X -3/8 LG PIN HINGE PIN CONNECTOR BAR WELDMENT 9 (GALVANIZED) 8-03 CONNECTOR BAR WELDMENT 0 (GALVANIZED) U-BOLT 30-0 LINK SPACER, LG. 30- LINK SPACER, / LG FLANGE LOCK NUT, /8 - * PLATFORM + FLIPOVER DEPTH

46 PLATFORM, FLIPOVER, AND CHAIN ASSEMBLY - (ALUMINUM) - Continued ( PLACES) 7 ( PLACES) 7 0 ( PLACES) ( PLACES) 8 9

47 ITEM QTY. PART NO. DESCRIPTION HEX HEAD BOLT, 3/8 - X -/ LG, GRADE HEX HEAD CAP SCREW, / -3 X -/ LG, GRADE SOCKET SCREW, / -3 X -/ LG, GRADE FLAT HEAD SOCKET SCREW, 3/8 - X -/ NYLON NUT, 3/ NYLON LOCK NUT, / NUT, / FLAT WASHER, 3/ FLAT WASHER, / FLAT WASHER, 3/ FLAT WASHER, / LOCK WASHER, 3/ FLAT WASHER, / ROLL PIN, 3/ X LG ROLL PIN, / X -/ LG BEARING, SELF LUBE, -/ I.D. X -/ LG. 7

48 PLATFORM ASSEMBLY (ALUMINUM) 3 REF ITEM QTY. PART NO. DESCRIPTION REF PLATFORM, 9 WIDE VEHICLE PLATFORM, 0 WIDE VEHICLE NUT / BRACKET FLAT HEAD SOCKET SCREW, 3/8 - X -/ LG HEX HEAD SCREW, / LOCK NUT, 3/ LOCK WASHER, /8 8

49 THIS PAGE INTENTIONALLY LEFT BLANK 9

50 FLIPOVER ASSEMBLY (ALUMINUM) 9 0 REF 3 REFER TO ALUMINUM RETENTION RAMP ASSEMBLY (FOR ALUMINUM PLATFORM)

51 ITEM QTY. DESCRIPTION REF PART NO. 30 DEEP 3 DEEP DEEP FLIPOVER, 9 WIDE VEHICLE FLIPOVER, 0 WIDE VEHICLE BUMPER 78-0 BUTTON SCREW, / -8 X -/ LG LOCK NUT, / FLAT WASHER, / BUTTON HEAD SCREW, 3/8 - X -/ LG, GRADE SOCKET HEAD SCREW, 3/8 - X -/ LG, GRADE LOCK NUT, 3/ FLAT WASHER, 3/ LOCK WASHER, / X / THICK FLASHING SAFETY LIGHT 9070 BUTTON SCREW, / -0 X -/

52 FLIPOVER ASSEMBLY W/FIXED RAMP (ALUMINUM) 7 3 REF ITEM QTY. DESCRIPTION 7 PART NO. 3 3 DEEP DEEP REF FLIPOVER, 9 WIDE VEHICLE FLIPOVER, 0 WIDE VEHICLE BUMPER 78-0 BUTTON SCREW, / -8 X -/ LG LOCK NUT, / FLAT WASHER, / LOCK WASHER, / X / THICK 900- FLASHING SAFETY LIGHT BUTTON SCREW, / -0 X -/

53 THIS PAGE INTENTIONALLY LEFT BLANK 3

54 ALUMINUM RETENTION RAMP ASSEMBLY (FOR ALUMINUM PLATFORM) (3 PLACES) 3 (3 PLACES) (3 PLACES) 3 (3 PLACES) 3 (3 PLACES) D 8 (3 PLACES) C A B 9 9 9A

55 ITEM QTY. PART NO. DESCRIPTION REF AL RET. RAMP ASSEMBLY, (9 WIDE VEH) (GALVANIZED) AL RET. RAMP ASSEMBLY, (0 WIDE VEH) (GALVANIZED) 97-0 ALUMINUM RAMP X 7 LG. (9 WIDE VEH) ALUMINUM RAMP X 80 LG. (0 WIDE VEH) 3-0 HINGE ASSEMBLY, LH (GALVANIZED) FLAT WASHER, 3/ NYLON LOCK NUT, 3/ RUBBER BUMPER SCREW, FLAT SOCKET HEAD, 3/8 - X -/ LG SCREW, FLAT SOCKET HEAD, 3/8 - X -/ LG. 9 8 PIN WELDMENT HINGE ASSEMBLY, RH (GALVANIZED) ROLL PIN, / X -/ LG. 38 PIN WELDMENT 3 3 BEARING, SELF LUBE, DIA. X LG ROLL PIN, 3/8 X LG. 77 PIN WELDMENT, / LG LOCKING ARM ASSEMBLY A 3 BEARING, SELF LUBE, / DIA. X / LG. B BOLT, 3/8 - X -/ GRADE 8 C 900- HEX NUT, 3/8 - D NORD-LOCK WASHER, 3/8 - M TORSION SPRING, LH ROLL PIN, /8 X LG LOCKING CAM 9A BEARING, SELF LUBE, 3/ DIA. X LG.

56 LH CHAIN ASSEMBLY (FOR ALUMINUM PLATFORM) 3 3A ITEM QTY. PART NO. DESCRIPTION REF CHAIN ASSEMBLY LH 88-0 CHAIN CLEVIS PIN, / X -7/8 LG TEAR DROP ASSEMBLY, LH 3A 0078 BEARING, SELF-LUBE COTTER PIN, /8 X -/ LG. REF KEEP HANDS CLEAR (PLATE) (SEE DECAL SEC) REF POP RIVET, 3/ X 7/ LG.! CAUTION MAXON recommends replacing LH & RH platform support chains as a set. Possible harm to users or bystanders and/ or equipment damage could result if chains are only replaced one at a time.

57 RH CHAIN ASSEMBLY (FOR ALUMINUM PLATFORM) 3A 3! ITEM QTY. PART NO. DESCRIPTION REF CHAIN ASSEMBLY RH 88-0 CHAIN CLEVIS PIN, / X -7/8 LG TEAR DROP ASSEMBLY, RH 3A 0078 BEARING, SELF-LUBE COTTER PIN, /8 X -/ CAUTION MAXON recommends replacing LH & RH platform support chains as a set. Possible harm to users or bystanders and/ or equipment damage could result if chains are only replaced one at a time. REF KEEP HANDS CLEAR (PLATE) (SEE DECAL SEC) REF POP RIVET, 3/ X 7/ LG. 7

58 HYDRAULIC COMPONENTS SECTION DUAL PUMP ASSEMBLY REFER TO BOX ASSEMBLY FOR DUAL PUMPS 8

59 ITEM QTY. PART NO. DESCRIPTION REF DUAL PUMP ASSEMBLY (BMRSD) POWER UP TUBE ASSEMBLY, / 33 FLOW DIVIDER STRAIGHT CONNECTOR, #8 00 ELBOW, 90, SAE 37, JIC#8-M & JIC#8-F UNION, BULKHEAD, SAE 37 FLARE TWIN NUT, BULKHEAD, SAE 37 FLARE TWIN FLAT WASHER, 3/ ELBOW, JIC # M-F SW NUT, BULKHEAD, JIC# FLAT WASHER, 7/ X / THICK 9009 STRAIGHT UNION JIC# POWER CLOSE TUBE ASSEMBLY, / STRAIGHT CONNECTOR, F/S # O-RING # M-M POWER OPEN TUBE ASSEMBLY, / 908 STRAIGHT ELBOW, F/S #8 O-RING # M-M 9

60 DUAL PUMP ASSEMBLY - Continued 7 7 REFER TO VDC POWER UNIT (POWER DOWN) 8 ( PLACES) 3 30 A REFER TO VDC POWER UNIT (NO MANIFOLD) 7 0 ( PLACES) 9 ( PLACES) 0

61 ITEM QTY. PART NO. DESCRIPTION 90-0 PUMP TO PUMP TUBE ASSEMBLY, 3/ ELBOW, NPSC, SAE # F/S O-RING M-M 8 39 CAP SCREW, 3/8 - X -3/ LG LOCK WASHER, 3/ O-RING SPIN-ON OIL FILTER (HEAD & CARTRIDGE) A FILTER (SPIN-ON CARTRIDGE) ELBOW, # M O-RING, 3/8 M NPT OIL FILTER TUBE ASSEMBLY, 3/ FLAT WASHER, 9/ 9008 NUT, BULKHEAD JIC# 90 ELBOW, 90, SAE 37, JIC # M-F STRAIGHT UNION JIC# POWER DOWN TUBE ASSEMBLY, 3/ STRAIGHT CONNECTOR, # LONG CONNECTOR, NPSC SAE # ELBOW, NPSC, SAE # O-RING M-F SWIVEL DECAL, UNFOLD DECAL, FOLD

62 SINGLE PUMP ASSEMBLY REFER TO BOX ASSEMBLY FOR SINGLE PUMP

63 ITEM QTY. PART NO. DESCRIPTION REF DUAL PUMP ASSEMBLY (BMRSD) POWER UP TUBE ASSEMBLY, / 33 FLOW DIVIDER ELBOW, NPSC, SAE #8 F/S O-RING M-M 00 ELBOW, 90, SAE 37, JIC#8-M & JIC#8-F UNION, BULKHEAD, SAE 37 FLARE TWIN NUT, BULKHEAD, SAE 37 FLARE TWIN FLAT WASHER, 3/ ELBOW, JIC # M-F SW NUT, BULKHEAD, JIC# FLAT WASHER, 7/ X / THICK 9009 STRAIGHT UNION JIC# POWER CLOSE TUBE ASSEMBLY, / STRAIGHT CONNECTOR, F/S # O-RING # M-M POWER OPEN TUBE ASSEMBLY, / 908 STRAIGHT ELBOW, F/S #8 O-RING # M-M 3

64 SINGLE PUMP ASSEMBLY - Continued REFER TO VDC POWER UNIT (POWER DOWN) A

65 ITEM QTY. PART NO. DESCRIPTION ELBOW, NPSC, SAE # O-RING M-F SWIVEL ELBOW, NPSC, SAE # F/S O-RING M-M 8 39 CAP SCREW, 3/8 - X -3/ LG LOCK WASHER, 3/ O-RING SPIN-ON OIL FILTER (HEAD & CARTRIDGE) A FILTER (SPIN-ON CARTRIDGE) ELBOW, # M O-RING, 3/8 M NPT OIL FILTER TUBE ASSEMBLY, 3/ FLAT WASHER, 9/ NUT, BULKHEAD JIC# 90 ELBOW, 90, SAE 37, JIC # M-F STRAIGHT UNION JIC# POWER DOWN TUBE ASSEMBLY, 3/ STRAIGHT CONNECTOR, # LONG CONNECTOR, NPSC SAE # DECAL, UNFOLD DECAL, FOLD

66 VDC POWER UNIT CAUTION To prevent damage to metal case starter solenoid, hold bottom terminal nut securely when loosening and tightening top terminal nut. Do not over-tighten the terminal nuts. For the / load terminals, torque nuts 3-0 lbs.-in. Torque the nuts on #0-3 control terminals -0 lbs.-in. CAUTION To prevent damage when installing -way valves, torque valve cartridge nut to 30 lbs.-in. max. (NOT SHOWN) 0 SOCKET HEAD SCREW (REF) , 7 (NOT SHOWN) (BETWEEN MANIFOLD & DRIVE PLATE) 9

67 ITEM QTY. PART NO. DESCRIPTION REF VDC POWER UNIT 0 OIL SEAL, PUMP (NOT SHOWN) MANIFOLD ASSEMBLY PUMP ASSEMBLY (MODEL 0) 88 O-RING, RESERVOIR (NOT SHOWN) MOTOR, VDC, H.D VALVE, POS-3 WAY, WITH COIL O-RING (NOT SHOWN) CHECK VALVE FILTER, PUMP INLET VALVE CARTRIDGE, WAY 900 VALVE CARTRIDGE, WAY 909 RELIEF VALVE (RAISE & UNFOLD/FOLD, 00 PSI) SWITCH, SOLENOID ASSEMBLY, VDC 800 CABLE RELIEF VALVE (LOWERING, 00 PSI) FLOW CONTROL VALVE, GPM 7

68 VDC POWER UNIT (PUMP, NO MANIFOLD) (, 7 NOT SHOWN) SERIAL PLATE (REF) 3 ITEM QTY. PART NO. DESCRIPTION REF VDC POWER UNIT (NO MANIFOLD) MOTOR, VDC HD PUMP ASSEMBLY, FILTER, PUMP INLET SWITCH, SOLENOID ASSEMBLY, VDC 800 CABLE ASSEMBLY 0 OIL SEAL (SHAFT SEAL, NOT SHOWN) O-RING (NOT SHOWN) 8

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70 BOX ASSEMBLY FOR DUAL PUMPS ( PLACES) 9 PART OF ITEM SIGHT GLASS (REF)

71 ITEM QTY. PART NO. DESCRIPTION REF BOX ASSEMBLY, DUAL PUMP (BMRSD) 80-0 COVER WELDMENT GROMMET, 3/ 3-0 RUBBER SEAL, 0 LG. 90 BUMPER, / X 3/ X 3/8 339 FILLER 3 37 CABLE TIE MOUNTING BASE LATCH 8 7 PLUG, / (MAGNETIZED) 9 83 DECAL, PUMP SELECTOR SWITCH DECAL, HYDRAULIC FLUID LEVEL (BMR) 73-0 DECAL, GROUND STUD BOLT, #0- X / LG HEX PLUG, / SHOULDER SCREW, / X / LG NYLON NUT, # FLAT WASHER, #0 X /3 THICK FLAT WASHER, 3/ LOCK WASHER, 3/8 X 3/3 THICK HEX HEAD NUT, 3/ BLIND RIVET, 3/ X 9/ DECAL, POWER DOWN ON-DEMAND 7

72 BOX ASSEMBLY FOR SINGLE PUMP PART OF ITEM ( PLACES) SIGHT GLASS (REF)

73 ITEM QTY. PART NO. DESCRIPTION REF BOX ASSEMBLY, SINGLE PUMP (BMRSD) COVER WELDMENT 379 LATCH 3-0 RUBBER SEAL, 00 LG. 339 FILLER BOLT, #0- X / LG HEX PLUG, / 7 7 PLUG, / (MAGNETIZED) BLIND RIVET, 3/ X 9/ 9 90 BUMPER, / X 3/ X 3/ SEMI-TUBULAR RIVET DECAL, HYDRAULIC FLUID LEVEL (BMR) 73-0 DECAL, GROUND STUD 3 GROMMET, 3/ FLAT WASHER, 3/ LOCK WASHER, 3/8 X 3/3 THICK 900- HEX HEAD NUT, 3/ DECAL, POWER DOWN ON-DEMAND 73

74 HYDRAULIC COMPONENTS LEFT CYLINDER A D- B C 3 D-3 D D- 7,7A B 7,7A 9 C A 3 0-7/8 (SEE NOTE) RIGHT CYLINDER 8B REFER TO CARRIER GUARD MOUNTING 8,8C 8A 3 CAUTION To prevent damage to hose assembly, item 9, make sure hose is relaxed inside the carrier guard before tightening hose connections. Connectors on each end of the hose must be loose to relax the hose. Hold swivel nut and pivot connector to align each end of the hose. When the hose is relaxed, make connections & torque each connector to 7. lb-ft. NOTE: The twin line hose fi ttings, with -7/8 offset, must be connected to cylinder. 7

75 ITEM QTY. PART NO. DESCRIPTION 907 ELBOW, 3/8 X / M-M REF HYDRAULIC LOCK VALVE A 908 ELBOW STRAIGHT, FACE SEAL #8, O-RING, # M-M B 0 ELBOW 90, O-RING, # M-M / NPTF C 93-0 VALVE ASSEMBLY, PRESSURE COMPENSATED, 3 GPM D HYDRAULIC LOCK VALVE ASSEMBLY D COIL, VDC D VALVE CARTRIDGE (WP) D NUT, CARTRIDGE VALVE FACE SEAL TUBE ASSEMBLY, RETURN LINE FACE SEAL TUBE ASSEMBLY, LIFT LINE ELBOW 90, FACE SEAL, #8 M-M TUBE ASSEMBLY 7 7A REF SK-0 COMB 803SK-0 COMB CYLINDER, -3/ BORE X 3-/8 STROKE (BMRSD-3/-) CYLINDER, BORE X 3-/8 STROKE (BMRSD-/-) SEAL KIT (COMBINATION, BMRSD-3/-) SEAL KIT (COMBINATION, BMRSD-/-) CYLINDER ASSEMBLY, -/ BORE, -3/ STROKE 8A 37 BEARING, SELF LUBE DIA. I.D. X LG. 8B 9079 CONNECTOR, FACE SEAL #, O-RING, # M-M 8C 9000 SEAL KIT (CYLINDER) HOSE, TWIN LINE, OPENING & CLOSING RUBBER SPACER ELBOW 90, FACE SEAL, # M-M UNION, ELBOW, FACE SEAL #M-#M 90 DEG TEE, UNION 3/8 FACE SEAL MALE, -JLO 7

76 HYDRAULIC COMPONENTS - Continued LEFT CYLINDER RIGHT CYLINDER 0 REFER TO CARRIER GUARD MOUNTING

77 ITEM QTY. PART NO. DESCRIPTION 9-0 HP HOSE /, 00 LG HP HOSE /, LG HP HOSE 3/8, LG. (3 INSTALLATION) HP HOSE 3/8, 9 LG. (0 INSTALLATION) HP HOSE 3/8, LG. ( INSTALLATION) HP HOSE 3/8, 3 LG. (0 INSTALLATION) HP HOSE 3/8, LG. (8 INSTALLATION) HP HOSE 3/8, LG. (3 INSTALLATION) HP HOSE 3/8, 7 LG. (0 INSTALLATION) HP HOSE 3/8, 33 LG. ( INSTALLATION) HP HOSE 3/8, 39 LG. (0 INSTALLATION) HP HOSE 3/8, 90 LG. (8 INSTALLATION) HP HOSE /, 3 LG. (3 INSTALLATION) HP HOSE /, LG. (0 INSTALLATION) HP HOSE /, LG. ( INSTALLATION) HP HOSE /, 8 LG. (0 INSTALLATION) HP HOSE /, 38 LG. (8 INSTALLATION) HP HOSE /, LG. (3 INSTALLATION) HP HOSE /, 88 LG. (0 INSTALLATION) HP HOSE /, 8 LG. ( INSTALLATION) HP HOSE /, 308 LG. (0 INSTALLATION) HP HOSE /, 0 LG. (8 INSTALLATION) O-RING, # (/ FACE SEAL TUBE-END) O-RING, # (3/8 FACE SEAL TUBE-END) O-RING, #8 (/ FACE SEAL TUBE-END) 77

78 TO VEHICLE WIRING HARNESS ELECTRICAL COMPONENTS SECTION ELECTRICAL COMPONENTS R P STOP, TURN & TAILLIGHTS STOP, TURN & TAILLIGHTS LH COLUMN LEFT CYLINDER RH COLUMN RIGHT CYLINDER TO VEHICLE WIRING HARNESS P0 P7 3 P8 R8 8 PUMP BOX R P 9 R R ALIGN MARKS ALIGNING ROUND CONNECTORS OPTIONAL BATTERY BOX GROUND CABLE (REF) P P 7 P9 R9 P R 78

79 NOTE: MAXON recommends using dielectric grease on all electrical connections. ITEM QTY. PART NO. DESCRIPTION 90-0 HARNESS, MOLDED RH 8-0 CABLE FLEXIBLE, MOLDED SWITCH & CABLE, MOLDED 90-0 HARNESS ASSEMBLY, STOP/TAIL LIGHTS 8-0 CABLE, MOLDED, 90 LG. 900 SWITCH SEAL BOOT, HALF-TOGGLE HARNESS INTCON, POWER DOWN, MOLDED CONTROL BOX, POWER DOWN, POWER OPEN 83-0 CABLE EXTENSION, MOLDED, 3 LG CABLE EXTENSION, MOLDED, 7 LG CABLE EXTENSION, MOLDED, 7 LG CABLE EXTENSION, MOLDED, 33 LG. 79

80 ELECTRICAL COMPONENTS - DUAL PUMP BOX, 3 ( PLACES) 0 3,, , 0, NOTE: MAXON recommends using dielectric grease on all electrical connections , 0, 7, 8,, ( PLACES) 80

81 ITEM QTY. PART NO. DESCRIPTION REF DUAL PUMP ASSEMBLY (BMRSD) TIE, PLASTIC 7 LG GASKET, CONNECTOR ( PIN) 3 79 CIRCUIT BREAKER, 0 AMP 88-0 SWITCH ASSEMBLY (POWER DOWN ON DEMAND) 8-0 CABLE ASSEMBLY, GA, 8 LG. 8-0 CABLE ASSEMBLY, GA, LG CABLE ASSEMBLY, GA, 0-/ LG CABLE ASSEMBLY, GA, -/ LG WIRE ASSEMBLY, GA, 7 LG HARNESS, DUAL PUMP (BMRSD) TOGGLE SWITCH (PUMP SELECTOR) PAN HEAD SCREW, #-0 X / LG LOCK NUT, NYLON, #-0, GRADE PAN HEAD SCREW, 0 - X / LG FLAT WASHER, #0 (STAINLESS STEEL) NYLON NUT, # SWITCH, MASTER DISCONNECT O-RING CAP SCREW, / -8 X /8 LG, GRADE FLAT WASHER, / X / THICK LOCK WASHER, / X / THICK, GRADE FLAT WASHER, # PAN HEAD SCREW, #0- X LG. 8

82 ELECTRICAL COMPONENTS - SINGLE PUMP BOX, ( PLACES) , 7, 8 ( PLACES), 3 NOTE: MAXON recommends using dielectric grease on all electrical connections. 3 8

83 ITEM QTY. PART NO. DESCRIPTION REF SINGLE PUMP ASSEMBLY (BMRSD) 0780 TIE, PLASTIC 7 LG. 87 MASTER SWITCH, O-RING SEALED SHAFT 3 87 PLATE, SWITCH FACE GASKET, CONNECTOR ( PIN) 79 CIRCUIT BREAKER, 0 AMP 80-0 CABLE ASSEMBLY, GA, 0-/ LG CABLE ASSEMBLY, GA, LG HARNESS, SINGLE PUMP (BMRSD) WIRE ASSEMBLY, GA, 7 LG SWITCH ASSEMBLY (POWER DOWN ON DEMAND) PAN HEAD SCREW, #0- X LG FLAT WASHER, #0 (STAINLESS STEEL) LOCK NUT, # PAN HEAD SCREW, #-0 X / LG LOCK NUT, #-0, GRADE CAP SCREW, / -8 X /8 LG, GRADE LOCK WASHER, / X / THICK, GRADE FLAT WASHER, / X / THICK 83

84 ELECTRICAL COMPONENTS - BATTERY BOX 3 (GROUND CABLE TO PUMP BOX) VOLT BATTERY CONNECTIONS (-) BATTERY CABLE TO COMMON GROUND CHARGE LINE TO TRUCK OR TRACTOR BATTERY (POWER CABLE WITH FUSE TO PUMP BOX) (IN PARTS BOX) NOTE: MAXON recommends using dielectric grease on all electrical connections. ITEM QTY PART NO. DESCRIPTION 73 CIRCUIT BREAKER 0 AMP 8-07 CABLE ASSEMBLY, GA,8 LG CABLE ASSEMBLY, GA, 7 LG. 87- CABLE ASSEMBLY, GA, 0 LG CABLE ASSEMBLY, GA, 00 AMP, LG. 8

85 THIS PAGE INTENTIONALLY LEFT BLANK 8

86 BATTERY BOX ASSEMBLY! WARNING Explosive hydrogen gas from charging batteries can accumulate in battery box if not vented from the box. To prevent hydrogen gas from accumulating, ensure the 3 ventilation holes in battery box are not plugged or covered. VENTILATION HOLES 9 (3 PLACES) 0 (3 PLACES) 8 (3 PLACES) (3 PLACES) ROD ANCHOR POINT (REF) (3 PLACES),, ( PLACES) REFER TO BATTERY BOX ( PLACES) ( PLACES), 3, ( PLACES) 8

87 ITEM QTY PART NO. DESCRIPTION 93-0G BATTERY MOUNT PLATE WELDMENT, GALVANIZED FLAT WASHER, 9/ LOCK WASHER, 9/ CAP SCREW, / -0 X -/ LG, GRADE HEX NUT, / ROD, L-SHAPE BATTERY HOLD DOWN BRACKET (BATTERY HOLD DOWN) FLAT WASHER, / HEX NUT, / -8, GRADE LOCK WASHER, # FLAT WASHER, / PAN HEAD SCREW, / -0 X LG LOCK NUT, / MANUAL RESET BRACKET PAN HEAD SCREW, / -0 X 3/ LG. 73 CIRCUIT BREAKER, 0 AMP (MANUAL RESET) 87

88 BATTERY BOX (3 PLACES) ( PLACES) ( PLACES) 7 3 ( PLACES) 9 0 ( PLACES)

89 ITEM QTY PART NO. DESCRIPTION REF 9-0 BATTERY BOX 9-0 BOX PLUG, / PLUG, -/ PLUG, GROMMET, 98-0 COVER RUBBER LATCH FASTENING KNOB BATTERY BOX HINGE STAINLESS STEEL BLIND RIVET, / X / -3/ WASHER, / PLUG, 9/ BUTTON HEAD SCREW, / -0 X LG LOCK NUT, / -0, NYLON PLUG, / 89