Leyman FBGxxNP Series Liftgate

Owner’s Manual

FBGxxNP & FBGxxNPPD Fold-A-Vador Rail Style

10900 Kenwood Road • Cincinnati, OH 45242 Ph: 513.891.6210 • Toll-Free: 866.539.6261 Fax: 513.891.4901 www.leymanlift.com • sales@leymanlift.com

LML00396-9-10-09

GENERAL TERMINOLOGY

Page 4

WALK AROUND ELECTRICS GRAVITY DOWN DUAL PWR. UNIT with TWO PLASTIC TANKS

Page 12

WALKAROUND ELECTRICS POWER DOWN DUAL PWR. UNIT with TWO PLASTIC TANKS

Page 13

SWITCH WIRING GRAVITY DOWN NP SERIES

LEGEND G – GREEN W – WHITE B – BLACK O – ORANGE R – RED B - BLUE

REPLACEMENT SWITCHES ARE SUPPLIED WITH THE NECESSARY HARDWARE TO CONNECT INTO THE EXISTING WIRING. Index No. 1 2 3 4 5 6 7 8 9

Req. 1 1 1 1 1 1 10 1 1

Part No. AA-551-523 AA-551-524 BP-805-256 BP-805-258 P46747 P46475 P17518 P46445 P46139

Part Name POTTED OUTER TWO SW. ASSY POTTED INNER SINGLE SW ASSY RECESSED SWITCH PLATE

Matl.

Remarks

16-4 16-6

10 FT. (120”) 40 FT. (480”)

RECESSED SINGLE SWITCH PLATE

JACKETED WIRE – HIGH FLEX JACKETED WIRE SELF TAPPING SCREW CORD GRIP CORD GRIP

IN OUTER MAST IN INNER MAST

Page 14

SWITCH WIRING POWER DOWN NPPD SERIES

LEGEND G – GREEN W – WHITE B – BLACK O – ORANGE R – RED B - BLUE

REPLACEMENT SWITCHES ARE SUPPLIED WITH THE NECESSARY HARDWARE TO CONNECT INTO THE EXISTING WIRING. Index No. 1 2 3 4 5 6 7 8 9

Req. 1 1 1 1 1 1 10 1 1

Part No. AA-551-525 AA-551-522 BP-805-256 BP-805-258 P46747 P46475 P17518 P46445 P46139

Part Name POTTED OUTER TWO SW. ASSY POTTED INNER SINGLE SW ASSY RECESSED SWITCH PLATE

Matl.

Remarks

16-4 16-6

10 FT. (120”) 40 FT. (480”)

RECESSED SINGLE SWITCH PLATE

JACKETED WIRE – HIGH FLEX JACKETED WIRE SELF TAPPING SCREW CORD GRIP CORD GRIP

IN OUTER MAST IN INNER MAST

Page 15

PARTS REPLACEMENT –

HYDRAULIC ASSEMBLY

Index No.

Qty Req’d

Part Number

Part Name

Remarks

1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16

2 1 1 1 1 4 2 2 2 8 6 4 1 4 4 4 4

P33931 See chart See chart See chart See chart P33006 P33064 P33619 P33914 P46251 P17518 P46497 P33547K AA-811-328 P43577 P34014 P31048

Hyd. Cylinder Hydraulic line assy (incl. item 15) Hydraulic line assy (incl. item 15) Hydraulic line assy (incl. item 15) Hydraulic line assy (incl. item 15) Street elbow 3/8 Nipple Pipe 3/8 Flow control 2.8 GPM Flow control 2.0 GPM Loom clamp ! in.

Self tapping screw !” Split loom Equalizer with adapter fittings (incl. item 15) Cylinder Pin with 2 snap rings Cylinder Mounting Block Bearing Straight Adapt. 3/8 NPT(M) – 9/16-18 JIC(M) Plug, Pipe 3/8 SHCS

54 Stroke RH Lifting LH Lifting RH “Down” Line LH “Down” Line

Grav Dn Assy

Power Dn Assy

Gate Width

Qty Req’d

CT-819-084-002 CT-819-084-001

CT-819-035-002 CT-819-035-001

102” 96”

1 ea.

1 ea.

RH Lifting Item 2 BT-501-442-129 BT-501-442-123

LH Lifting Item 3 BT-501-442-085 BT-501-442-085

Gravity Down Power Down Not Shown Not Shown 24” Lg ea.

SAE “O” Ring Ports Not Shown Not Shown

RH “Down” Line Item 4 BT-501-442-093 BT-501-442-093

Page 32

LH “Down” Line Item 5 BT-501-442-131 BT-501-442-125

POWER FOLD ASSEMBLY

Index No. 1 2 2 3 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16

Qty. 1 1 1 1 1 1 1 1 1 1 2 1 1 4 2 3 1 1 1

Part No. P33877 P33915 P33646 P33064 P33217 P33671 P33984 P33750 AT-501-284-074 AP-811-200 P24019 S754-005.500 P47532 P26019 P46462 P46750 P34174 P34106 P34110

Description Hyd. Cylinder Breather Vent - 1/8 NPT Breather Vent – 3/8 NPT Pipe Nipple Male Elbow (used when cylinder port is recessed) Flow Control – steel platform Flow Control – alum. platform Adapter (Qty. 2 if using elbow block) Hose Assembly Top Ram MTG Shaft Retaining Ring Bottom Ram MTG Pin Roll Pin Washer Cable Tie 11” Stainless Steel Cable Tie Spring Guard Bulkhead Elbow Straight Adapter

Page 33

REPLACEMENT ROLLER 4” REPLACEMENT UPPER ROLLER PARTS GREASED / GREASELESS ROLLERS WITH SIDE PADS

ROLLER ASSEMBLY CAN BE ORDERED COMPLETE UNDER PART NO. BA-818-435 OR BY INDIVIDUAL COMPONENTS LISTED BELOW.

Index No. 1 2 3 4 5

Qty Req’d 1 1 2 1 1

Part Number BA-818-196 BA-805-304 P43565 P47507 P32016

Part Name Roller Sub Assembly Roller Shaft Assy.

Thrust Bearing Roll Pin Grease Fitting

Page 34

REPLACEMENT ROLLER 4” REPLACEMENT LOWER ROLLER PARTS GREASED / GREASELESS ROLLERS WITH SIDE PADS

ROLLER ASSEMBLY CAN BE ORDERED COMPLETE UNDER PART NO. BA-819-175 OR BY INDIVIDUAL COMPONENTS LISTED BELOW. Index No. 1 2 3 4 5 6 7

Qty Req’d 1 1 2 2 1 1 1

Part Number BA-818-382 BA-819-177 P24021 P43565 P47507 P26517 P32016

Part Name Roller Sub Assembly Roller Shaft Assy.

Retaining Ring Thrust Bearing Roll Pin Flat Washer Grease Fitting

Page 35

PLATFORM PINS AND BUSHINGS

PLATFORM BEARING (1 REQ’D EACH SIDE)

Index No. 1 2 3 4 5 6 7 8 9

Qty. 2 2 1 2 1 1 1 1 2

Part Number P11048 P26017 BA-818-205 P26020 S790-060.000 AP-808-108 S055-002.000 BA-818-206 P43567

Part Name Bolt Washer Lock Split 3/8 Pin Sub Assy Spacer Washer Torsion Bar Hex Sleeve Mtg. Plate Pin Sub Assy Platform Bearing

Material Size/Notes 3/8 16 x 1 ! gr. 8 Driver Side 60” lg Curb Side

Page 36

Hand Rail Parts Standard Hand Rails

Index No.

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

2 6 2 2 2 2 4 2 2 2 2 2 2 2 2 1 1 2 1 2

Part Number AA-811-384 P26517 P24021 BA-811-363 AA-811-383 P26020 P47514 CA-811-371 S758-020.250 P47508 S403-000.250 BA-811-362 S149-002.500 BP-811-385 S498-002.500 BP-999-045 AA-999-021 AP-811-459 S057-007.000 S192-001.750

Part Name Spacer – Double Barrel Washer Retaining Ring Side Rail –Front Pin for FBG Narrow Rim Washer Roll Pin Front Rail Assembly Shaft Roll Pin Spacer Side Rail – Back Flat Platform Ear Rail Stop Sign Plate Chain Assembly Pin for Std Hand Rail Spacer Stop Block

Material Size/Notes

! x 1-1/2

For ear on platform

Not shown

For platform ear For Front Rail Assembly

Page 37

(THIS PAGE INTENTIONALLY LEFT BLANK)

Hand Rail Parts Collapsible Hand Rails

Page 38

Hand Rail Parts Collapsible Hand Rails Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Qty. 6 2 2 2 2 4 2 2 2 2 2 2 2 2 1 2 2 2 1 2 2 2 2 2 2 2 2 2

Part Number P26517 P24021 BA-811-363 AA-811-383 P26020 P47514 CA-811-373 S758-020.250 S403-000.250 BA-811-364 AP-811-377 S149-002.500 BP-811-385 S498-002.500 AA-999-012 P17518 P56577 P29020 S057-007.000 BA-811-362 S413-000.500 S192-001.750 P26004 S777-000.875 P25201 BP-811-367 P47521 BP-811-368

Part Name Washer Retaining Ring Side Rail – Front Pin for FBG Narrow Rim Washer Roll Pin Front Rail Assembly Shaft Spacer Front Side Assembly Spacer Flat Platform Ear Rail Stop Chain Assembly Self Tapping Screw Lanyard Assembly Hair Spring Cotter Pin Spacer Side Rail - Back Spacer Stop Block Washer Spring Spacer Spring Pin Roll Pin Handle

Material Size/Notes

! x 1-1/2 Includes items 23 - 28 Not shown

For ear on platform (not shown)

For platform ear (not shown) For Front Side Assembly For Front Rail

Page 39

POWER UNIT PARTS DUAL GRAVITY DOWN UNIT PRIMARY UNIT (FRONT, CA-501-429)

B C

A

Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Qty. 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1

Part Number P34117 P34045 P34040 P34047 P34131 P34133 P34132 P34020 P34050 P34046 P34044 P34048 P34135 P34137 P34154

Part Name Monarch Power Unit Elbow Tee Valve Alum. Block Bi-Directional Locking Valve Valve Alum. Block Bi-Directional Locking Valve Elbow Adapter Filter Adapter Tee Straight Adapter Elbow 3way/2pos valve

Material Size/Notes

For #8 Locking valve #8, Poppet For #10 Locking valve #10, Poppet

“A” valve Page 40

POWER UNIT PARTS DUAL GRAVITY DOWN UNIT SECONDARY UNIT (REAR, CA-501-430)

Index No. 1 2 3 4 5

Qty. 1 1 1 1 1

Part Number P34117 P34044 P34051 P34134 P34154

Part Name Monarch Power Unit Adapter Elbow Elbow 3way/2pos Valve

Material Size/Notes

“A” valve

Page 41

POWER UNIT ASSEMBLY DUAL GRAVITY DOWN ASSEMBLY (DA-501-433)

Page 42

POWER UNIT ASSEMBLY DUAL GRAVITY DOWN ASSEMBLY (DA-501-433) Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Qty. Part Number 1 CA-658-323 1 CA-501-429 1 CA-501-430 4 P10526 7 P26017 11 P26501 2 P10534 1 P46627 1 P46627 1 P46127 1 P46127 1 P46405 2 P18519 8 P23504 1 AT-501-424-035 1 AT-501-354-027 1 P46139 1 P46445 2 P34106 1 P46608H 8 P46403 2 P46236 7 P19501 1 P46474 4 P19519 4 P23535 1 P25181 3 P10501 1 P23538 4 P23501 2 P34004 1 P25136 1 CA-551-474 1 P55337 1 P55338 1 P48007 1 BA-551-475

Part Name Enclosure Assy.

Primary Power Unit Secondary Power Unit Hex Bolt Split Lock Washer Flat Washer HH Cap Screw Battery Cable – Black Battery Cable – Black Battery Cable – Red Battery Cable – Red Circuit Breaker Screw Lock Nut Hose Assembly Hose Assembly Cord Grip Cord Grip Bulkhead Elbow Maintenance Minder Battery Terminal 20 AMP Circuit Breaker Screw Terminal Block Screw Lock Nut Grommet Bolt Nut Lock Nut Cap Nut Grommet Power Unit Elect. Assy Important Instruction Decal Fault Codes Decal Foam Tape Walk Around Electrics

Material Size/Notes

3/18-16 x !

3/8 3/8 5/8-18 x !

6 in 12 in 18 in 12 in 10-24 x 1 10-24

9/16-18 JIC (M) 3/8-16

3/8-16 x 1 G-2 3/8-16 3/8-16 9/16-18 27 Deg.

122In.

Page 43

POWER UNIT ASSEMBLY DUAL GRAVITY DOWN ASSEMBLY (DA-501-433) Index No. 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Qty. Part Number 1 P55401 1 AT-501-354-015 1 AT-501-354-036 1 P46487 1 P46449 2 P27027 1 P34051 1 P55407 1 AP-658-339 6 P26001 2 P10567 4 P23502 2 P10517 1 P55185

Part Name Elec/Hyd Diagram Decal Hose Assy.

Hose Assy.

Relay Terminal Block Lock Washer Elbow General Tips Decal Valve Support Bracket ! Flat Washer !-20 x 2 HHCS ! Lock Nut !-20 x 5/8 HHCS Fold/Unfold Decal

Material Size/Notes

5/16 9/16 JIC (M) – 9/16 (F)

Page 44

(THIS PAGE INTENTIONALLY LEFT BLANK)

POWER UNIT PARTS DUAL POWER DOWN UNIT PRIMARY UNIT (FRONT, CA-501-435)

D

B C

A

Page 45

POWER UNIT PARTS DUAL POWER DOWN UNIT PRIMARY UNIT (FRONT, CA-501-435)

Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Qty. 1 2 2 2 1 1 1 2 2 1 1 2 1 1 1 1 1

Part Number P34118A P34045 P34040 P34047 P34131 P34133 P34132 P34020 P34042 P34046 P34044 P34048 P34135 P34137 P34091 P46693 P34155

Part Name Monarch Power Unit Elbow Tee Valve Alum. Block Bi-Directional Locking Valve Valve Alum. Block Bi-Directional Locking Valve Elbow Adapter Filter Adapter Tee Straight Adapter Elbow Locking Valve Pressure Switch 4way/2pos valve

Material Size/Notes

For #8 Locking valve #8, Poppet For #10 Locking valve #10, Poppet

#8, Poppet “A” valve

Page 46

POWER UNIT PARTS DUAL POWER DOWN UNIT SECONDARY UNIT (REAR, CA-501-436)

Index No. 1 2 3 4 5 6 7

Qty. 1 2 2 1 1 1 1

Part Number P34118A P34044 P34051 P34134 P34048 P46693 P34155

Part Name Monarch Power Unit Adapter Elbow Elbow Tee Pressure Switch 4way/2pos valve

Material Size/Notes

“A” valve Page 47

(THIS PAGE INTENTIONALLY LEFT BLANK)

POWER UNIT ASSEMBLY DUAL POWER DOWN ASSEMBLY (DA-501-434)

Page 48

POWER UNIT ASSEMBLY DUAL POWER DOWN ASSEMBLY (DA-501-434) Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Qty. Part Number 1 CA-658-323 1 CA-501-435 1 CA-501-436 4 P10526 7 P26017 11 P26501 2 P10534 1 P46627 1 P46627 1 P46127 1 P46127 1 P46405 2 P18519 9 P23504 1 AT-501-424-035 1 AT-501-354-027 1 AT-501-354-036 1 P46139 1 P46445 3 P34106 1 P46608H 8 P46403 2 P46236 7 P19501 1 P46474 4 P19519 4 P23535 1 P46487 3 P10501 1 P23538 4 P23501 2 P34004 1 P25136 1 CA-551-474 1 P55337 2 P27027 1 P48007

Part Name Enclosure Assy.

Primary Power Unit Secondary Power Unit Hex Bolt Split Lock Washer Flat Washer HH Cap Screw Battery Cable – Black Battery Cable – Black Battery Cable – Red Battery Cable – Red Circuit Breaker Screw Lock Nut Hose Assembly Hose Assembly Hose Assembly Cord Grip Cord Grip Bulkhead Elbow Maintenance Minder Battery Terminal 20 AMP Circuit Breaker Screw Terminal Block Screw Lock Nut Relay Bolt Nut Lock Nut Cap Nut Grommet Power Unit Elect. Assy Important Instruction Decal Lock Washer Foam Tape

Material Size/Notes

3/18-16 x !

3/8 3/8 5/8-18 x !

6 in 12 in 18 in 12 in 10-24 x 1 10-24

9/16-18 JIC (M) 3/8-16

3/8-16 x 1 G-2 3/8-16 3/8-16 9/16-18 27 Deg.

5/16 122 in.

Page 49

POWER UNIT ASSEMBLY DUAL POWER DOWN ASSEMBLY (DA-501-434) Index No. 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

Qty. Part Number 1 BA-551-477 1 P55402 1 AT-501-354-015 1 AT-501-354-020 2 AT-501-354-013 1 P46449 2 P27027 2 P34051 1 P55412 1 AP-658-339 6 P26001 2 P10567 4 P23502 2 P10517 1 P55185

Part Name Walk Around Electrics Elec/Hyd Diagram Decal Hose Assembly Hose Assembly Hose Assembly Terminal Block Lock Washer Elbow General Tips – PWR Down Valve Support Bracket ! Flat Washer ! - 20 x 2 HHCS ! Lock Nut ! - 20 x 5/8 HHCS Fold/Unfold Decal

Material Size/Notes

5/16 9/16 JIC (M) – (F)

Page 50

INSTALLATION OF THE WARNING SIGNS/DECALS STREET SIDE DECALS Warning Signs and Decals will be replaced at any time FREE OF CHARGE

Will receive two of these decals. One goes on each side at bottom of outer mast

Page 51

INSTALLATION OF THE WARNING SINGS/ DECALS CURB SIDE DECALS Warning Signs and Decals will be replaced at any time FREE OF CHARGE

Mount each decal next to the Corresponding toggle switch.

Will receive two of these decals. One goes on outer Mast as marked, the other goes on inner mast next to the switch

Page 52

INSTALLING SAFETY DECALS REAR OF VEHICLE DECALS Warning Signs and Decals will be replaced at any time FREE OF CHARGE

Will receive two of these decals One goes on each side of the outer mast

CAUTION KEEP FEET FROM EDGE OF PLATFORM

Page 53

MODEL AND SERIAL NUMBER TAGS Serial No. is also located in MENU 1 of Maintenance Minder 2 Serial number tag is located inside power unit box.

10900 KENWOOD ROAD CINCINNATI, OHIO 45242 513-891-6210 WWW.LEYMANLIFT.COM

MODEL

FBG35NP-8042CRL 269999

SERIAL NO.

3500 lbs.

CAPACITY MANUFACTURE DATE

MAY-06

Model number tag is located on the left-hand outer mast.

10900 KENWOOD ROAD CINCINNATI, OHIO 45242 513-891-6210 WWW.LEYMANLIFT.COM

MODEL

FBG35NP-8042CRL

CAPACITY

3500 lbs.

MANUFACTURE DATE

MAY-06

PATENTS PENDING

Page 54