CHAMPION GodwinTheGrouOperation & Installation poperation Manual 5530DM UNDERBODY HOIST
CHAMPION HOIST & EQUIPMENT 200 Champion Drive Dunn, N.C. 28334 800-649-4995 3/2009 2
UNDERBODY HOIST Table of Contents Page 4 Page 5-6 Page 7 Page 8-9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20-21 Service Information Operations and Service Do s & Don ts (SAFTY INFORMATION) Hoist Operation Instructions Champion Subframe Hoist Installation Procedures Subframe Installation Detail Lubrication Instructions Detailed Instructions to Reverse Rotation on a C102 Pump SP4 Valve & Valve Bracket/Control Handle Assembly Safety Prop Cup Installation Hydraulic Plumbing Diagram 9 Gallon Reservoir Assembly Hydraulic Plumbing Diagram w/ SP-4 Valve P20 Series Pumps 8 1/2 Gallon Reservoir Assembly Parts, Performance, and Layout Dimensions CHAMPION 3
4 HOISTANDEQUIPMENTCHAMPION200CHAMPIONDRIVEDUNN,N.C.28334Phone#(910)-897-4995(910)-897-7306fax#whencaling,specify(parts)-(service)-(sales)havethefolowinginformationonhandforfasterservice,bodymodel#&Serial#hoistmodel#&serial#year,make,typeoftruck.thisinformationisprovidedasindicatedPhone#(800)-649-4995
5 DonotloadtheequipmentbeyondtheGVWratingofthevehicleorthehoistDonotmoveavehiclewitharaisedhoist.DonotoperatethehoistUNDERPOWERLINES!Donotraisethehoistwhenvehicleisinmotion.Donotoperatethehoistonanunlevelorsoftsurface.rating.Donotalowcontrolsandareaaroundthemtobecomecluteredwithtools,cans,Donotalowpersonneltorideinoronthebed.Donotleavetruckunatendedwithbedraised.etc.Donotgounderneathatruckwithenginerunning.DonotgounderneathanunloadedraisedbedunlessthesafetypropsareDonotgounderneathaloadedraisedbedunderANYcircumstances.properlypositioned.DANGER!DonotoperatethisequipmentwithoutfulyreadingandunderstandingthisDonotalowunauthorizedpersonneltooperatethisequipment.OperationsandServiceManualmanual.Donotusehandsorotherbodypartstocheckforhydraulicleaks.CHAMPION
6 *Lubricatehoistandrearhingeassemblyevery90to180days*Addcorecthydraulicoiltoreservoirasneeded.*Checkhydraulicoillevelweekly.*Understandandfolowalsafetydecalsandkeepthemingoodcondition.*Keepunitproperlymaintainedandserviced.*FolowalFederal,State,Localregulationspertainingtothisequipment.Besureto.WhencalingforParts/ServiceBeSureToHave.Hoist:modelnumberserialnumberSerialPlateLocation*ForPTOdrivenpumpsuseHD32hydraulicoil.*ForelectricdrivenpumpsuseATF,automatictransmissionfluid.*UseEP-3greaseforalgreasefitings.dependingonuseage.(SeeMP50077)*Checkalbolts,welds,electricalconnectionsfrequently.CHAMPION
HOIST OPERATION To Operate Hoist: (1) Engage PTO per PTO operation instructions. (2) The pump/hoist control should be in the neutral or hold position. (3) For a manual control - pull to raise, push to lower. NOTE: Manual push/pull controls require a 1/2 inch mounting hole. (4) When bed raises to desired height, push the pump/hoist controls to the center neutral or hold position. This will stop bed movement up or down. (5) To lower bed - push pump/hoist control. (6) Disengage PTO. 7 CHAMPION
INSTALLATION INSTRUCTIONS REFER TO MP50074 STEP #1 STEP #2 STEP #3 STEP #4 STEP #5 STEP #6 STEP #7 STEP #8 STEP #9 SET SUB FRAME ON CHASSIS 4 FROM CAB. (NOTE: MAKE SURE THERE ARE NO OBSTRUCTIONS (MUFFLER ETC.) DRILL (8) 1/2 HOLES THRU CHASSIS AND INSTALL HARDWARE. (EACH SIDE) DRILL (2) 5/8 HOLES THRU CHASSIS AND INSTALL 5/8 x 2-1/2 BOLT. (EACH SIDE) REMOVE EXCESS CHASSIS. INSTALL PUMP CABLE ASSEMBLY IN CAB OF TRUCK. THIS REQUIRES A 1/2 HOLE DRILLED THRU CAB FLOOR. (NOTE: CONTROL MUST MOUNTED IN FLOOR DUE TO CABLE LENGTH) MOUNT HYDRAULIC PUMP TO PTO. BEFORE MOUNTING, CHECK ROTA- TION OF PUMP. IF PUMP HAS A ROTATION THAT NEEDS TO BE REVERSED SEE MP50078 - PROCEDURES TO REVERSE C102 PUMPS ROTATION. IF APPLICATION CALLS FOR A P22 PUMP SEE NOTE ON PD40030 FOR FURTHER INSTRUCTIONS. INSTALL RESERVOIR TANK IN FRONT OF LOWER BUNK FOR A C102 PUMP APPLICATION AS INDICATED ON MP50077. FOR A P22 PUMP APPLICATION, TWO THINGS NEED TO BE CONSIDERED: #1 - REQUIRES A SP4 VALVE & VALVE MOUNTING BRACKET & A CABLE SUPPORT BRACKET. (SEE MP50079) #2 - RESERVOIR MOUNTING. SP4 BRACKET IS TO BE MOUNTED IN SUCH A WAY THAT THE PORTS ARE ACCESSIBLE AND THE CABLE CONTROLS OPERATE FREELY. AFTER DETERMINING WHERE THE SP4 VALVE MOUNTING BRACKET WILL BE MOUNTED, INSTALL RESERVOIR. (SEE MP50077) PLUMB HYDRAULICS PER PLUMBING DIAGRAM: PD40029 - SINGLE ACTING CYLINDERS W/ C102 PUMP PD40030 - DOUBLE ACTING CYCILNDERS W/ P22 PUMP AFTER HYDRAULIC CONNECTIONS ARE COMPLETED AND CABLE ASSEMBLY INSTALLED, FILL RESERVOIR WITH OIL. 8 CHAMPION
INSTALLATION INSTRUCTIONS CONTINUED STEP #10 SET BODY. THERE ARE 2 METHODS. #1 FOR A SINGLE ACTING ASSEMBLY - WITH HOIST RAISED SUSPEND BODY OVER SUBFRAME A MINIMUM OF 4 AWAY FROM CAB, AND LOWER BODY DOWN LOW ENOUGH TO INSTALL UPPER LIFT ARM PINS TO BODYS UPPER BUNK. (SEE MP50077 ITEM 1) AFTER IN- STALLATION OF LIFT ARM PINS AND COTTER PINS, LOWER HOIST AND BODY ONTO CHASSIS MAKING SURE CYLINDER IS FULLY RE TRACTED. BODY SHOULD BE EVEN WITH FRONT SUBFRAME RAILS. WELD REAR HINGE FLIPPERS SECURELY TO BODY. #2 FOR A DOUBLE ACTING ASSEMBLY - RAISE HOIST AND SUSPEND BODY OVER SUBFRAME A MINIMUM OF 4 AWAY FROM CAB, AND LOWER BODY DOWN LOW ENOUGH TO INSTALL UPPER LIFT ARM PINS TO BODYS UPPER BUNK. (SEE MP50077 ITEM 1) AFTER IN- STALLATION OF LIFT ARM PINS AND COTTER PINS, WHILE LOWERING BODY ONTO CHASSIS AND AT THE SAME TIME USING HYDRAULIC POWER, BOTTOM OUT CYLINDER TO PULL SLACK OUT OF HOIST. SECURELY WELD REAR HINGE FLIPPERS TO BODY. CAUTION - IF SLACK IS NOT REMOVED DAMAGE TO HOIST/BODY COULD OCCUR!!! STEP #11 STEP #12 STEP #13 INSTALL SAFETY PROP CUPS ON BODY IN SUCH A MANNER THAT THE PROP IS ANGLED SLIGHTLY TO THE REAR. (SEE MP50080) REINSPECT ALL WELDS, CHECK THAT ALL HARDWARE IS SECURE, AND PLUMBING CONNECTION FOR LEAKS. (REPAIR AS NECESSARY) GREASE ALL PIVOT POINTS AND GREASE FITTINGS. (SEE MP50077) NOTE: NEVER WORK ON A RAISED EMPTY BODY WITHOUT SAFETY PROPS IN PLACE!!!! DANGER 9 CHAMPION
4(C.A. = CAB TO CENTER OF AXLE) 4" MINIMUM BETWEEN CAB & SUBFRAME/BODY C.A. DIMENSIONS ( CAB TO CENTER OF AXLE) C.A. DIMENSION 72" 84" BODY LENGTH 9' 10' CHASSIS DRILLL THRU CHASSSIS 1/2" HOLES (EACH SIDE) 1/2" CONTINUOUS WELD ON BODY ONLY!!MBODY SUBFRAME CAB 10 CHAMPION P507
11 -INDICATESGREASEFITTINGLOCATIONSTHATMUSTBELUBRICATEDDEPENDINGONUSAGE,LOAD,ENVIRONMENTANDCLIMATE.LUBRICATEALLPIVOTPOINTSUSINGEP-2CHASSISGREASEOREQUAL.LUBRICATIONINSTRUCTIONSMP503605530DM*Greasehoistandrearhingeassemblyeachtimetruckisserviced.CHAMPION Dunn, North Carolin, U.S.A.
12 STEP#1SECURELYMOUNTPUMPFLANGEINVISESHAFTDOWN!STEP#2REMOVE(4)HEXBOLTS,WASHERS.STEP#3LIFTOFFVALVEANDCENTERSECTIONOFPUMPLEAVINGFRONTCOVERANDGEARSSTEP#4LOWERCENTERSECTIONANDVALVEONTOFRONTCOVERANDGEARSBEINGCAREFULNOTTODISTURBPOCKETSEALSINTRUSTPLATES.(IFNEEDEDGLUEINWITHCHASSISGREASE).STEP#5REINSTALLBOLTSANDWASHERSANDEVENLYTORQUEASSEMBLYBOLTSTO200FOOTLBS.INPLACE,ANDROTATE180.*SUCTIONPORT* * * *CYLINDERPORTMP50078INSTRUCTIONSTOREVERSEC102PUMPROTATIONCHAMPION
13 HYDRAULICCONTROLCABLEFORSTANDARDCABS-R38LLR8'LONG,STANDARD.OTHERLENGTHSAVAILABLESP4VALVECONTROLHANDLEASSEMBLYMP50079REMOTEVALVEforDAAPPLICATIONPORTSA=BODYDOWNB=BODYUPINLET=DISCHARGEFROMPUMPOUTLET=RETURNTORESERVOIRCHAMPION
14 ARESUPPORTEDBYABODYCROSSCHANNEL.SLIGHTLYTOTHEREAR.ALSO,BESURECUPSRUNNERSOTHATTHESAFETYPROPISANGLEDLOCATESAFETYPROPCUPSONBODYMAINCONTACTALLPOINTSOF3/8"WELDATBODYCROSSCHANNELSAFETYPROPCUPSAFETYPROPCUPINSTALLATIONMP50080CHAMPION
HYDRAULICPLUMBINGDIAGRAMCHAMPION DG102 PUMP cautionpthis port is not to be plugged. it is to be routed back to the reservoir bottom. any other method will cancel the warranty. 15 40029 Dunn, North Carolin, U.S.A.
GALONRESERVOIR5616 9A1CHAMPION 10 Dunn, North Carolin, U.S.A.
17 3/4"90 SWIVELADAPTER1/2"90 SWIVELADAPTER1"CLOSENIPPLEIFREARPORTSAREOBSTRUCTED.NOTE:SIDEPORTSMAYBEUSED1-1/4"BARBEDADAPTER1-1/4"BARBEDADAPTER1"TO1-1/4"REDUCERCOUPLING1-1/4"90 STREETELBOW1-1/4"HOSECLAMPP22PUMP3/4"90 SWIVELADAPTER3/4"90 MALLEABLESTREETELBOWFORRETURNLINEONLY(NOTAPPLICABLEFORPRESSURIZEDCOMPONENTS)(NOTAPPLICABLEFORPRESSURIZEDCOMPONENTS)FORRETURNLINEONLYMALLEABLESTREETELBOWA B 3/4"90 1-1/4"HOSECLAMPHYDRAULICPLUMBDIAGRAM-DAPD40030CHAMPION
18 MP50328P20SERIESPUMPSP21PUMPP22PUMPP23PUMPCHAMPION Dunn, North Carolin, U.S.A.
19 8.5GALLONRESERVOIRA15066PARTNUMBERNO.QTY.DESCRIPTION2118.5GALLONRESERVOIRWELDMENTW15053CAPP102411CHAMPION Dunn, North Carolin, U.S.A.
CHAMPION HOIST MODEL: 5530DM STANDARD SUBFRAME LENGTHS (FT): 12,13,14 REFERENCE REFERENCE DESIGNED FOR TRUCKS WITH 24,000 TO 33,000 GVW CHAMPION Dunn, North Carolin, U.S.A. 910-897 - 4995 Fax 910-897 - 6822 20
12 8 9 8 15 10 11 4 15 2 3 14 13 4 6 7 1 8 15 6 5 8 7 Parts List ITEM QTY PART NUMBER 1 1 W13439 2 3 4 5 6 7 8 9 10 11 12 13 14 15 DESCRIPTION WELDMENT SUBFRAME 5530DM WELDMENT CROSS ARM 5530DM CYLINDER, UNDERBODY LIFT ARM, 5530DM SHAFT, REAR HINGE HINGE PLATE WASHER COTTER PIN, 1/4 X 2 1/2 HEX BOLT, 5/8-11 UNC X 4, GR 9 1 W13149 2 5530-DA 2 W13152 1 SM20065 2 PC10355 2 122-15 4 125-259 2 102-617-L 2 118-7-A1 LOCK WASHER, 5/8 2 143-7 LOCK NUT, 5/8 2 PC10560 CYLINDER PINS 1 P10200 SERIAL PLATE 4 PAAP43 POP RIVET, 1/8 8 PT7608 GREASE FITTING 21 CHAMPION