E/H HYBRID 24 VOLT SYSTEM - Amazon Web Services › public... · Top of Box Front Back Wall of Box...

E/H HYBRID 24 VOLT SYSTEM

2-2015

1. Attach adapters to E/H valve and install inside cavity on headache rack.

2. Attach valve harness per diagram on decal.

3. Attach return hose to valve and filter housing. Attach pressure hose from pump.

4. Attach 1/2” hoses from squeeze cylinder to valve parts #3 & #4.

5. Attach 3/8” hoses from lift cylinder to valve parts #1 & #2.

6. Use cover plate to locate cutout in right side toolbox.

7. Use access cover or edge molding to protect hoses.

8. Drill holes for 3/8” bolts as indicated and bolt pump to inside of toolbox.

.

9. Attach power harness as indicated.

10. Attach 30-amp fuse holder to positive terminal on batter, run wire through switchon dash and then to the red wire on the harness.

11. Attach suction hose and pressure hose to pump with adapters provided. 12. Attach suction hose to bottom of reservoi

13. Run batter cables through hole in toolbox and attach to E/H motor as indicated.

14. Run battery cables along frame rail and attach black cable to negative terminal on battery.

15. Attach 200-amp fuse holder to positive battery terminal.

16. Insert 200-amp fuse.

17. Attach red cable from E/H ontop of “ice cube” fuse. Install rubber cap.

Parts List

DESCRIPTIONPART #QTYITEM

EDGE TRIM10036521 in1

BOLT, 3/8-16 X 1, WIZ FLANGE11044042

WASHER, 3/8" LOCK11067243

WASHER, 3/8" FLAT STANDARD11067644

NUT, 3/8-16 GR 511082645

ADAPTER, 12BH-10MB9012018416

ADAPTER, 8MJ-8MB9012028817

ADAPTER, 20MB-12FOR12054418

ADAPTER, 12BH-12MB 45°12054519

ACCESS COVER FRAME211849110

HOSE, SUCTION, .75 X 54220603111

Hose, Pressure HD E/H220738112

E/h Motor Pump/unit, Heavy Duty 12V230159113

Strap, Motor-Solenoid Connecting2321021

Solenoid, 4 Post, 12VDC Contactor2321031

Shield, HD, E/H260400114

Access Cover, HD E/H260401115

CLAMP, HOSE #12 .75"520099216

SCREW, 1/4 X 1 TEK SELF-TAP710586417

Back of Box

Front of Box

Hybrid 24V E/H

8

9

16

12

11 1

15 1017

16

6

7

2 4 3 5

14

13

5/8/20153.625

3.75

6.375

6.0

n.391

12V/24V Switch Unit Kit Part# 735022DESCRIPTIONPART #QTYITEM

NUT, M8 X 1.25 WIZFLANGE11014111

Bolt, 5/16-18 X .75 Wiz Flng Gr 5 Zinc11044442

Nut, 5/16-18, Wiz Flng11060643

Terminal, Ring, 22-16ga13204014

FUSE COVER, BUSS CFCOVER-1R13209215

FUSE HOLDER, BUSS CFBAR1-M8XSP13209316

FUSE 200 AMP, BUSS MRBF-20013209427

BATTERY CABLE, 2GA TWIN LEAD, 48"23016128

12V/24V Series/Parallel Switch Unit 73502119

Top of Box

Frontof BoxBack Wall

of Box

Battery Tray & Hold Down Kit Part# 235023DESCRIPTIONPART #QTYITEM

BOLT, 5/16-18 X 0.75, WIZ FLANGE11044421

NUT, 5/16-18 WIZ FLANGE11060622

Battery Tray13212513

Battery Hold Down13212614

Battery Hold Down Bolt, Pkg90209715

Hybrid 24V E/HSwitch Unit Kit

7.52.75

10.3

2.5

n.344

Hybrid 24V E/HBattery Tray

Existing Step Hole

5.0 4.45

n.344

5/8/2015

STACK WITH WIRE FROM MOTOR CONTROL UNIT WILL TURN ON WHENEVER MOTOR IS ON

5/8/2015

BASIC WIRING HOOKUP DIAGRAM FOR 735021 SWITCH UNIT

Black Ground WireFrom Valve Harness

Purple Switch WireFrom Valve Harness (B)

Recomended Second BatteryAGM or Other Non-Vented

Hybrid 24V E/H Kit W/Remote Part# 205098DESCRIPTIONPART #QTYITEM

NUT, 10-24 LOCK11011931


BOLT, 10-24 X .5 STAINLESS, PHILLIPS11026433

BOLT, 5/16-18 X 3.011053824

NUT, 5/16-18 WIZ FLANGE11060625

PLUG, 1/2" BUTTON PLASTIC11075326




FUSE HOLDER, ATC, 14 GA., MINI132001110

FUSE, MINI 30 AMP132002111

SWITCH BOOT132035212

Switch, Spst, Rocker Led132044113




DECAL, SWITCH IDENTIFICATION202003117

Decal, Double Poppet Valve202052118

Decal, Wiring Diagram, HD E/H, Wireless202061119

Flatbed Valve, HD E/H, 12V, Dbl Poppet Deutsch223059120


SWITCH, DPDT, M, 6 PIN, PUSH ON232086222

Harness, HD E/H, Wireless232100123

Harness, HD E/H, Power232104124

Transmitter & Receiver, Kar-Tech233003125

15

216

14

19

21

12 17

22

25

20

5

9

74

8

7

1

36

Hybrid 24V E/H KitW/ Remote

5/8/2015

18

10

11

13

Hybrid 24V E/H Kit W/Hand Control Part# 205099DESCRIPTIONPART #QTYITEM


BOLT, 5/16-18 X 3.011053822

NUT, 5/16-18 WIZ FLANGE11060623




FUSE HOLDER, ATC, 14 GA., MINI13200117

FUSE, MINI 30 AMP13200218

Switch, Spst, Rocker Led13204419




Hand Control & Cable Assy, 2 Bank150044113

Decal, Double Poppet Valve202052114

Decal, Wiring Diagram, HD E/H, Hand Control202062115

Flatbed Valve, HD E/H, 12V, Dbl Poppet Deutsch223059116


Harness, HD E/H, Hand Control232101118

Harness, HD E/H, Power232104119

11

1

12

10

15

17

3

6

4 2

5

4

13

Hybrid 24V E/H KitW/ Hand Control

5/8/2015

14

9

7

8

230159 E/H MOTOR & PUMP, HD 12V

DESCRIPTIONPART #QTYITEM

Strap, Motor-Solenoid Connecting23210211

Solenoid, 4 Post, 12VDC Contactor23210312

223059 Flatbed Valve, HD E/H, 12V, Dbl Poppet DeutschDESCRIPTIONPART #QTYITEM

O-Ring Plug, #4 7/16-2012006211

Valve, #8 Dbl Poppet, N.C.22205142

Valve, #8 Spool, 4-Way 2-Position22205213

Coil, #8 Hydraforce, 12V, Deutsch DT04-2P22205354

Valve, #8 Relief, 3000 psi22205415 -10 Suction Port

-8 Pressure Port

Motor Gnd CableFrom Switch Box

Motor Pos CableFrom Switch Box

Purple Switch WireFrom Valve Harness

(B)

4 243

5

1 SQUEEZE CYLINDER -BASE-

SQUEEZE CYLINDER -ROD-

LIFT CYLINDER -BASE-

LIFT CYLINDER-ROD-

CHECK VALVE222039

TO THIS PORT

2

1

Hybrid 24V E/HValve

Motor & Pump

5/8/2015

Red WireFrom Switch Box

GREEN

TRANSMIT

RED

BATTERY/DIAGNOSTIC

POWER

LOADUNLOAD

SQUEEZE

UNSQUEEZE

WORK LIGHTS

Decal Part# 202061

Harness Part# 232100

Decal Part# 202062

Harness Part# 232101

Hybrid 24V E/H

W/ Hand Control

Hybrid 24V E/H

W/ Remote

FLOAT

6 BLK

1 RED

2 GRN

3 BRN

5 YEL

4 BLU

1 RED

2 GRN

4 BLU

5 YEL

6 PUR

5/8/2015

3 GRN/

YEL

E/H HYBRID 24 VOLT SYSTEM - Amazon Web Services › public... · Top of Box Front Back Wall of Box...

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