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P/N 1808684 Rev. I

17

Electric Installation

Item Part #

Description

1. 1703845 Solenoid

2. 1703896 Solenoid Cover

3. 1801726 Toggle Switch

4. 1801265 Toggle Switch Plate

5. 1800430 Ring Terminal - 8 Ga. x 1/4"

6. 1801486 Ring Terminal - 8 Ga. x 3/8"

7. 1800417 Circuit Breaker - 60-Amp 12V

8. 1800441 Butt Connector - 18-22 Ga.

A. 1800802 Sheet Metal Screw - #10 x 1"

B. 1800783 Cap Screw - 1/4" x 1 1/2"

L. 1800699 Lock Nut - 1/4"

T. 1800784 Flat Washer - 1/4" SAE

NOTE:

New electric motor kits include dual-conductor wire. If

not using new electric kit, use existing wire on truck.

STEP 1:

Locate solenoid in sheltered location, such as bat

-

tery box, cab or under cab. Using solenoid as guide,

mark and drill 1/4" holes. Loosely fasten solenoid with

screws

B

and nuts

L

.

1

2

7

3

STEP 2:

Locate circuit breaker near battery. Fasten with

screws

A

and washers

T

.

4

5

6

8

solenoid

drill

1/4"

holes

60a

circuit

breaker

CAUTION

Do not pull dual-strand wires apart. To separate,
carefully cut through insulation between wires with
knife. Pulling wires apart could damage wire insula-
tion and expose wire. This could result in equipment
damage and/or personal injury.

!

NOTE:

Cut wires to length and strip only enough wire insulation

to install ring terminals. Insert bare wire into ring terminals and

crimp securely.

strip

wire

insulation

ring

terminal

crimp

securely

CAUTION

Do not spray electric components with pressure
washer or hose.

!

L

A

B

T

A

B

L

A

T

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Содержание Donovan Quick-Flip III

Страница 1: ...Quick Flip III Electric P N 1808684 Rev I ...

Страница 2: ...r work purchase of a replacement product or return of the product all of which will be at the owner s expense Payment authorization must be received by us before any non warrantable product is repaired replaced or returned All expenses associated with deliver ing the repaired non warrantable product a replacement product or the non warrantable product from our factory to the owner will be paid by ...

Страница 3: ...nstallation 2 Housing Assembly Installation 3 Spring Pivot Installation Single Axle Fixed Gantry 4 5 Spring Pivot Installation Tandem Axle Hydraulic Gantry 6 7 Spring Pivot Installation Trailers 8 9 Pivot Arm Installation Single Axle 10 Pivot Arm Installation Tandem Axle Hydraulic Gantry 11 Pivot Arm Installation Trailers 12 Tarp Tube Assembly Tarp Installation 13 Pre Load Springs 14 Hydraulic Pum...

Страница 4: ...ge Bolt 1 2 x 1 1 2 1800994 Flat Washer 3 8 1804139 Cap Screw 3 8 x 3 1 4 1800561 Pan Hd Cap Screw 5 16 x 2 1 4 1800993 Nylon Lock Nut 3 8 1800989 Flat Washer 5 16 1800990 Lock Nut 5 16 1800790 Cap Screw 3 8 x 1 1 2 1800991 Lock Washer 3 8 1800784 Flat Washer 1 4 1800802 Sheet Metal Screw 10 x 1 1800783 Cap Screw 1 4 x 1 1 2 1800787 Lock Washer 5 16 1800699 Lock Nut 1 4 1800431 Hex Nut 5 16 180097...

Страница 5: ...ATION CAUTION Welding components to truck frame may weaken frame and will void warranty on truck Weld angle brackets to existing brackets on frame when pos sible When not possible drill holes in frame and bolt brackets in place CAUTION To prevent damage to and ensure proper operation of Quick Flip II system center base assembly be tween cab and hoist with at least 6 of clearance 6 minimum cab tilt...

Страница 6: ... on base assembly to housing assembly with screws K washers Z and nuts R Item Part Description 1 1808662 Housing Assembly 2 1801622 Base Assembly Hydraulic 1808652 Base Assembly Fixed 3 1704878 Durabuilt Motor w Cover K 1801024 Cap Screw 1 2 x 4 R 1800995 Lock Nut 1 2 Z 1800996 Flat Washer 1 2 hole in base assembly stud on housing assembly hydraulic cylinder rod housing assembly base assembly 1 2 ...

Страница 7: ...t plate at marked location Using holes in plate as guide mark hole locations on frame rail and drill 5 8 holes Fasten with grade 5 or better 5 8 bolts washers and nuts not included Repeat to install frame mount plate at same location on pas senger side frame rail NOTE Do not weld directly to truck frame as this can weaken frame and potentially void warranty Components may be welded to plates struc...

Страница 8: ...ssembly With spring catch aligned with spring hook as shown insert driver side internal spring assembly into pivot tube Adjust spring leg into rear groove on pivot tube with spring leg pointing toward rear of truck Fasten assembly to pivot tube with carriage bolts J and nylon lock nuts R Repeat on passenger side Spring Pivot Installation Single Axle Fixed Gantry continued frame mount plate pivot t...

Страница 9: ...cate spring assemblies as low on truck frame as possible to allow clearance between roll off container and spring assemblies Top of spring assemblies must be less than 5 above rollers used to support container If needed pull container onto truck and check for clearance Item Part Description 1 1808664 Bridge Mount Spring Assembly Passenger Side 2 1808665 Bridge Mount Spring Assembly Driver Side 3 1...

Страница 10: ... screws H washers Q and nuts Y Repeat for passenger side Rotate spring shafts so spring catch engages spring hook as shown then reinstall covers STEP 2B Fabricatesupportstobeequalinwidth withanoverall width of 107 1 2 Secure supports to truck frame STEP 4 Compare springs to those illustrated below to find driver side assembly NOTE Spring pivot supports must be equal in length so system will be cen...

Страница 11: ...trailer frame as this can weaken frame and potentially void warranty Components may be welded to plates structure already existing on trailer frame STEP 3 To determine spring pivot tube lengths first measure distance between outside faces of pivot mount plates frame width plus thickness of two plates Subtract measurement from overall width of 99 1 2 and divide remainder in half Cut spring pivot tu...

Страница 12: ...plates for added strength STEP 5 Internal spring assembly With spring catch aligned with spring hook as shown insert driver side internal spring assembly into pivot tube Adjust spring leg into rear groove on pivot tube with spring leg pointing toward rear of trailer Fasten assembly to pivot tube with carriage bolts J and nylon lock nuts R Repeat on passenger side rear groove spring leg spring catc...

Страница 13: ...or is close to horizontal assembled arm length tarp housing pivot shaft STEP 3 Slide return arm onto spring pivot connector Align outer profiles to match and let end of arm rest on ground Fasten return arms to spring pivot connectors with screws F washer V and nuts P as shown 2 1 P F V Item Part Description 1 1800421 Aluminum Return Arm Straight 2 1801636 Spring Pivot Connector F 1800561 Pan Hd Sc...

Страница 14: ...ntil you feel shaft contact hook on spring Slide spring pivot connector onto shaft so connector is close to horizontal then tighten screws STEP 4 Slide arm coupler into lower arm and fasten withscrews F washers V and nuts P NOTE To continue installation turn to Tarp Tube Assembly Tarp Installation on page 13 STEP 5 Slide upper arm onto arm cou pler and fasten with screws F washers V and nuts P V F...

Страница 15: ...800561 Pan Hd Screw 5 16 x 2 1 4 V 1800989 Flat Washer 5 16 P 1800990 Lock Nut 5 16 assembled arm length 1 2 P V F STEP 2 Turn spring shaft counter clockwise on driver side and clockwise on passenger side until you feel shaft contact hook on spring Slide spring pivot connector onto shaft so connector is close to horizontal STEP 3 Slide return arm onto spring pivot connector Align outer profiles so...

Страница 16: ... ends of rod to fit tarp plastic rod on front of tarp slot in roller bar arm STEP 2 Insert cast elbow into upper arm and fasten with screws F washers V and nuts P V F P cast elbow upper arm STEP 5 Center tarp on roller bar and rear cross piece STEP 6 Insert rear cross piece into 90 elbows Using holes in 90 elbow as guide mark and drill 5 16 holes Fasten with screws I and nuts S S I rear cross piec...

Страница 17: ...ounter clock wise for driver side and clockwise for passenger side until you feel shaft engage rear hook on spring Use 7 8 wrench or pipe wrench to continue turning shaft in same direction until next flat on hex shaft lines up with hex flats in pivot connector then slide pivot con nector onto spring shaft STEP 3 Pre load spring one flat 1 6 turn at a time on hex shaft until desired pre load is rea...

Страница 18: ...p Installation STEP 1 Locate pump mount bracket on outside of leg or other easily accessible location Locate bracket so pump will be vertical with control valve and motor on top and reservoir on bottom as shown pump and mounting bracket outside of leg weld to leg 1 2 3 4 5 6 D W STEP 2 Mark bracket location on trailer Unfasten and remove hydraulic pump from bracket Weld bracket in place then repla...

Страница 19: ... breather cap onto fill port Do not reinstall shipping plug STEP 5 Connect negative wire from battery to stud on hydrau lic pump STEP 6 Connect positive wire from battery to circuit breaker and from circuit breaker to solenoid on pump STEP 7 Place solenoid cover over solenoid Secure cover to pump with 8 cable tie CAUTION Replace shipping plug with breather cap on hydrau lic pump or pump will be da...

Страница 20: ... bat tery box cab or under cab Using solenoid as guide mark and drill 1 4 holes Loosely fasten solenoid with screws B and nuts L 1 2 7 3 STEP 2 Locate circuit breaker near battery Fasten with screws A and washers T 4 5 6 8 solenoid drill 1 4 holes 60A circuit breaker CAUTION Do not pull dual strand wires apart To separate carefully cut through insulation between wires with knife Pulling wires apar...

Страница 21: ...gle switch where switch can easily be accessed by system operator Weld toggle switch plate in place STEP 7 Fasten toggle switch to plate with screws A and washers T STEP 4 Cut section of dual conductor wire to run from solenoid tobattery Crimptwo1 4 ringterminals 5 ononeendof wire and connect terminals to posts on solenoid marked Batt and Batt Crimp one 1 4 ring terminal 5 and one 3 8 ring termina...

Страница 22: ...s hardware not provided STEP 4 Insert bumper hold down bars into slots in rubber bumpers Item Part Description 1 1801012 Rubber Bumper 2 1800140 Bumper Hold Down Bar 3 1801324 Pivot Arm Rest C 1800998 Cap Screw 5 16 x 1 R 1800995 Lock Nut 5 16 V 1800989 Flat Washer 5 16 1 2 3 arms housing assembly housing assembly bracket pivot arm pivot arm rest rubber bumper motor housing assembly bracket pivot ...

Страница 23: ...lange Reversed 3 1800699 Lock Nut 1 4 4 1704878 Durabuilt Motor w Cover 5 1800460 Self Tapping Screw 5 16 x 1 1 4 6 1800989 Flat Washer 5 16 7 1800767 Cap Screw 1 4 x 3 4 8 1800784 Flat Washer 1 4 9 1800996 Flat Washer 1 2 10 1800995 Lock Nut 1 2 11 1801024 Cap Screw 1 2 x 4 12 1800477 Modular Housing Deflector 13 1802015 Roller Bar 14 1800942 Bolt 5 16 x 2 1 2 15 1800980 Shaft Extension 3 4 x 4 1...

Страница 24: ...crew 1 2 x 4 1 2 4 1800995 Lock Nut 1 2 5 1808653 Outer Stage Fixed Weldment 6 1801621 Inner Stage Quick Weldment 7 1800901 Cap Screw 1 2 x 3 8 1801619 Outer Stage Quick Weldment 9 1800996 Flat Washer 1 2 10 1800306 Fitt Hyd 4M JI C x 3 8 90D 11 1800082 Cylinder 1 5 x 42 x 1 12 1801017 Fitting Hyd 4MJ 4MP STR 13 1801018 Pres Flow Comp Hyd 1 3 4 14 1801016 Fitting Hyd 90 3 8 MP 15 1800726 Mount Cha...

Страница 25: ...0 1808671 Spring Shaft 7 8 Hex x 14 1 4 11 1118955 Spring Retainer 12 1704476 Torsion Spring 2 3 4 OD Left Hand 13 1804477 Torsion Spring 2 3 4 OD Right Hand 14 1804139 Cap Screw 3 8 x 3 1 4 15 1800994 Flat Washer 3 8 16 1800993 Nylon Lock Nut 3 8 17 1808669 Spring Housing Base 1 2 3 4 5 6 7 8 17 6 1 2 11 12 10 1 9 14 15 16 15 14 5 13 4 3 SPRING PIVOT SUPPORTS TANDEM AXLES Item Part Description 1 ...

Страница 26: ...aring 7 8 5 1808639 Inner Bearing Plate 6 1800795 Hex Bolt 3 8 7 1808638 Bearing Spacer 8 1808637 Spring Catch 7 8 9 1808640 Outer Bearing Plate 10 1800995 Lock Nut 1 2 Grade 5 11 1808641 Spring Pivot Tube 12 1808635 Internal Mount Spring Assembly Driver Side 13 1808634 Internal Mount Spring Assembly Passenger Side 14 1800356 Carriage Bolt 1 2 x 1 1 2 15 1808646 Frame Mount Gusset 16 1808645 Frame...

Страница 27: ...rt Description 1 1800300 Rear Cross Piece 2 1800597 90 Cast Elbow 3 1800421 Aluminum Return Arm Straight 4 1801636 Spring Pivot Connector 5 1800561 Pan Hd Screw 5 16 x 2 1 4 6 1800989 Flat Washer 5 16 7 1800990 Lock Nut 5 16 8 1801025 Cap Screw 7 16 x 2 3 4 9 1800329 Nylon Lock Nut 7 16 8 9 ...

Страница 28: ...1 1800300 Rear Cross Piece 2 1800597 90 Cast Elbow 3 1800548 Upper Arm 4 1800547 Arm Coupler 5 1800545 Lower Arm 6 1801636 Spring Pivot Connector 7 1800561 Pan Hd Cap Screw 5 16 x 2 1 4 8 1800989 Flat Washer 5 16 9 1800990 Lock Nut 5 16 10 1801025 Cap Screw 7 16 x 2 3 4 11 1800329 Nylon Lock Nut 7 16 9 8 7 6 10 11 ...

Страница 29: ...2 Cap Screw 5 16 x 1 1 2 5 1800989 Flat Washer 5 16 6 1800990 Lock Nut 5 16 1 2 3 4 5 6 PIVOT ARMS TRAILERS Item Part Description 1 1800300 Rear Cross Piece 2 1800597 90 Cast Elbow 3 1801241 Aluminum Return Arm 4 1801636 Spring Pivot Connector 5 1800561 Pan Hd Screw 5 16 x 2 1 4 6 1800989 Flat Washer 5 16 7 1800990 Lock Nut 5 16 8 1801025 Cap Screw 7 16 x 2 3 4 9 1800329 Nylon Lock Nut 7 16 9 8 ...

Страница 30: ... Terminal 8 Ga x 1 4 10 1801486 Ring Terminal 8 Ga x 3 8 11 1800417 Circuit Breaker 60 Amp 12V 12 1800441 Butt Connector 18 22 Ga 1 2 11 3 8 4 5 7 9 10 12 8 6 6 HYDRAULIC COMPONENTS Item Part Description 1 1800090 Hydraulic Pump 12 Volt M310 2 1801623 Pump Mount Bracket 3 1801223 Spacer Steel Pump Bracket 4 1800906 Hose Clamp 5 to 7 5 1801125 Motor Mount Rubber Tire 6 1801627 Hydraulic Hose 84 OAL...

Страница 31: ...P N 1808684 Rev I 28 Notes ...

Страница 32: ...s Arm Matic DuraPull Econo Pull Turbo Tarp2 2000 Series 5000 Series Hammer Bullet Flash Long Arm Waste Products SWAT The Ox Quick Flip III Sidewinder Sidewinder 350 HyTower SL HyTower DL Double Flip Donovan Belt Ratchet DBR ...

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