M-94-09 REV. D APRIL 00 BMR-44 PARTS MANUAL 9 Slauson Avenue. Santa Fe Springs, CA. 90670 (800) 7-46 MAXON Lift Corp. 009
LIFT CORP. CUSTOMER SERVICE: (56) 464-0099 (800) 7-46 FAX: (888) 77-77 9 Slauson Ave. Santa Fe Springs, CA. 90670 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. 9055 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.
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 60545 (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
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
WARNINGS WARNING PAGE 6
LIFTGATE TERMINOLOGY LH COLUMN LH CHAIN ASSY. RH COLUMN RH CHAIN ASSY. PLATFORM ASSY. FOLDOVER ASSY. PAGE 7
R.H. COLUMN ASSEMBLY P/N 5577 4 5 5 0 9 8 7 4 6 8 7 9 0, 5,6 4a PAGE 8
R.H. COLUMN ASSEMBLY P/N 5577 ITEM QTY. PART NO. DESCRIPTION 0 040597 BOLT, /4-0 x /4" 0 0055 WASHER, /4" LOCK 8 00564 WASHER, /4" FLAT 64 COVER, (-LIGHT COLUMN) 4 COVER WELD'T (-LIGHT 5767 COLUMN) 5 46 PIN, ROLL /8" x " LONG 6 6457 PIN, " x 5-7/8" LONG COLUMN WELDMENT, RH (- 55-00 7 LIGHT) COLUMN WELDMENT, RH (- 55 LIGHT) 8 60478 MAXON VERTICAL PLATE " x 0" 9 07644 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 4 5975 CLOSING CYLINDER ASSEMBLY 4a 5657 BEARING, SELF LUBE, x 5 577 PIN, " x -/" LONG 6 05004 PIN, ROLL /4" x " LONG 7 5694 SWITCH PLATE 8 50876 RUBBER SEAL, SWITCH 9 609 COVER WELDMENT, RH COLUMN 0 556 RUNNER ASSEMBLY, RH 555-0 LOCKING PLATE x -/" RH 600 LIGHT MOUNT BRACKET (-LIGHT) 600-00 LIGHT MOUNT BRACKET (-LIGHT) PAGE 9
L.H. COLUMN ASSEMBLY P/N 5578 4 5 9 7 6 0, 8 6 7 4 4 5 5 PAGE 0
L.H. COLUMN ASSEMBLY P/N 5578 ITEM QTY. PART NO. DESCRIPTION 8 040597 BOLT, /4-0 x /4" 8 0055 WASHER, /4" LOCK 8 00564 WASHER, /4" FLAT 4 64 COVER, (-LIGHT COLUMN) 5767 COVER WLDM'T (-LIGHT COLUMN) 5 46 PIN, ROLL /8" x " LONG 6 6457 PIN, " x 5-7/8" LONG COLUMN WELDMENT, LH (- 550-00 7 LIGHT) COLUMN WELDMENT, LH (- 550 LIGHT) 8 60478 MAXON VERTICAL PLATE " x 0" 9 07644 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 4 5565 RUNNER ASSEMBLY, LH 5 609-0 COVER WELDMENT, LH COLUMN 6 555-0 LOCKING PLATE x -/" LH 7 600 LIGHT MOUNT BRACKET (-LIGHT) 600-00 LIGHT MOUNT BRACKET (-LIGHT) PAGE
R.H. RUNNER ASSEMBLY P/N 556 5,6 0 9 4 8 7 4 6 6,7,,8 5 4 9 5 0 PAGE
R.H. RUNNER ASSEMBLY P/N 556 ITEM QTY. PART NO. DESCRIPTION 4 60560 BOLT, /8-6 x 4 00555 WASHER, LOCK /8 5566 UPPER PAD SUPPORT ASSEMBLY 4 556 RUNNER WELDMENT R.H. 5 5544 PAD POLY,.5" x 8" 6 07644 RIVET POP, /6 x.40 7 554 PAD.8 DIA. 8 5567 LOWER PAD SUPPORT ASSEMBLY 9 60559 BOLT, /4-0 x -/" 0 565 PIN COLLAR x /" 04066 NUT, NYLON LOCK 5/6-8 5595 BEARING, SELF-LUBE.5 5586 PIN 4 040604 BOLT, 5/6-8 x 5 00564 WASHER, FLAT, /4" 6 578-0 BUMPER 7 6057 COUPLING, INSIDE WELDMENT 8 5695 BEARING x /4" 9 6079 TORSION SPRING 0 6056-0 COUPLING, OUTSIDE WELDMENT 5596 BEARING, SELF-LUBE. 55-0 TANDEM ASSEMBLY 8 040597 BOLT, /4-0 x /4" 4 8 0055 WASHER, LOCK, /4" 5 564 CHAIN BRACKET WELDMENT PAGE
L.H. RUNNER ASSEMBLY P/N 5565 5,6 0 9 4 6,7,,8 5 6 4 7 8 0 9 PAGE 4
L.H. RUNNER ASSEMBLY P/N 5565 ITEM QTY. PART NO. DESCRIPTION 4 60560 BOLT, /8-6 x 4 00555 WASHER, LOCK /8 5566 UPPER PAD SUPPORT ASSEMBLY 4 5568 RUNNER WELDMENT L.H. 5 5544 PAD POLY,.5" x 8" 6 07644 RIVET POP, /6 x.40 7 554 PAD.8 DIA. 8 5567 LOWER PAD SUPPORT ASSEMBLY 9 60559 BOLT, /4-0 x -/" 0 565 PIN COLLAR x /" 04066 NUT, NYLON LOCK 5/6-8 5595 BEARING, SELF-LUBE.5 5586 PIN 4 040604 BOLT, 5/6-8 x 5 00564 WASHER, FLAT, /4" 6 578-0 BUMPER 7 5696 PIN COLLAR x -/4" 8 5596 BEARING SELF-LUBE x. 9 5579 PIN COLLAR WELDMENT 0 55-0 TANDEM ASSEMBLY 8 040597 BOLT, /4-0 x /4" 8 0055 WASHER, LOCK, /4" 564 CHAIN BRACKET WELDMENT PAGE 5
R.H. CHAIN ASSEMBLY a b ITEM QTY. DESCRIPTION 5,7 6,7 (4 x 4 Only) 4" x 4" 65-0 4" x 0" 65-04 PAGE 6 0 4,7 8,9 PLATFORM SIZE (ASSEMBLY PART NUMBER) 6" x 6" 65-06 6" x 4" 65-08 0" x 0" 65-0 4" x 48" ( Pc) 65- TEAR DROP ASSY. RH 6074-0 a BRNG, SELF-LUBE x / 60078 b BRNG, SELF-LUBE / x / 554 DOUBLE CLEVIS 5585-0 CHAIN 5606-5606-4 5606-5 5606-07 SLEEVE 4-/4" LONG 6609-05 N/A 4 SLEEVE " LONG N/A 6609-0 N/A SLEEVE 0" LONG N/A 6609-04 N/A 5 SLEEVE 6-/" LONG 6609-0 N/A SLEEVE 5-/4" LONG N/A 6609-0 N/A 6609-0 N/A 6 SLEEVE -/4" LONG 6609-06 N/A 6609-06 N/A SLEEVE " LONG N/A 6609-07 N/A 7 6 TIE WRAP (NOT SHOWN) 05780 8 CLEVIS PIN 6078 9 COTTER PIN 6086-0 N/A 0 OPENER ASSEMBLY (RH) 65-0 65-04 65-06 65-08 65-0
L.H. CHAIN ASSEMBLY a 8,9 b ITEM QTY. DESCRIPTION 4,7 0 4" x 4" 65-0 4" x 0" 65-0 PAGE 7 5,7 6,7 PLATFORM SIZE (ASSEMBLY PART NUMBER) 6" x 6" 65-05 6" x 4" 65-07 0" x 0" 65-09 4" x 48" ( Pc) 65- TEAR DROP ASSY. LH 6074-0 a BRNG, SELF-LUBE x / 60078 b BRNG, SELF-LUBE / x / 554 DOUBLE CLEVIS 5585-0 CHAIN 5606-5606-4 5606-5 5606-07 SLEEVE 4-/4" LONG 6609-05 N/A 4 SLEEVE " LONG N/A 6609-0 N/A SLEEVE 0" LONG N/A 6609-04 N/A 5 SLEEVE 6-/" LONG 6609-0 N/A SLEEVE 5-/4" LONG N/A 6609-0 N/A 6609-0 N/A 6 SLEEVE -/4" LONG 6609-06 N/A 6609-06 N/A SLEEVE " LONG N/A 6609-07 N/A 7 6 TIE WRAP (NOT SHOWN) 05780 8 CLEVIS PIN 6078 9 COTTER PIN 6086-0 N/A 0 OPENER ASSEMBLY (LH) 65-0 65-0 65-05 65-07 65-09
-PC. PLATFORM ASSEMBLY (REF. RH RUNNER) PIN (P/N 5586) BOLT, /- x -/4 (P/N 90006-0) LOCKNUT, / (P/N 040066) (REF. LH RUNNER) BOLT, /4-0 x (P/N 90008-7) 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 60090-0 60090-0 60090-0 60090-04
PLATFORM ASSEMBLY, BMR-44 (REF. RH RUNNER) PIN (P/N 5586) BOLT, /4-0 x (P/N 90008-7) BOLT, /- x -/4 (P/N 90006-0) LOCKNUT, / (P/N 040066) (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 5575-07 5575-08 5575-09 5575-0 5575-5575- PAGE 9
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 040540) (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 657-657-0 657-0 657-0 657-4 657-04 657-05 657-06 PAGE 0
ROLLER ASSY. (P/N 5550-00) WASHER,.5 OD x.78 ID (P/N 68) ROLLER BRACKET (P/N 5547-00) TANDEM ASSEMBLY P/N 55-0 ROLLER BRACKET (P/N 559-00) 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 5509-0) ROLLER AXEL (P/N 5509) NOTE: This Tandem Assembly Supercedes all previous Assemblies and is fully compatable PAGE
SPRING GUARD MOUNTING 6054 Ref. Electrical Schematic 6059 Ref. Electrical Schematic 574 Ref. Hydraulic Schematic 6099 SCREW, FLT. HD. /4-0 UNC x 90000 NUT, NYLON /4-0 560-0 SPRING GUARD 00708 BOLT, /4-0 x LONG Ref. RH Runner Assembly 605 Ref. Electrical Schematic 560-0 SPRING GUARD 90000 NUT, NYLON /4-0 56 RD. TUBE.5OD x.94 LG. PAGE
HYDRAULIC SECTION PAGE
PUMP 555 (994 TO JAN.997) 5 5b 5c 5 4 0 4 9 5a 8 5f 7 5e 6,6 5d PAGE 4
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 4 6075 MANIFOLD BLOCK ASSEMBLY 5 609 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 6 606 RESERVOIR,.5 GAL. 7 99 FILLER/BREATHER CAP 8 6050 FILTER 9 606 PUMP ASSEMBLY 0 5884 O-RING 6074 DRIVEPLATE ASSEMBLY, 5" 606 OIL SEAL 900 COUPLING 4 999 BUS BAR 5 6070 SOLENOID SWITCH *6 4 90 CAPSCREW, HEX HD. WASHER * NOT SHOWN PAGE 5
PUMP 60545 (JAN.997 TO PRESENT) a c b d f 8, 8a 9 8, 8a 7 4,5 e 9 8 0 7 6 4 5 6,6a PAGE 6
PUMP 60545 (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 60847 FILLER-BREATHER CAP 606 RESERVOIR,.5 GAL. 4 6050 FILTER 5 606 PUMP ASSEMBLY 6 5884 O-RING 7 6074 DRIVEPLATE ASSEMBLY 5" 8 606 OIL SEAL 9 900 COUPLING 0 6966 BUS BAR 699 SOLENOID, PRESTOLITE 5009 HEAVY DUTY MOTOR, VDC 674 MANIFOLD BLOCK ASSEMBLY 4 60 CONTROL, NEEDLE VALVE 5 650 O-RING, NEEDLE VALVE 6 6076 VALVE, SOLENOID, 4-WAY 6a 6595 O-RING KIT, 4-WAY VALVE 7 5706 STR. UNION, SAE #8 x JIC #8 M-M 8 55 VALVE, SOLENOID, -WAY 8a 6594 O-RING KIT, -WAY VALVE 9 90595 6044 VALVE, RELIEF PAGE 7
HYD. COMPONENTS, PUMP GRAVITY DOWN 4 7,8,9 4 8 5 7 LH CYLINDER 9 0 6 5 4,5 7,8,9 5 RH CYLINDER 5 6 See Pump Fittings- Pump, Gravity Down 0 Closing Cylinder Assy. (Ref. #5975) PAGE 8
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" 4 80090 TEE, /4" 5 9054-04 STR. FTG. /4 TUBE x /4 NPT (M) 6 470-7 RETURN LINE HOSE /4" x 0"LG. 7 646 STR. BULKHEAD JIC#8 8 646 NUT, BULKHEAD JIC#8 9 68 WASHER, FLAT -/4" x /4" 0 0406 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#5 4 55 FLOW DIVIDER 5 5707 HOSE, /8HP JIC#8 M-F x 40-/6" 6 594 HYD. LOCK VLV. W/MAN. OVERRIDE 7 576 FTG. /"TUBE x /4" NPT (M) 8 5745 VALVE, PRESSURE COMP. GPM 9 6064 ELBOW, SAE#6 (M) x /4 NPT (M) 0 597 HOSE, /8HP JIC#8 M-F (SW) x 8" 470- HOSE, PLASTIC /4" x 87" LONG 470-0 HOSE, PLASTIC /4" x 77" LONG 5706 STR. THD. SAE#8 X JIC#8 4 5700 HOSE, /8HP JIC#8 F-F x -5/8" PAGE 9
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
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
HYD. COMPONENTS, PUMP POWER DOWN 7,8,9 0 0 8 5 7 LH CYLINDER 9 0 5 6 4 4,5,8,9 6,8,9 5 RH CYLINDER See Pump Ftgs. Pump, Power Down Closing Cylinder Assy. (Ref. #5975) PAGE
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. 4 575 HOSE, /8HP JIC#8 F-F x -5/8" 4 60976 TEE, JIC#8 BULKHEAD 5 600 ELBOW, M JIC#8 x F SWVL. JIC#8 6 646 ELBOW, BULKHEAD JIC#8 7 646 STR. BULKHEAD JIC#8 8 4 646 NUT, BULKHEAD JIC#8 9 4 68 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#5 4 574 HOSE, /4HP JIC#5 xjic#6 x 4-/4" 5 5707 HOSE, /8HP JIC#8 M-F x 40-/6" 6 594 HYD. LOCK VLV. W/MAN. OVERRIDE 7 576 FTG. /"TUBE x /4" NPT (M) 8 5745 VALVE, PRESSURE COMP. GPM 9 6064 ELBOW, SAE#6 (M) x /4 NPT (M) 0 597 HOSE, /8HP JIC#8 M-F (SW) x 8" 5706 STR. THD. SAE#8 X JIC#8 5700 HOSE, /8HP JIC#8 F-F x -5/8" PAGE
HYD. COMPONENTS, PUMP GRAVITY DOWN 4 5 5 6 7 4 7 9 9 5 L.H. CYL. 8 0 4 4 0 R.H. CYL. 7 7 8 6 See Pump Fittings- Pump, Gravity Down PAGE 4 Closing Cylinder Assy. (Ref. #5975)
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. 4 5700 HOSE, /8HP JIC#8 F-F x -5/8" 5 609 TEE, JIC#8, (M) x (F SWIVEL) x (M) 6 575 HOSE, /8HP JIC#8 F-F x " 7 5707 HOSE, /8HP JIC#8 M-F x 40-/6" 8 57 STR. THD. SAE#6 X JIC#5 9 470-0 HOSE, PLASTIC /4" x 77" LONG 0 576 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 4 607 ELBOW, /" TUBE x /4"NPT 5 597 HOSE, /8HP JIC#8 M-F (SW) x 8" 6 600 ELBOW, JIC#8 M x JIC#8 F (SW) 7 646 NUT, BULKHEAD JIC#8 8 55 FLOW DIVIDER 9 646 STR. UNION JIC#8 (M) BULKHEAD 0 5706 STR. THD. SAE#8 X JIC#8 470- HOSE, PLASTIC /4" x 87" LONG PAGE 5
PUMP FITTINGS, PUMP GRAVITY DOWN TO FLOW DIVIDER 7 6 TO FILTER TO FILTER PUMP TO FILTER 5 4 PUMP 9 7,8 4 0 5 4 5 6 PAGE 6
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" 4 04095 ELBOW, 90 /8 NPT(M) x JIC#8 (M) 5 0406 ELBOW, 90 /4 NPT(M) x /4 TUBE 6 80090 TEE, /4 NPT (F) 7 8008 BUSHING, /8 NPT(M) x /4 NPT(F) 8 8006 NIPPLE, CLOSE /4 NPT (SCH. 80) 9 470- HOSE, PLASTIC /4" x 87" LG. 0 470-0 HOSE, PLASTIC /4" x 77" LG. 6099 DUAL PUMP, VDC 6068 STR. UNION /4 NPT(M) x JIC#8 (M) 4 5706 UNION SAE#8 (M)x JIC#8 SWIVEL (M) 4 4 5705 UNION /8NPT (M)x JIC#8 SWIVEL (F) 5 4 60490 VALVE, NEEDLE /8 NPT (F) 6 6464 TEE, JIC#8(M)x /8 NPT(M)x JIC#8(M) 7 6050 TEE, /8 NPT(M)x JIC#8(M)x JIC#8(M) PAGE 7
THIS PAGE INTENTIONALLY LEFT BLANK PAGE 8
ELECTRICAL SECTION PAGE 9
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 60896 BRACKET, MTG. SWITCH CNTRL BOX 4849 SWITCH, TOGGLE, 6 TERMINAL 597 SWITCH, TOGGLE POS. DBL. POLE 4 67-0 BOX, COVER 5 67-0 CONTROL BOX 6 675 RECEPTACLE ASSY, FEMALE 5 POLE 7 590 NUT, /" 8 696 RECEPTACLE ASSY, FEMALE POLE 9 68 NUT, /4" 8,9 7,0 0 674 RECEPTACLE ASSY, FEMALE 4 POLE 50876 BOOT, SWITCH RUBBER SEAL PAGE 40
CONTROL BOX GRAVITY DOWN (OLD STYLE) P/N 577-00,0 4 5 FOLD & UNFOLD FOLD UP DOWN UNFOLD UP OWN FOLD UNF UNF FOL 6 7 8,0 ITEM QTY. PART NO. DESCRIPTION 60896 BRACKET, MTG. SWITCH CNTRL BOX 4849 SWITCH, TOGGLE, 6 TERMINAL 597 SWITCH, TOGGLE POS. DBL. POLE 4 609 BOX, COVER 5 590 NUT, /" WATERTIGHT FITTING 9 6 609 CONTROL BOX 7 6090 SPACER, SMALL BOX 8 6 CONNECTOR, WATERTIGHT 9 5784 CABLE ASSY. 5 POLE x 6FT. 0 50876 BOOT, SWITCH RUBBER SEAL PAGE 4
CONTROL BOX POWER DOWN (NEW STYLE) P/N 667-0 UP, OWN FOLD UNF 4, FOLD & UNFOLD FOLD UP DOWN UNFOLD UNF FOL 5 6,7 ITEM QTY. PART NO. DESCRIPTION 60896 BRACKET, MTG. SWITCH CNTRL BOX 4849 SWITCH, TOGGLE, 6 TERMINAL 597 SWITCH, TOGGLE POS. DBL. POLE 4 67-0 BOX, COVER 5 67-0 CONTROL BOX 6 675 RECEPTACLE ASSY, FEMALE 5 POLE 7 590 NUT, /" 8 696 RECEPTACLE ASSY, FEMALE POLE 9 68 NUT, /4" 8,9 7,0 0 674 RECEPTACLE ASSY, FEMALE 4 POLE 50876 BOOT, SWITCH RUBBER SEAL PAGE 4
CONTROL BOX POWER DOWN (OLD STYLE) P/N 667-00 4, UP DOWN FOLD & UNFOLD FOLD POWER DOWN UNFOLD UP OWN 5 POWER DOWN FOLD UNF UNF FOL 6,7, ITEM QTY. PART NO. DESCRIPTION 60896 BRACKET, MTG. SWITCH CNTRL BOX 4849 SWITCH, TOGGLE, 6 TERMINAL 597 SWITCH, TOGGLE POS. DBL. POLE 4 67-0 BOX, COVER, 8,9 7,0 5 650 CONTROL BOX & COVER REWORKED 6 675 RECEPTACLE ASSY, FEMALE 5 POLE 7 590 NUT, /" 8 67 RECEPTACLE ASSY, MALE POLE 9 68 NUT, /4" 0 674 RECEPTACLE ASSY, FEMALE 4 POLE 4 50876 BOOT, SWITCH RUBBER SEAL 60 SWITCH, TOGGLE POS. SGL. POLE PAGE 4
WIRING, PUMP GRAVITY DOWN 5 PIN CONNECTOR P/N 5687 NUT, WATERTIGHT P/N 590 4 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
WIRING, PUMP GRAVITY DOWN Gnd. To Mtr. Solenoid Mtg. Screw -Pole Splitter P/N 5698 D BRN 5 Pin Conn. P/N 5687 4 Pin Conn. P/N 5684 Mtr. Solenoid Mtg. Screw 5 4 4 LT BLU Connector P/N 0049 Shrink Tubing P/N 5067-0 (Typ. -Plcs.) D WHT RED ORG BLK RED BLK WHT Mtr. Solenoid Pin # Fuse Holder P/N 90508 Fuse P/N 6468 ORG BLK RED GRN To Mtr. Solenoid Pin # Terminal Ring P/N 50670 6 Ga. Wire x Lg. P/N 040047 (Typ. Plcs.) A B C E To Mtr. Solenoid Pin # Shrink Tubing P/N 5067-0 To Mtr. Solenoid Pin # Terminal Ring P/N 50707 6 Ga. Wire x Lg. P/N 040047 (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
WIRING, PUMP POWER DOWN 5 PIN CONNECTOR P/N 5687 NUT, WATERTIGHT P/N 590 4 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
WIRING, PUMP POWER DOWN Gnd. To Mtr. Solenoid Mtg. Screw -Pole Splitter P/N 5698 D BRN 5 Pin Conn. P/N 5687 4 Pin Conn. P/N 5684 Mtr. Solenoid Mtg. Screw 5 4 4 LT BLU Connector P/N 0049 Shrink Tubing P/N 5067-0 (Typ. -Plcs.) D WHT RED ORG BLK RED BLK WHT Mtr. Solenoid Pin # Fuse Holder P/N 90508 Fuse P/N 6468 ORG BLK RED GRN To Mtr. Solenoid Pin # Terminal Ring P/N 50670 6 Ga. Wire x Lg. P/N 040047 (Typ. Plcs.) A B C E To Mtr. Solenoid Pin # To Mtr. Solenoid Pin # Terminal Ring P/N 50707 6 Ga. Wire x Lg. P/N 040047 (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
WIRING, PUMP GRAVITY DOWN 5 PIN CONNECTOR P/N 5687 NUT, WATERTIGHT P/N 590 4 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
WIRING, PUMP GRAVITY DOWN 5-Pin Conn. P/N 5687 4-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 5067-0 (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 5067-0 ORG ORG WHT BLK RED ELEC. SWITCH BOX Switch P/N 6049 RED WHT BLK ORG WHT BLK RED PUMP PUMP RED 6 9 5 8 4 7 0 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 607-0 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
WIRING, PUMP POWER DOWN 5 PIN CONNECTOR P/N 5687 NUT, WATERTIGHT P/N 590 4 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
WIRING, PUMP POWER DOWN 5-Pin Conn. P/N 5687 4-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 5067-0 (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 6 9 5 8 4 7 0 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 607-0 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
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OPTIONAL SECTION PAGE 5
HAND PUMP KIT P/N 6604 8,,,,4 9 0,5,6,7 0 9 8 6 7 8 4 5 6 7 6 SHOWN IN POWER DOWN CONFIGURATION. GRAVITY DOWN REPLACES THIS HOSE AND FITTINGS WITH A PLUG IN THE MANIFOLD. 6 7 5 4 PAGE 54
HAND PUMP KIT P/N 6604 ITEM QTY. PART NO. DESCRIPTION 05004 NIPPLE CLOSE PIPE, /8 4 60490 NEEDLE VALVE, /8 NPT 05007 FTG. SWIVEL ELBOW 4 549-05 TABULATED HOSE ASSEMBLY, 4" 5 8004-0 HOSE ASSY. HP 4" 6 5854 HOSE CLAMP, SCREW 7 585 ELBOW, 90 /4"M x /8 BARB 8 506 BRACKET, HAND PUMP KIT 9 00405 PIN, ROLL /6" x " 0 5407 HAND PUMP 008 FITTING, NIPPLE, /4 x -/ 80090 TEE, /4 NPT (F) 6057 ELBOW, JIC#8 x /4" NPT 4 5856 HOSE, /8"LP x 0" LG. 5 6675 DECAL, SGL. PLUMB. ASSY. 6 04095 ELBOW, 90 /8"NPT x JIC#8 (M) 7 6058 ELBOW, 90 /8"NPT x JIC#8 (F) 8 585 TEE, /8" M x /8" (F-F) 9 575 HOSE, /8"HP (F-F) x -5/8" LG. 0 5705 STR. SWVL. /8NPT (M) x JIC#8 (F) * 90005 NUT, HEX 5/6-8 * 900009- SCREW, CAP 5/6-8 x " LG. * 9000- WASHER FLAT 5/6 x /6 *4 900- WASHER, LOCK 5/6 x 5/64 *5 04066 NUT, NYLON LOCK /4-0 *6 900000-0 BOLT, HEX /4-0 x -/" *7 4 00564 WASHER, FLAT /4" * NOT SHOWN PAGE 55
BOTTOM STOP ASSEMBLY P/N 6058 4 5 6 6057-0 BOTTOM STOP ASSY. LH (OPPOSITE) 6057-0 BOTTOM STOP ASSY. RH (SHOWN) PART NUMBER ITEM QTY DESCRIPTION 6057-0 6057-0 6055 HOOK, BOTTOM STOP 664-0 BLOCK, BOTTOM STOP LH 664-0 BLOCK, BOTTOM STOP RH 00579 WASHER, FLAT " 6078-0 BLOCK, ROTATING WELDMENT LH 4 6078-0 BLOCK, ROTATING WELDMENT RH 5 05004 PIN, ROLL /4" x " 6 60404-0 SPRING, TORSION, LH 60404-0 SPRING, TORSION, RH PAGE 56
FIXED RAMP, 6 & FOLDOVER ASSEMBLY (REF.) FIXED RAMP (SHOWN) 6 FIXED RAMP (NOT SHOWN) VEHICLE BODY WIDTH RAMP 90" 96" 0" 6" DEEP 5944-0 5944-0 5944-0 " DEEP 5944-04 5944-05 5944-06 PAGE 57
ALUMINUM RETENTION RAMP 4 6 7 4 8 ASSEMBLY 90" WIDE VEHICLE 96" WIDE VEHICLE 0" WIDE VEHICLE PART NO. 55-0 55 55-0 7 ITEM QTY. PART NUMBER DESCRIPTION 555 HINGE ASSEMBLY R.H 6 00556 WASHER, FLAT /8" 6 00955 LOCKNUT, /8-6 UNC 4 556 BUMPER 5 55-0 55 55-0 ALUMINUM RAMP 9 6 554 HINGE ASSEMBLY L.H. BOLT, /8-6 UNC x -/4" FLAT 7 4 040504 HD. BOLT, /8-6 UNC x -/" FLAT 8 0006 HD. 9 5985 PIPE, /4" SCH. 80 x 60" LG. PAGE 58 5
ALUMINUM RETENTION RAMP R.H. HINGE ASSEMBLY, P/N 555 4 5 6 7 9 8 ITEM QTY PART NUMBER DESCRIPTION 46 ROLL PIN /8" x " 55 LOCK & BUSHING WELDMENT 554 BEARING, SELF-LUBE " DIA. x " LG. 4 557 BUSHING x /4" 5 558 PIN WELDMENT 6 557 HINGE ARM WELDMENT R.H. 7 5460 TORSION SPRING 8 6047 LOCKING ARM ASSEMBLY 9 558 PIN WELDMENT PAGE 59
CART STOP RAMP SEE BREAKDOWN ON NEXT PAGE. ASSEMBLY 90" W IDE VEHICLE 96" W IDE VEHICLE PAGE 60 4 0" W IDE VEHICLE PART NO. 580-04 580 580-0 ITEM QTY. PART NUMBER DESCRIPTION 585-09 585-05 585-08 RAMP, POP-UP CART STOP 554 BEARING, SELF-LUBE / x / 6496-0 PIN, 4.8" LG 4 5850-04 5850 5850-0 CART STOP, /8" DIAMOND PLATE 5 040504 BOLT, /8-6 x -/4" 6 00955 NUT, LOCK, /8-6 7 00556 WASHER, FLAT /8" 8 6060 LOCKING HOOK R.H. 9 058-0 TORSION SPRING 0 669 PIN, LOCKING HOOK SUPPORT 60558 BOLT, /4-0 x " LG. 00564 WASHER, FLAT /4" 5460 TORSION SPRING 4 04066 NUT, LOCK, /4-0 5 60 LOCKING CAM, R.H. 6 6496-0 PIN, 7." LG 7 6090-0 RETAINING RING,.5 x.5
CART STOP RAMP 5 5,6,7 4 9 8 6,7 0 PAGE 6
DUAL CART STOP RAMP SEE BREAKDOWN ON NEXT PAGE. 9 4 PAGE 6
DUAL CART STOP RAMP (RH ASSY. SHOWN, LH OPPOSITE) 5,0 5,6,7 4 9,8 8, 6,7 0 PAGE 6