Upload
lamque
View
216
Download
0
Embed Size (px)
Citation preview
CHAMPIONHoist and Equipment
Dunn, North Carolina, U.S.A.
200 CHAMPION DRIVEDUNN, N.C. 28334
(910) 897-4995 FAX: (910) 897-7306
AN AFFILIATE OF
TRAILER CONVERSION HOIST
Operation & Installation Manual
2
CHAMPION HOIST & EQUIPMENT
200 Champion Drive Dunn, NC 28334
800-649-4995 7/23/2009
WARRANTY
Champion Hoist and Equipment warrants these products for a period of 36 months from the date of sale to the customer. This warranty provides that the equipment shall be free of defective materials and workmanship, or we will replace or repair at our factory, any part that our inspection shows to be defective. The hydraulic valve, pump, motor, hoses, and other purchased products are not manufactured or warranted by Champion Hoist and Equipment and are therefore covered by the warranties of the manufacturer of these products. Any part shipped to the factory shall be prepaid, and will be returned collect. Champion Hoist and Equipment does not assume responsibility for shipping, labor or travel expenses. We reserve the right to make improvements to any of our product without notice or obligation regarding model previously sold.
3
CHAMPION TRAILER SCISSOR HOIST TABLE OF CONTENTS
PAGE 4 OPERATIONS AND SERVICE PAGE 5 DOUBLE ACTING ELECTRIC PUMP SYSTEM PAGE 6 SINGLE ACTING ELECTRIC PUMP SYSTEM PAGE 7-8 ELECTRIC PUMP PRIMING PROCEDURE AND TROUBLESHOOTING PAGE 9 SAFETY PROP & REAR HINGE HARDWARE PAGE 10-11 INSTALLATION PROCEDURES AND LUBRICATION PAGE 12 SAFETY PROP INSTALLATION PAGE 13-26 HOIST RATINGS AND ASSEMBLIES PAGE 27 NOTES
4
* Grease hoist and rear hinge assembly as needed.
* Add correct hydraulic oil to reservoir as needed.* Check hydraulic oil level each time equipment 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.........
When calling for Parts/Service Be Sure To Have....
Hoist: model number
Serial Plate Location
serial number
Do not load the equipment beyond the hoist rating.
Do not move a trailer with a raised hoist.
Do not operate the hoist UNDER POWER LINES!!Do not raise the hoist when trailer is in motion.
Do not operate the hoist on an unlevel or soft surface.
Do not allow controls and area around them to become cluttered with tools, cans, etc.
Do not allow personnel to ride in or on the bed.Do not leave trailer unattended with bed raised.
Do not go underneath a loaded raised bed under ANY circumstances.
DANGER!
Do not operate this equipment without fully reading and understanding this manual.Do not allow unauthorized personnel to operate this equipment.
Operations and Service
Do not use hands or other body parts to check for hydraulic leaks.
5
DO NOT GROUND TO CHASSIS!!.NOTE: Ground Wire is to be ground at SOURCE.
1/2" 90° SWIVEL ADAPTER
HYDRAULIC PLUMB DIAGRAM
PD40045DOUBLE ACTING ELECTRIC PUMP
3/8" 90° SWIVEL ADAPTERPART # P12-14-6-6
6 DO NOT GROUND TO CHASSIS!!.NOTE: Ground Wire is to be ground at SOURCE.
1/2" 90° SWIVEL ADAPTER
3/8" 90° SWIVEL ADAPTER
HYDRAULIC PLUMB DIAGRAM
1/2" 90° SWIVEL ADAPTER
PART # P12-14-6-6
7
ELECTRIC PUMP PRIMING PROCEDURE ( Single or Double acting )
(A) Be sure hoist and electric pump are completely installed and ready to safely operate. Fill electric pump 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 does not start to raise within 10 seconds, stop and check that the hydraulic lines are correctly installed. See below: Monarch 3551 (double acting) “C1” port = hoist raise (white button) = 2800psi “C2” port = hoist lower (black button) = 800psi Monarch 3519 (single acting) “P” port = hoist raise (white button) = 2800psi “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 of fluid. 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. Once the hoist has fully lowered CONTINUE to hold the “black” button until the oil in the
reservoir stops moving. (about 20 seconds) The turbulence you see in the reservoir during this crucial step is in reality filling the top side (down side) of the cylinder. This typically has to be done only upon the initial installation or when the unit has run out of oil and is
being refilled. (F) Once this has been done fill the reservoir as needed to maintain 2/3 to ¾ full. 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) Electric power units are NOT to be used with twin cylinder hoists or any hoist with a volume larger than a 6” bore X 24” stroke cylinder. (4) Make sure the customer understands that the electric power unit (used when necessary) will have the same capacity but be slower than a PTO driven unit. (5)If voltage drops below about 10.5vdc the up and down coils may be affected first.
8
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 2800psi and down (on double acting units) should be 800psi. 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
9
DET
AIL
AH
ING
E KI
T
DET
AIL
B1
HIN
GE
KIT
PART
S LI
STD
ESCR
IPTI
ON
PAR
T N
UM
BER
QTY
ITEM
HIN
GE
FLIP
PER
PC10
636
21
HIN
GE
BLO
CKPC
1058
32
23/
8" H
EX N
UT
116-
3-A1
23
3/8"
LO
CK W
ASH
ER11
8-3-
A12
43/
8" x
3"
GRAD
E 8
HEX
BO
LT10
2-21
3-A1
25
SAFE
TY P
RO
P H
OO
KPC
1046
81
6SA
FETY
PRO
P BR
ACKE
TPC
2100
61
7
SAFE
TY P
RO
P CU
PPC
1041
51
8
SAFE
TY P
ROP
PC13
033
19
1/2"
GRAD
E 8
HEX
BO
LT10
2-41
7-A1
110
DES
CRIP
TIO
NPA
RT
NU
MBE
RQ
TYIT
EM 111/
2" L
OCK
WAS
HER
118-
5-A1
112
1/2"
HEX
NU
T11
6-5-
A11
13H
ING
E PI
NPC
1081
62
SAFE
TY P
RO
P KI
T PA
RTS
LIST
23
4
13
5
K101
019
SAFE
TY P
RO
P KI
T
3/8
3/8
ALL
POIN
TSO
F CO
NTA
CT
6
7
10,1
1,12
9
8
K101
020
SAFE
TY P
RO
P AN
D H
ING
E H
ARD
WAR
E
10
DET
AIL
A
DET
AIL
B
DET
AIL
C
G
REA
SE L
OCA
TIO
N P
OIN
TS
GD
IMEN
SIO
NSE
E H
OIS
T
PAG
E
PR
OC
ED
UR
E I
- H
OIS
T L
OC
AT
ION
ON
TR
AIL
ER
& R
EA
R H
ING
E IN
ST
AL
LA
TIO
N
PR
OC
ED
UR
E S
TE
PS
:
LOC
AT
E A
ND
WE
LD R
EA
R H
ING
E
BR
AC
KE
T T
O F
RA
ME
. LO
CA
TE
HO
IST
ON
FR
AM
E S
O
TH
AT
TH
E C
EN
TE
RLI
NE
OF
T
HE
LO
WE
R L
IFT
AR
M IS
AT
T
HE
DE
SIR
ED
LO
CA
TIO
N
FR
OM
TH
E R
EA
R H
ING
E F
OR
T
HE
DU
MP
AN
GLE
RE
-Q
UIR
ED
. W
ELD
LO
WE
R L
IFT
AR
M T
O
FR
AM
E .
PLA
CE
BO
DY
ON
FR
AM
E T
O T
HE
D
ES
IRE
D L
OC
AT
ION
. T
HE
B
OD
Y M
US
T B
E P
AR
ELL
EL
WIT
H T
HE
FR
AM
E.
WE
LD R
EA
R H
ING
E F
LIP
PE
RS
TO
F
RA
ME
. US
ING
1/2
” C
ON
TIN
U-
OU
S F
ILLE
T W
ELD
S A
RO
UN
D
ALL
CO
NT
AC
T
AR
EA
S.
11
PR
OC
ED
UR
E S
TE
PS
: (S
EE
ILLU
ST
RA
TIO
N L
EF
T)
U
SIN
G T
HE
HO
IST
PO
WE
R, R
AIS
E T
HE
B
OD
Y A
PP
RO
XIM
AT
ELY
1-1
/2”
AS
M
EA
SU
RE
D F
RO
M T
HE
EN
D O
F B
ED
. W
ELD
LIF
T A
RM
S T
O L
ON
G S
ILLS
US
ING
3/
8” C
ON
TIN
UO
US
FIL
LET
WE
LD. (
SE
E
BE
LOW
) M
AK
E S
UR
E H
OIS
T IS
CE
NT
ER
ED
WIT
HIN
T
HE
RA
ILS
AN
D S
EC
UR
EIN
PLA
CE
W
ITH
CO
LLA
RS
. C
AU
TIO
N:
FA
ILU
RE
TO
PE
RF
OR
M T
HIS
PR
O-
CE
DU
RE
AS
SP
EC
IFIE
D C
OU
LD C
AU
SE
HO
IST
F
AIL
UR
E A
ND
TH
ER
EF
OR
E V
OID
S A
SS
OC
IAT
ED
W
AR
RA
NT
Y.
1/4"
x 4
1/2
" PL
ATE
SUPP
LIED
BY
INST
ALLE
R
TYP.
1/4
TYP.
3/8
TYP.
3/8
PART
# M
1229
0 (L
OW
ER P
IVO
T)
PART
# P
C104
71 (
UPP
ER)
6 3/
8
21 M
IN.
30 M
AX.
MIN
.
PART
# P
C121
61 (
COLL
AR)
SEE
NO
TE
()
NO
TE:
IF
LOW
ER L
IFT
ARM
IS
EXTE
ND
ED O
UT
FURT
HER
TH
ATN
2"
THEN
CO
LLAR
MU
ST B
E U
SED
.
NO
TE
: MA
KE
SU
RE
TO
GR
EA
SE
ALL
LU
BR
ICA
TIO
N F
ITT
ING
S B
EF
OR
E O
PE
RA
TIN
G. R
E-
FE
R T
O P
AG
E (
10)
FO
R F
ITT
ING
LO
CA
TIO
NS
.
INCO
RRE
CT I
NST
ALLA
TIO
N
UPP
ER L
IFT
ARM
BOD
Y LO
NG
SIL
L
PR
OC
ED
UR
E II
I - R
EM
OV
ING
SL
AC
K F
RO
M H
OIS
T A
ND
RE
AR
HIN
GE
IMP
OR
TAN
T!
SLA
CK
MU
ST
BE
RE
-M
OV
ED
FR
OM
HO
IST
AN
D
RE
AR
HIN
GE
DU
RIN
G IN
-S
TA
LLA
TIO
N.
UP
PE
R L
IFT
AR
MS
AN
D T
OP
OF
LO
NG
S
ILL
S M
US
T B
E P
AR
AL
LE
L.
LON
G S
ILL
TRAI
LER
FRA
ME
12 SAFETY PROP INSTALLATION
13
Trailer bed lengths -10 - 12 feet
C H A M P IO NH o is t a n d E q u ip m e n t
D u n n , N o rth C a ro lin a , U .S .A .9 1 0 - 8 9 7 - 4 9 9 5
F a x 9 1 0 - 8 9 7 - 6 8 2 2
24
401116
15 716
1038
CS415T
"G" DIMENSION40° TILT 84 inches45° TILT 74 inches
- GREASE FITTING LOCATIONS
1812
Ø178
SIDE VIEW
FRONT VIEW
BACK VIEW
TOP VIEW
BOTTOM VIEW
6
Hoist System
Pressure PSI
Capacity (TONS) - Trailer Length (FT) - 18 inches Overhang
10 12
CS 415T 3,200 6.0 4.7
14
CS415T TRAILER HOIST ASSEMBLY
MP50335
15
CS515T
"G" DIMENSION40° TILT 84 inches45° TILT 74 inches
- GREASE FITTING LOCATIONS
24
401116
151116
1038
1812
Ø178
SIDE VIEW
TOP VIEW
BACK VIEW
BOTTOM VIEW
FRONT VIEW
Trailer bed lengths -10 - 12 feet
Hoist System
Pressure PSI
Capacity (TONS) - Trailer Length (FT) - 18 inches Overhang
10 12
CS 515T 3,200 9.5 7.3
C H A M P IO NH o is t a n d E q u ip m e n t
D u n n , N o rth C a ro lin a , U .S .A .9 1 0 - 8 9 7 - 4 9 9 5
F a x 9 1 0 - 8 9 7 - 6 8 2 2
16
CS515T TRAILER HOIST ASSEMBLY
MP50334
17
CS615T
"G" DIMENSION40° TILT 84 inches45° TILT 74 inches
- GREASE FITTING LOCATIONS
24
401116
151116
1038
1812
Ø178
SIDE VIEW
BOTTOM VIEW
BACK VIEW
TOP VIEW
FRONT VIEW
Trailer bed lengths -10 - 12 feet
Hoist System
Pressure PSI
Capacity (TONS) - Trailer Length (FT) - 18 inches Overhang
10 12
CS 615T 3,200 13.6 10.6
C H A M P IO NH o is t a n d E q u ip m e n t
D u n n , N o rth C a ro lin a , U .S .A .9 1 0 - 8 9 7 - 4 9 9 5
F a x 9 1 0 - 8 9 7 - 6 8 2 2
18
CS615T TRAILER HOIST ASSEMBLY
MP50336
19
CS520T
"G" DIMENSION40° TILT 119 inches45° TILT 104 inches
- GREASE FITTING LOCATIONS
24
51 316
1814
111516
26
Ø214
SIDE VIEW
TOP VIEW
BACK VIEWFRONT VIEW
BOTTOM VIEW
Trailer bed lengths -12 - 14 feet
Hoist System
Pressure PSI
Capacity (TONS) - Trailer Length (FT) - 18 inches Overhang
12 14
CS 520T 3,200 9.5 7.7
C H A M P IO NH o is t a n d E q u ip m e n t
D u n n , N o rth C a ro lin a , U .S .A .9 1 0 - 8 9 7 - 4 9 9 5
F a x 9 1 0 - 8 9 7 - 6 8 2 2
20
CS520T TRAILER HOIST ASSEMBLY
MP50354CHAMPIONHoist and Equipment
Dunn, North Carolin, U.S.A.
PARTS LISTDESCRIPTIONPART NUMBERQTYITEM
520 CYLINDER520CYLINDER11HEX BOLT, 5/8-11 UNC X 4, GR 9102-617-L12LIFT ARM 2-1/4"PC1047023SET COLLOR FOR UPPER LIFT ARM 2-1/4"PC1215744SET SCREW 3/8"-16 x 3/4" SQHDP3485SHAFT, CYLINDER ENDCAP, CS 520TSM1230416PIN- COTTER125-25727LOWER LIFT ARM MODIFICATION, TRAILER HOIST, 2 1/4"M12345285/8" LOCK NUT162-10-S19CS 520T, & 620T WELDMENTW12335110
55 3
4
4
5
5
3
2
1
8
5
5
4
7
76
8 5
4
5
10
9
21
CS620T
"G" DIMENSION40° TILT 119 inches45° TILT 104 inches
- GREASE FITTING LOCATIONS
24
51 316
1814
111516
26
Ø214
SIDE VIEW
TOP VIEW
BACK VIEWFRONT VIEW
BOTTOM VIEW
Trailer bed lengths -12 - 14 feet
Hoist System
Pressure PSI
Capacity (TONS) - Trailer Length (FT) - 18 inches Overhang
12 14
CS 620T 3,200 13.7 11.2
C H A M P IO NH o is t a n d E q u ip m e n t
D u n n , N o rth C a ro lin a , U .S .A .9 1 0 - 8 9 7 - 4 9 9 5
F a x 9 1 0 - 8 9 7 - 6 8 2 2
22
55 3
4
4
5
5
3
2
1
8
5
5
4
7
76
8 5
4
5
10
9
PARTS LISTDESCRIPTIONPART NUMBERQTYITEM
620 CYLINDER620CYLINDER11HEX BOLT, 5/8-11 UNC X 4, GR 9102-617-L12LIFT ARM 2-1/4"PC1047023SET COLLOR FOR UPPER LIFT ARM 2-1/4"PC1215744SET SCREW 3/8"-16 x 3/4" SQHDP3485SHAFT, CYLINDER ENDCAP, CS 520TSM1230416PIN- COTTER125-25727LOWER LIFT ARM MODIFICATION, TRAILER HOIST, 2 1/4"M12345285/8" LOCK NUT162-10-S19CS 520T, & 620T WELDMENTW12335110
CS620T TRAILER HOIST ASSEMBLY
MP50355CHAMPIONHoist and Equipment
Dunn, North Carolin, U.S.A.
23
CS5520T
"G" DIMENSION40° TILT 119 inches45° TILT 104 inches
- GREASE FITTING LOCATIONS
24
51 316
2414
111516
26
Ø214
SIDE VIEW BACK VIEW
BOTTOM VIEW
FRONT VIEW
TOP VIEW
Trailer bed lengths -14 - 16 feet
Hoist System
Pressure PSI
Capacity (TONS) - Trailer Length (FT) - 18 inches Overhang
14 16
CS 5520T 3,200 15.5 13.1
C H A M P IO NH o is t a n d E q u ip m e n t
D u n n , N o rth C a ro lin a , U .S .A .9 1 0 - 8 9 7 - 4 9 9 5
F a x 9 1 0 - 8 9 7 - 6 8 2 2
24
3
5
4
5
4
3
5
5
99
22
1
1
11
6
8
4
5
5
8
4
55
7
10
PARTS LISTDESCRIPTIONPART NUMBERQTYITEM
520 CYLINDER520CYLINDER21HEX BOLT, 5/8-11 UNC X 4, GR 9102-617-L22LIFT ARM 2-1/4"PC1047023SET COLLOR FOR UPPER LIFT ARM 2-1/4"PC1215744SET SCREW 3/8"-16 x 3/4" SQHDP3485SHAFT, OUTER CYL. MT.SM1205816Hex Bolt, 3/8" x 3"102-213-A117LOWER LIFT ARM MODIFICATION, TRAILER HOIST, 2 1/4"M12345285/8" LOCK NUT162-10-S29CS 5520T, & 6620T WELDMENTW12336110LOCK NUT, 3/8"162-7-S111
CS5520T TRAILER HOIST ASSEMBLY
MP50356CHAMPIONHoist and Equipment
Dunn, North Carolin, U.S.A.
25
CS6620T
"G" DIMENSION40° TILT 119 inches45° TILT 104 inches
- GREASE FITTING LOCATIONS
24
51 316
2414
111516
26
Ø214
SIDE VIEW
TOP VIEW
BACK VIEW
FRONT VIEW
BOTTOM VIEW
Trailer bed lengths -14 - 16 feet
Hoist System
Pressure PSI
Capacity (TONS) - Trailer Length (FT) - 18 inches Overhang
14 16
CS 6620T 3,200 22.4 18.9
C H A M P IO NH o is t a n d E q u ip m e n t
D u n n , N o rth C a ro lin a , U .S .A .9 1 0 - 8 9 7 - 4 9 9 5
F a x 9 1 0 - 8 9 7 - 6 8 2 2
26
CS6620T TRAILER HOIST ASSEMBLY
MP50357CHAMPIONHoist and Equipment
Dunn, North Carolin, U.S.A.
PARTS LISTDESCRIPTIONPART NUMBERQTYITEM
620 CYLINDER620CYLINDER21HEX BOLT, 5/8-11 UNC X 4, GR 9102-617-L22LIFT ARM 2-1/4"PC1047023SET COLLOR FOR UPPER LIFT ARM 2-1/4"PC1215744SET SCREW 3/8"-16 x 3/4" SQHDP3485SHAFT, OUTER CYL. MT.SM1205816Hex Bolt, 3/8" x 3"102-213-A117LOWER LIFT ARM MODIFICATION, TRAILER HOIST, 2 1/4"M12345285/8" LOCK NUT162-10-S29CS 5520T, & 6620T WELDMENTW12336110LOCK NUT, 3/8"162-7-S111
3
5
4
5
4
3
5
5
99
22
1
1
11
6
8
4
5
5
8
4
55
7
10
27
Notes: