hoist and equipment and equipment group thegodwin 200 champion drive dunn, n.c. 28334 (910) 897-4995...

CHAMPIONHoist and Equipment

GroupThe Godwin

200 CHAMPION DRIVEDUNN, N.C. 28334

(910) 897-4995 FAX: (910) 897-7306

AN AFFILIATE OF

CONVERSION HOIST

Operation & Installation Manual

2

CHAMPION HOIST & EQUIPMENT 200 Champion Drive

Dunn, NC 28334 800-649-4995

11/2011 2/17/2012

3

CHAMPION CONVERSION HOIST TABLE OF CONTENTS

PAGE 4 OPERATIONS AND SERVICE PAGE 5 ABOUT THE HYDRAULIC CONTROLS AND PUMP/

HOIST CONTROL HANDLE INSTALLATION. OPERATION INSTRUCTIONS FOR THE HYDRAULIC

SYSTEM PAGE 6 HYDRAULIC PLUMBING DIAGRAM FOR P21 PUMP,

8C VALVE, AND 15 QUART RESERVOIR. (SINGLE CYLINDER APPLICATION)

HYDRAULIC PLUMBING DIAGRAM FOR P22 PUMP,

8C VALVE, AND 21 QUART RESERVOIR. (DUAL CYL-INDER APPLICATION)

PAGE 7 PUMP ROTATION AND PORTING PAGE 8-9 ELECTRIC PUMP PLUMBING DIAGRAMS PAGE 10-11 ELECTRIC PUMP PRIMING PROCEDURES AND TROUBLESHOOTING PAGE 12 - 14 INSTALLATION PROCEDURES AND LUBRICATION. PAGE 15 SAFETY PROP INSTALLATION PAGE 16-27 HOIST RATINGS

4

* Add correct hydraulic oil to reservoir as needed.* Check hydraulic oil level each time truck is serviced.* Understand and follow all safety decals and keep them in good condition.* Keep unit properly maintained and serviced.* Follow all Federal, State, Local regulations pertaining to this equipment.

CAUTION

ELECTRIC PUMP APPLICATIONS ONLY!!!

(DEXTRON AUTOMATIC TRANSMISSION FLUID)

USE DEXTRON ATF OIL ONLY!

ELECTRIC PUMP APPLICATIONS

Be sure to.........

CAUTION

EXXON NUTO HD 32

OR COMPARABLESHELL TELLUS HD 32

TEXACO RANDO HD 32

USE HYDRAULIC OIL ONLY!

PTO PUMP APPLICATIONS

When calling for Parts/Service Be Sure To Have....

Body: model number

Hoist: model number

Serial Plate Location

Serial Plate Location

serial number

serial number

Do not go underneath a loaded raised bed under ANY circumstances.

DANGER!

Do not operate this equipment without fully reading and understanding this

Do not allow unauthorized personnel to operate this equipment.

manual.

OPERATIONS AND SERVICE INFORMATION

5

︵7 ︶ When bed raises to desired height push the pump/hoist controls to the

︵9 ︶ Depress clutch pedal, and push PTO control to disengage.

︵8 ︶ To lower bed depress the saftey button and push pump/hoist control .

center neutral or "hold" position this will stop bed movement up or down.

DETAIL D

To Operate the Hoist:︵2 ︶ Depress clutch pedal.

on the PTO control.

raise the bed. See Detail D below.

︵5 ︶ The pump/hoist control should be in the neutral or "hold" position.

︵6 ︶ Depress the saftey button and pull the pump/hoist control to

︵4 ︶ Once the PTO is engaged, release the clutch pedal to supply power to the pump.

illuminate, and PTO does not engage, Slowly release the clutch pedal while pulling

︵3 ︶ Pull PTO control out until the red PTO light illuminates. Note: if light does not

︵1 ︶ With engine running at idle speed, transmission in neutral, and the park brake set.

BODY DOWN

ELECTRIC CONTROL

To Operate the push button Hoist:Press and hold approate button.

NOTE: Pump will stop when button is released.

PRESS RED SAFETYAND PUSH

BODY UP (PULL LEVER)

RED SAFETY BUTTON

FOR ELECTRIC PUMP APPLICATION

6

PUMP MAY OCCUR!!

WHEN PLUMBING PUMP, BE SURE TO USETHE PROPER PORT. IF YOU ARE NOT SUREWHICH PORT IS SUCTION & WHICH IS MAINPRESSURE, LEAVE SHIPPING PLUGS IN PORTSAND OPERATE PUMP NO LONGER THAN 3 SEC-ONDS. THIS WILL POP OUT THE MAIN PRESSURESHIPPING PLUG. BE SURE IT RUNS NO LONGERTHAN 3 SECONDS, OR PERMANENT DAMAGE TO

NOTE:

IF REAR PORTS ARE OBSTRUCTED.NOTE: SIDE PORTS MAY BE USED

Body Down Relief Port Setting 500-700 PSI

Body Up Relief Port Setting 2800-3000 PSI.

DUAL CYLINDERAPPLICATION

SINGLE CYLINDER APPLICATION

7

PUMP ROTATION AND PORTING

CLOCKWISE ROTATION (CW)(SEE ABOVE)

COUNTER-CLOCKWISE ROTATION (CCW)(SEE ABOVE)

INPUTSHAFT

OPTIONAL SIDE PORT(OTHER SIDE AS WELL)

REAR PORTS

PRESSURE SIDE

SUCTION SIDE

CW CCW

THE P21 AND P22 PUMPS ARE BI-DIRECTIONAL AND OFFER SIDE AND REAR (NPT) PORTING.

THE PUMPS ARE SHIPPED WITH THE SIDE PORTS PLUGGED. TO UTILIZE SIDE PORTING MOVE THE STEEL PLUGS FROM THE SIDE PORTS TO THE REAR PORTS AND PLUMB AC-CORDINGLY.

USE THE ILLUSTRATION ABOVE FOR PORT DESIGNATION BASED ON PUMP ROTATION. HELPFUL HINT:

TO DETERMINE PUMP ROTATION, DO NOT REMOVE THE PLASTIC SHIPPING PLUGS. TEMPORARILY BOLT PUMP TO THE MOUNTED PTO. START TRUCK ENGINE AND ENGAGE PTO FOR APPROXIMATELY (3) SECONDS AND SHUT-OFF.THE PLASTIC SHIPPING PLUG ON THE PRESSURE PORT SHOULD HAVE POPPED OUT OF THE PUMP HOUSING.

8

DO NOT GROUND TO CHASSIS!!.NOTE: Ground Wire is to be ground to valve body.

1/2" 90° SWIVEL ADAPTER


HYDRAULIC PLUMB DIAGRAM

PD40048SINGLE ACTING ELECTRIC PUMP


PART # P12-14-6-6

9

HYDRAULIC PLUMB DIAGRAM

PD40045DOUBLE ACTING ELECTRIC PUMP

DO NOT GROUND TO CHASSIS!!.NOTE: Ground Wire is to be ground to valve body.


3/8" 90° SWIVEL ADAPTERPART # P12-14-6-6

NOTE:HYDRAULIC PORT FITTINGS ORIENTATION MAYVARY DEPENDING ON CHASSIS TYPE.

10

PRIMING PROCEDUREMP50398

ELECTRIC PUMP

Electric Pump Priming Procedure Single acting (3519) or Double acting (3551)

(A) Be sure hoist and electric pump are completely installed and ready to safely operate. Fill electricpump reservoir with Automatic Transmission Fluid to within 1” of top.

(B)Power the hoist “Up” using the “White” button on the push button controller. NOTE: If hoist doesnot start to raise within 10 seconds, stop and check that the hydraulic lines are correctly installed. Seebelow: Monarch 3551 (double acting, yellow) “C1” port = hoist raise (white button) = 3200psi “C2” port = hoist lower (black button) = 750psi

Monarch 3519 (single acting, orange) “P” port = hoist raise (white button) = 3200psi Must be connected > “S”port = lower/vent to res. (black button) = -0- psi

(C) When powering the hoist “Up” the first time it is imperative that the reservoir NOT run out offluid. Maintain a half tank of fluid on the first lift by stopping and filling as needed.

(D) As you are fully raising the hoist safely check for leaks, any visual obstructions, etc.

(E) For Double Acting Pump Only - Lower the hoist by pressing the black button. NOTE: Lower thehoist 1/3 and stop for 20 seconds, repeat two more times until hoist is fully lowered. Once the hoist hasfully lowered CONTINUE to hold the “black” button until the oil in the reservoir stops moving(turbulence). (about 20 seconds) The turbulence you see in the reservoir during this crucial step is inreality filling the top side (or down side) of the cylinder. This typically has to be done only upon theinitial installation or when the unit has run low in oil and is being refilled.

(F)After steps A through E have been done fill the reservoir as needed to maintain 2/3 to ¾ full with beddown.

HELPFUL HINTS:(1) Perform the above priming steps no more than twice in 30 minutes due to the oil aerating.

(2) If the reservoir overflows when lowering, the following could cause this. (a)Aerated oil

(b)“Hoist lower” line too small or obstructed (c)wrong ports used on pump (d)extremely cold conditions.

(3) Make sure the customer understands that the electric power unit (used when necessary) will have thesame lifting capacity but will be slower than a PTO driven unit.

(4) Do not operate pump more than (2) minutes at a time or without truck engine running so as to keep acharge in battery.

Rev. 5/15/09 JrG

11

PRIMING TROUBLESHOOTINGMP50399

ELECTRIC PUMP

MONARCH M-3519 (single acting). M-3551 (double acting)ELECTRIC PUMP TROUBLESHOOTING

Motor on pump does not operate.

Electric pump Solenoid does not click.(A) Bad hot(+) or ground(-) cable(s) from battery to pump. Be sure to use both cables and connect directly to battery. It is advisable to install a 250amp Mega fuse at the positive battery connection. Note: On newer trucks the ground cable from battery to chassis is too small to carry the load of the electric pump unit. This is why you need (2) individual positive and ground cables from battery to electric pump unit.

(B) Check for 12v signal at small post of solenoid when pressing the “up” button of the control. If voltage is below 12 volts it may be a sign of an alternator or battery issue. If no voltage it may be the switch or a broken or corroded wire

Electric pump Solenoid clicks but motor does not operate.(A) Check battery connection between solenoid and motor.

(B) Contacts in solenoid could be burned. (Check this by shorting the two large posts on the solenoid, if motor turns replace solenoid assembly)

(C) Motor could be bad.

(D) Pump could be seized.

Motor/pump turns but hoist will not work.(A) Check for 12 volts at valve coil(s). Could be bad switch or broken wire.

(B) Is/are coil(s) magnetized when button is pressed? Could be bad coil/ or connector.

(C) Cartridge stem could be bent. With bed down, remove cartridge and roll on table to check for alignment.

(D) Check pump unit pressure. Up should be 3200psi and down (on double acting units) should be 750psi.

Hoist stuck in up position, will not come down.(A) Check for 12 volts at “down” coil.

(B) Bent stem on “down” cartridge. Call for service technician. DO NOT ATTEMPT TO REPAIR!

Rev. 5/15/09 JrG

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50° TILT 68.5 inches

- GREASE FITTING LOCATIONS

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26534


Dunn, North Carolin, U.S.A.910 - 897 - 4995

Fax 910 - 897 - 6822

Truck bed lengths -10 - 12 feet GVW - 8000 - 10000 lbs

18



Fax 910 - 897 - 6822

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23

"G" DIMENSION45° TILT 105.5 inches50° TILT 95.5 inches


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27



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Fax 910 - 897 - 6822

Truck bed lengths -18 - 24 feet GVWR- 35000 - 50000 lbs

hoist and equipment and equipment group thegodwin 200 champion drive dunn, n.c. 28334 (910) 897-4995...

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