Leyman FDCxxNP Series Liftgate

Owner’s Manual

FDCxxNP & FDCxxNPPD 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

LML00398-9-10-09

GENERAL TERMINOLOGY

INNER MAST PREP TUBE DIVIDER VALVE

OUTER MAST

POWER CLOSE CYL. RAMP, FIXED TAPER, CART STOP

AUTO LOCKING

TIE BAR

INNER PLATFORM TENSION ARM OUTER PLATFORM

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

ELECTRIAL DIAGRAM – SELECTOR SWITCH DUAL POWER UNIT with PLASTIC OIL TANKS SELECTOR SWITCH PARTS – GRAVITY or POWER DOWN CONNECTIONS CABLE FROM SECONDARY POWER UNIT CONNECTS TO LEFT SIDE

CABLE FROM GATE SWITCHES CONNECTS TO CENTER ROW CABLE FROM PRIMARY POWER UNIT CONNECTS TO RIGHT SIDE

CONNECTIONS VIEWED FROM REAR GRAVITY DOWN - NOT USED POWER DOWN - BLACK (FROM "D" VALVE) BLUE GREEN (FROM MM2) ORANGE

GREEN WHITE RED BLUE (FROM MM2)

POWER UNIT SELECTOR SWITCHES

Index No. 1 2 3 4 5 6 7 8 9 10 11

Req. 2 1 1 24 2 2 1 2 2 2 1

Part Number P46599 AP-551-442 P55332 P46476 P10517 P23502 P46475 P46250 P17518 P46291 P46186

GATE SWITCHES

CAUTION! BOTH SWITCHES MUST BE POSITIONED IN SAME DIRECTION FOR PROPER OPERATION. SWITCHES MUST BE TOWARD RIGHT FOR PROPER WALK AROUND CONTROL OPERATION. P55332

SECONDARY POWER UNIT

SEC.(RH)PWR. UNIT or WALK AROUND CONTROL OPERATES

PRIMARY POWER UNIT

PRIMARY (LH) POWER UNIT OPERATES

Part Name SWITCH

Comments

SELECTOR SWITCH MTG PLATE

SELECTOR SWITCH DECAL FORK TERMINAL BOLT LOCK NUT CABLE 16-6 LOOM CLAMP SELF TAPPING SCREW RUBBER BOOT CABLE 16-3

!-20 X 5/8 16-6 X 12”

16-3 X 48”

Page 17

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

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

SAE “O” Ring Ports Not Shown Not Shown

Drawing No.

Gate Width

Qty Req’d

RH Lifting Item 2

LH Lifting Item 3

RH “Down” Line Item 4

LH “Down” Line Item 5

CA-811-447 CA-811-436

102” 96”

1 ea.

1 ea.

BT-501-442-125 BT-501-442-119

BT-501-442-081 BT-501-442-081

BT-501-442-089 BT-501-442-089

BT-501-442-128 BT-501-442-121

Page 33

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-501-284-077 AP-811-200 P24019 S754-005.500 P47532 P26019 P46462 P46750 P34173 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 34

REPLACEMENT ROLLER 4” REPLACEMENT 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 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

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 37

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 38

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

Page 39

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 40

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 41

(THIS PAGE INTENTIONALLY LEFT BLANK)

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

D

B C

A

Page 42

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 43

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 44

(THIS PAGE INTENTIONALLY LEFT BLANK)

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

Page 45

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 46

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 47

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

P55295 Will receive two of these decals. One goes on each side at bottom of outer mast

P55309 Page 48

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

P55185

P55295

P55221

Mount each decal next to the Corres ponding toggle switch.

P55214

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

P55157

P55363 Page 49

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

P55296 Will receive two of these decals One goes on each side of the outer mast

CAUTION KEEP FEET FROM EDGE OF PLATFORM P55138

Page 50

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

FDC65RM-8084RRL 269999

SERIAL NO.

6500 lbs.

CAPACITY MANUFACTURE DATE

12-15-06 P55358

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

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

MODEL

FDC65RM-8084RRL

CAPACITY

6500 lbs.

MANUFACTURE DATE

12-15-06

PATENTS PENDING

AA-999-172

Page 51