TKL-25 (2002 Release, After September 9, 2002)

TKL-25 (2002 Release, After September 9, 2002)
TKL-25
MAINTENANCE
MANUAL
M-02-19
REV. B
FEBRUARY 2004
11921 Slauson Ave.
Santa Fe Springs, CA. 90670
LIFT CORP.
CUSTOMER SERVICE:
TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116
FAX: (888) 771-7713
NOTE: For latest version Manuals (and replacements), download
Manuals from Maxon’s website at www.maxonlift.com.
WARRANTY/ RMA POLICY & PROCEDURE
LIFTGATE WARRANTY
Term of Warranty: 2 Years from Date of In-Service (In service date cannot exceed 3 months from ship date.)
Type of Warranty: Full Parts and Labor
This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s specifications as set forth
in MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments,
damage or malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this
warranty does not cover equipment that has had unauthorized modifications or alterations made to the product.
MAXON agrees to replace any components which are found to be defective during the first 2 years of service, and will reimburse for labor based
on MAXON’s Liftgate Warranty Flat Rate Schedule. (Copy of the Flat Rate is available at www.maxonlift.com.)
All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and
labor, MAXON’s Technical Service Department must be notified and an “Authorization Number” obtained.
All claims for warranty must be received within 30 Days of the repair date, and include the following information:
1. Liftgate Model Number and Serial Number
2. The End User must be referenced on the claim
3. Detailed Description of Problem
4. Corrective Action Taken, and Date of Repair
5. Parts used for Repair, Including MAXON Part Number(s)
6. MAXON R.M.A. # and/or Authorization # if applicable (see below)
7. Person contacted at MAXON if applicable
8. Claim must show detailed information I.e. Labor rate and hours of work performed
Warranty claims can also be placed on-line at www.maxonlift.com. On-line claims will be given priority processing.
All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s
Warranty Department within 30 days of repair date.
All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior
written approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with
original invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized
returns will be refused and will become the responsibility of the returnee.
Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in
plain view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned
parts are subject to no credit and returned back to the customer.
Defective Parts requested for return must be returned within 30 days of the claim date for consideration to:
MAXON Lift Corp.
16205 Distribution Way, Cerritos, CA 90703
Attn: RMA#__
MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income
due to downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.
MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.
All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not
returned in new condition will be subject to an additional reworking charge which will be based upon the labor and material cost required to return
the Liftgate or component to new condition.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase.
Type of Warranty: Part replacement only
MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts and original invoice.
All warranty replacements parts will be sent out via ground freight. If a Rush Shipment is requested all
freight charges will be billed to the requesting party.
TABLE OF CONTENTS
WARNINGS ......................................................................................................................... 5
LIFTGATE TERMINOLOGY ................................................................................................... 6
PERIODIC MAINTENANCE ................................................................................................ 7
PERIODIC MAINTENANCE CHECKLIST ............................................................................. 7
CHECKING HYDRAULIC FLUID ........................................................................................... 8
CHANGING HYDRAULIC FLUID ......................................................................................... 10
PLATFORM ADJUSTMENT ................................................................................................ 12
REPLACING PLATFORM TORSION SPRING .................................................................... 14
SAFETY HOOK MAINTENANCE ........................................................................................ 16
PARTS BREAKDOWN ...................................................................................................... 17
TKL-25 MAIN ASSEMBLY .................................................................................................. 18
EXTENSION PLATE ASSEMBLY ....................................................................................... 19
LIFT FRAME & PARALLEL ARMS ...................................................................................... 20
PLATFORM & FLIPOVER ASSEMBLY ............................................................................... 21
PUMP COVER & MOUNTING PLATE ASSEMBLY ............................................................. 22
GRAVITY DOWN HYDRAULIC COMPONENTS.................................................................. 23
12 VDC POWER UNIT (GRAVITY DOWN) .......................................................................... 24
POWER DOWN HYDRAULIC COMPONENTS ................................................................... 25
12 VDC POWER UNIT (POWER DOWN) ........................................................................... 26
DECALS ............................................................................................................................ 27
CONTROL SWITCH AND POWER CABLE ........................................................................ 28
HYDRAULIC SYSTEM DIAGRAMS .................................................................................. 29
HYDRAULIC SCHEMATIC (TKL-25 GRAVITY DOWN) ....................................................... 29
HYDRAULIC SCHEMATIC (TKL-25 POWER DOWN) ......................................................... 30
ELECTRICAL SYSTEM DIAGRAMS ................................................................................ 31
ELECTRICAL SCHEMATIC (TKL-25 GRAVITY DOWN) ...................................................... 31
ELECTRICAL SCHEMATIC (TKL-25 POWER DOWN) ....................................................... 32
TROUBLESHOOTING ...................................................................................................... 33
PLATFORM WILL NOT RAISE ............................................................................................ 33
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 34
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 35
LIFTGATE WILL NOT LIFT RATED CAPACITY ................................................................... 36
PLATFORM RAISES SLOWLY ........................................................................................... 37
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS TOO QUICKLY .. 38
Comply with the following WARNINGS while maintaining Liftgates. See Operation Manual
M-98-09 for operating safety requirements.
WARNINGS
• Read and understand the instructions in this Maintenance Manual before performing maintenance on the Liftgate.
• Before operating the Liftgate, read and understand the operating instructions in Operation Manual
M-98-09.
• Comply with all WARNING and instruction decals attached to the Liftgate.
• Keep decals clean and legible. If decals are defaced or missing, replace them. Free replacement
decals are available from Maxon Parts Department.
• Consider the safety and location of bystanders and location of nearby objects when operating the
Liftgate. Stand to one side of the platform while operating the Liftgate
• Do not allow untrained persons to operate the Liftgate.
• Do not stand under, or allow obstructions under the platform when lowering the Liftgate. Be sure
your feet are clear of the Liftgate.
• Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.
• Wear apppropriate safety equipment such as protective eyeglasses, faceshield and clothing while
performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.
• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no flames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek first aid. If acid gets on your
skin, immediately wash it off with soap and water.
• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the control
Toggle Switch and the Liftgate will stop.
• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the pump unit while the platform is raised. Listen for scraping, grating
and binding noises and correct the problem before continuing to operate Liftgate.
• If it is necessary to stand on the platform while maintaining the Liftgate, keep your feet and any
objects clear of the inboard edge of the platform. Your feet or objects on the platform could be
trapped between the platform and the Liftgate extension plate.
• Never perform unauthorized modifications on the Liftgate. Modifications may result in early failure of
the Liftgate and may create hazards for Liftgate operators and maintainers.
• Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial
number information with your parts order. Order replacement parts from:
MAXON LIFT CORP. Customer Service
11921 Slauson Ave., Santa Fe Springs, CA 90670
Phone: (800) 227-4116
• To order parts by e-mail, submit orders to [email protected]
5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
!
LIFTGATE TERMINOLOGY
TKL-25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL
SWITCH
EXTENSION
PLATE
LIFT FRAME
LIFT
CYLINDER
CONTROL
HANDLE
PLATFORM
OPENER
PARALLEL
ARM
PLATFORM
PUMP BOX
MAIN
FRAME
WEDGE FLIPOVER
6
PERIODIC MAINTENANCE
!
WARNING
Never operate the Liftgate with
parts loose or missing.
Annually
Visually check the entire Liftgate for excessively worn parts and broken welds, especially the
Hinge Pins. See PARTS BREAKDOWN section for replacement parts. Also, do the Semiannual and Quarterly Maintenance checks.
Semi-annually
Visually check the Platform Hinge Pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly Maintenance checks.
Quarterly
Check the Hydraulic Fluid level in the Pump Reservoir. Refer to the CHECKING HYDRAULIC
FLUID procedure in the PERIODIC MAINTENANCE section.
If Hydraulic Fluid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure in the PERIODIC MAINTENANCE section.
Keep track of the grade of Hydraulic Fluid in the Pump Reservoir and never mix two different
grades of fluid.
Check all Hoses and Fittings for chaffing and fluid leaks. Replace if necessary.
Check electrical wiring for chaffing and make sure wiring connections are tight and free of
corrosion.
Check that all WARNING and instruction decals are in place and legible.
Check that all roll pins are in place and protrude evenly from both sides of Hinge Pin collar.
Replace roll pins if necessary.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it off. Touch
up the paint where bare metal is showing.
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PERIODIC MAINTENANCE CHECKLIST
PERIODIC MAINTENANCE
CHECKING HYDRAULIC FLUID
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic
lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
NOTE: Use correct grade of hydraulic fluid for your location.
+70 to +140 Degrees F
- Grade ISO 32
+40 to +105 Degrees F
- Grade ISO 15
Below + 70 Degrees F
- Grade ISO 10 or MIL-H-5606
See TABLES 9-2, 9-3 & 9-4 on the next page for recommended brands.
1. Unbolt & remove Pump Cover (FIG. 8-1).
POWER UNIT
(REF)
NOTE: If the Hydraulic Fluid in the
Reservoir is contaminated, do
the CHANGING HYDRAULIC
FLUID procedure in this section.
CAP
SCREWS
NOTE: If you have a Power Down
Power Unit, skip steps 2 & 3.
2. For Gravity Down Power Unit, check
the Hydraulic Fluid level “H” in Reservoir
(FIG. 8-2 and TABLE 8-1). If needed,
add fluid to the Reservoir as follows.
CAP
SCREWS
PUMP COVER
FLAT
WASHERS
UNBOLTING / BOLTING PUMP COVER
FIG. 8-1
PLATFORM POSITION
FLUID LEVEL
"H"
STOWED
1-7/8" to 2-3/8"
VEHICLE BED HEIGHT
1-7/8" to 2-3/8"
ON THE GROUND
FILLER
CAP
3-1/2" to 4"
GRAVITY DOWN FLUID LEVEL
TABLE 8-1
3. Pull out (no threads) Filler Cap (FIG. 8-2).
Fill the Reservoir with Hydraulic Fluid to level RESERVOIR
“H” shown in FIG. 8-2 and TABLE 8-1.
Reinstall Filler Cap (FIG. 8-2)
“H”
GRAVITY DOWN POWER UNIT
FIG. 8-2
8
PLATFORM POSITION
FILLER
CAP
FLUID LEVEL
"H"
STOWED
2-5/8" to 3-1/8"
VEHICLE BED HEIGHT
2-5/8" to 3-1/8"
ON THE GROUND
2-3/8" to 2-7/8"
“H”
RESERVOIR
POWER DOWN FLUID LEVEL
TABLE 9-1
POWER DOWN POWER UNIT
FIG. 9-1
5. Pull out (no threads) Filler Cap (FIG. 9-1). Fill
the Reservoir with Hydraulic Fluid to level “H”
shown in FIG. 9-1 and TABLE 9-1. Reinstall
Filler Cap (FIG. 9-1).
6. Bolt on the Pump Cover (FIG. 8-1).Torque the
bolts (Cap Screws) to 10 - 14 lbs.- in.
ISO 15 HYDRAULIC OIL
ISO 32 HYDRAULIC OIL
RECOMMENDED BRANDS
PART NUMBER
RECOMMENDED BRANDS
PART NUMBER
AMSOIL
AWH-05
AMSOIL
AWF-05
CHEVRON
HIPERSYN 32
CHEVRON
FLUID A, AW-MV-15
KENDALL
GOLDEN MV
KENDALL
GLACIAL BLU
SHELL
TELLUS T-32
SHELL
TELLUS T-15
EXXON
UNIVIS N-32
EXXON
UNIVIS HVI-13
MOBIL
DTE-13M, DTE-24,
HYDRAULIC OIL-13
MOBIL
DTE-11M
TABLE 9-2
TABLE 9-3
ISO-10 OR MIL-H-5606 HYDRAULIC FLUID
RECOMMENDED BRANDS
PART NUMBER
AMSOIL
N/A
CHEVRON
FLUID A, FLUID G
KENDALL
GLACIAL BLU
SHELL
AEROSHELL FLUID-41
EXXON
UNIVIS HVI-13
MOBIL
AERO HFA
TABLE 9-4
9
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4. For Power Down Power Unit, check the Hydraulic
Fluid level “H” in Reservoir (FIG. 9-1 and TABLE
9-1). If needed, add fluid to the Reservoir as
follows.
PERIODIC MAINTENANCE
CHANGING HYDRAULIC FLUID
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic
lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
NOTE: Use correct grade of hydraulic fluid for your location.
+70 to +140 Degrees F
- Grade ISO 32
+40 to +105 Degrees F
- Grade ISO 15
Below + 70 Degrees F
- Grade ISO 10 or MIL-H-5606
See TABLES 9-2, 9-3 & 9-4 on previous page for recommended brands.
GRAVITY DOWN LIFTGATES
1. Remove the Pump Cover (FIG. 11-1). Place empty
5 Gallon Bucket under Drain Plug (FIG. 10-1).
FILLER
CAP
2. Lower Platform to ground. Pull out (no threads)
Drain Plug (FIG. 10-1). Drain hydraulic fluid
from system. Reinstall Drain Plug.
3. Pull out (no threads) Filler Cap (FIG. 10-1) and
refill reservoir with Hydraulic Fluid to level shown in
FIG. 10-1. Reinstall Filler Cap (FIG. 10-1).
3-1/2” - 4”
4. Bolt on the Pump Cover as shown in FIG. 11-1
Torque the bolts (Cap Screws) to 10 - 14 lbs.- in.
POWER DOWN LIFTGATES
1. Remove the Pump Cover (FIG. 11-1). Place empty
5 Gallon Bucket under Drain Plug (FIG. 10-1).
RESERVOIR
DRAIN
PLUG
LIFTGATE SHOWN WITH GRAVITY
DOWN PUMP & MOTOR
FIG. 10-1
2. Open and raise Platform to vehicle bed height. Pull out
(no threads) Drain Plug (FIG. 10-1). Drain hydraulic
fluid.
3. Disconnect the Motor Power Cable (FIG. 10-2)
BOTTOM
from bottom Starter Solenoid. Lower the Platform STARTER
while draining the remaining hydraulic fluid from SOLENOID
system. Reinstall Drain Plug. Reconnect the
Motor Power Cable to bottom Starter Solenoid.
4. Pull out (no threads) Filler Cap (FIG. 10-1) and
refill reservoir with Hydraulic Fluid to level shown in
FIG. 10-1. Reinstall Filler Cap (FIG. 10-1).
10
MOTOR POWER
CABLE
POWER DOWN PUMP
FIG. 10-2
POWER UNIT
(REF)
CAP
SCREWS
CAP
SCREWS
PUMP COVER
FLAT
WASHERS
UNBOLTING / BOLTING PUMP COVER
FIG. 11-1
11
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5. Bolt on the Pump Cover as shown in
FIG. 11-1. Torque the bolts (Cap
Screws) to 10 - 14 lbs.- in.
PERIODIC MAINTENANCE
PLATFORM ADJUSTMENT
NOTE: Before doing the following procedure,
make sure vehicle is parked on level ground.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Make sure Platform is at ground level. Unfold the
Platform and Flipover. As the Platform first touches
the ground, Shackles and tip of Flipover must touch
the ground at the same time (FIG. 12-1). If the
Shackles and the tip of Flipover touch the ground at
the same time, RAISE Platform to bed height. Tip of
Flipover should be above bed level (FIG. 12-2). If
indications are correct in both cases (FIGS. 12-1 &
12-2), Liftgate is installed correctly and no adjustment is needed. If indications are incorrect, continue
with instruction 2.
TIP OF
FLIPOVER
PLATFORM & SHACKLES
TOUCH GROUND
FIG. 12-1
TIP OF
FLIPOVER
LEVEL LINE
PLATFORM EDGE ABOVE
BED LEVEL
FIG. 12-2
NOTE: If tip of Flipover touches first (FIG. 123), do instruction 2. If the Shackle touches first
(FIG. 11-1), skip instruction 2 and do 3.
2. Make sure Platform is still at ground level. If the
Shackle is not touching the ground, measure
and compare distance “A” (FIG. 12-3) with
TABLE 12-1 to determine the correct shim.
Make shims as needed (FIG. 12-5). Weld
shim as shown in FIG. 12-4.
RAISE TIP OF
FLIPOVER
THIS DISTANCE " A"
REQUIRED SHIM
THICKNESS
7/8"
1/16"
1/16"
2"
1/8"
1/8"
3"
3/16"
3/16"
3-15/16"
1/4"
1/4"
WELD SIZE
“A”
(TABLE 12-1)
SHACKLES DO NOT
TOUCH GROUND
FIG. 12-3
"W"
CENTERED
(TOP EDGES FLUSH)
SHIM
(TABLE 12-1)
TABLE 12-1
PLATFORM
1-1/2”
2-1/4”
SHACKLE
(REF)
2 PLACES
“W”
(TABLE 12-1)
SHIM (1/16”, 1/8”, 3/16”, or 1/4”)
MADE FROM STEEL FLAT
FIG. 12-5
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 12-4
12
LOWER TIP OF
FLIPOVER
THIS DISTANCE " B "
GRIND METAL FROM
PLATFORM STOP
7/8"
1/16"
2"
1/8"
3"
3/16"
3-15/16"
1/4"
PLATFORM DOES NOT
TOUCH GROUND
FIG. 13-1
TABLE 13-1
PLATFORM
STOP
4. RAISE the Platform, then LOWER it to the
ground. As the Platform first touches the
ground, the tip of Flipover and Shackle
should touch at the same time as shown in
FIG. 12-1.
PLATFORM
GRIND HERE
(TABLE 13-1)
SHACKLE
(REF)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 13-2
13
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3. Make sure Platform is still at ground level.
If the tip of Flipover is not touching the
“B”
ground, measure and compare distance
(TABLE 13-1)
“B” (FIG. 13-1) with TABLE 13-1 to
determine how much to grind from the
TIP OF
FLIPOVER
Platform Stops (FIG. 13-2). Grind correct
amount of metal (TABLE 13-1) from
Platform Stop as shown in FIG. 13-2.
PERIODIC MAINTENANCE
REPLACING PLATFORM TORSION SPRING
NOTE: The following procedure shows how to replace Torsion Spring on RH side of
Platform. Use this procedure for replacing Torsion Spring on the LH Side.
1. Fold Flipover onto Platform.
2. Fold Platform.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ROLL PIN
(REMOVED)
3. Raise Liftgate to a convenient work height
to gain access and release tension on the
Torsion Spring.
TORSION
SPRING
! CAUTION
To prevent injury and equipment damage,
make sure there is no tension on torsion
spring before removing hinge pin.
4. Drive out the roll pin from pin collar on the
Platform Hinge Bracket. Drive the platform
Hinge Pin outboard from the Shackle just
enough to free the torsion spring (FIG. 14-1).
Remove torsion spring.
PIN
COLLAR
SHACKLE
PLATFORM
HINGE PIN
REMOVING HINGE PIN
(RH SIDE OF PLATFORM SHOWN)
FIG. 14-1
BLOCK
SHORT LEG
5. Install the Torsion Spring as shown
in (FIG. 14-2). Make sure the long
leg of the spring is inserted in the
bracket located on the Shackle.
Make sure the short end of the
spring is visible and resting against
the block on the Platform Hinge
Bracket (FIG. 14-2).
BRACKET
SHACKLE
LONG
LEG
PLATFORM
HINGE
BRACKET
INSTALLING HINGE PIN
(RH SIDE OF PLATFORM SHOWN)
FIG. 14-2
14
7. Operate the Liftgate according to
instructions in Operation Manual
M-98-09 to make sure it operates
correctly.
PLATFORM
HINGE PIN
ROLL PIN
(INSTALLED)
PIN
COLLAR
PLATFORM HINGE
BRACKET
FIG. 15-1
15
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6. Drive Platform Hinge Pin inboard to
correct position through the Platform
Hinge Bracket (FIG. 15-1). Line up
the hole in the Platform Hinge Pin
with the hole in the Pin Collar. Install
the roll pin through the Pin Collar until
roll pin protrudes equally from both
sides of the collar (FIG. 15-1).
PERIODIC MAINTENANCE
SAFETY HOOK MAINTENANCE
CHECK SAFETY HOOK FUNCTION
EXTENSION
PLATE
CORRECT
POSITION
PLATFORM LOOP
(WRONG POSITION)
1. When raising Platform to stowed position,
listen for sound of Safety Hook engaging
Platform Loop.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BEND IN
THIS
DIRECTION
2. When the Liftgate is stowed, see if Platform
Loop is positioned above the Safety Hook
as shown in FIG. 16-1.
SAFETY
HOOK
LOOP ADJUSTMENT
PLATFORM
1. If the Safety Hook is not positioned correctly,
LOWER Platform to ground level (Operation
Manual M-98-09).
FIG. 16-1
2. Adjust by bending the Platform Loop as shown
in FIG. 16-1.
3. Stow the Platform and check for correct Safety
Hook position. Repeat adjustment if required.
LUBRICATION (IF REQUIRED)
1. Make sure front surface of Safety
Hook FIG. 16-2 is lubricated with
automotive grease. Apply grease if
required.
CONTROL HANDLE ROD
(TYPICAL LUBE POINT)
BRACKETS
2. Make sure Control Handle rod
(FIG. 16-2) is lubricated where it
has contact with brackets. Apply
automotive grease if required.
SAFETY HOOK FRONT SURFACE
FIG. 16-2
16
17
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PARTS BREAKDOWN
TKL-25 MAIN ASSEMBLY
REFER TO EXTENSION
PLATE ASSEMBLY
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
5
1
2
4
3
REFER TO LIFT FRAME
& PARALLEL ARMS
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
REFER TO PUMP
COVER, HYDRAULIC
COMPONENTS, &
POWER UNITS
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
266423-01
MAIN FRAME, TKL
2
1
280790-01
PLATFORM OPENER
3
1
263018
CYLINDER PIN, 1" DIA X 4-1/8" LG.
4
1
221416
ROLL PIN, 3/8" X 2" LG.
5
1
260916-06
SELF LUBE BEARING, 1" DIA X 1" LG.
18
VIEWED FROM UNDER
EXTENSION PLATE
4
3C
3A
3B
5
3D
6
2
3
7
1
ITEM
QTY.
PART NO.
DESCRIPTION
1
6
207644
RIVET
2
1
050175
MAXON PLATE
3
2
262385
EXTENSION PLATE WELDMENT
3A
1
262373
BRACKET
3B
1
263052
SAFETY HOOK WELDMENT
3C
1
262370-01
3D
2
201561
FLAT, 1/4" X 1/2" X 1/2" LG
4
1
215345
EXTENSION SPRING, 7/64" X 2-1/2" LG
5
1
203417
RENTAL LOCK BRACKET (OPTIONAL)
6
1
055011
HANDLE, RUBBER
7
1
203570
INNER BRACKET, RENTAL LOCK (OPTIONAL)
HANDLE (CURBSIDE)
19
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
EXTENSION PLATE ASSEMBLY
LIFT FRAME & PARALLEL ARMS
3
6
5A
5
3
3
1A
6
3
5
1A
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
3
5A
4
2
1A
7
3
3
9
1A
1
10
11
8
3
12
10
8
3
ITEM
QTY.
PART NO.
1
1
262383
4
260916-03
2
1
263017
CYLINDER PIN
3
9
221416
ROLL PIN, 3/8" X 2" LG.
4
2
262342-02
5
2
263058
4
260916-02
SELF LUBE BEARING, 1" DIA X 1-1/2" LG.
6
2
262342-03
PIN, 1" DIA X 3-1/2" LG.
7
1
280794-01
TORSION SPRING, LH
8
2
262342-01
PIN, 1" DIA X 4-1/2" LG.
9
1
263049-02
SHACKLE, LH
10
2
262343
11
1
263049-01
SHACKLE, RH
12
1
280795-01
TORSION SPRING, RH
1A
5A
DESCRIPTION
LIFT FRAME
SELF LUBE BEARING, 1" DIA X 1" LG.
PIN, 1" DIA X 4" LG.
PARALLEL ARM
PIN, 1" DIA X 13" LG.
20
4
8
7
3
8
5
1A
8
1
1A
9
8
10
5
8
5
8
9
2
ITEM
1
1
1A
2
QTY.
2
1
PART NO.
DESCRIPTION
280730-01
PLATFORM WELDMENT, 72"X 48" WEDGE
280730-02
PLATFORM WELDMENT, 84"X 48" WEDGE
280820-01
PLATFORM WELDMENT, 78-1/2" X 24"
260916-03
SELF LUBE BEARING, 1" DIA X 2" LG.
280735-01
FLIPOVER WELDMENT, 72"X 48" WEDGE
280735-02
FLIPOVER WELDMENT, 84"X 48" WEDGE
280819-01
FLIPOVER WELDMENT, 78-1/2" X 24"
3
1
280751-01
TORSION BAR
4
1
280749-01
ANCHOR BOLT WELDMENT
5
3
901008
6
1
050162-16
CHAIN, # 2/0 X 3"LG
7
2
900033-4
CAP SCREW, 1/2"-20 X 1-3/4" LG.
8
6
902000-14
FLAT WASHER, 1/2"
9
2
280758-01
BUSHING, FLIPOVER
10
1
040208
LOCK NUT, 1/2"-20
"S" HOOK, 5/16"
21
6
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM & FLIPOVER ASSEMBLY
(RAMP)
PUMP COVER & MOUNTING PLATE ASSEMBLY
12
7
2
4
8
10
4
11
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3
9
6
13
5
9
12 VDC POWER UNIT
(REF)
MAIN FRAME (REF)
9
6
1A
1
ITEM
QTY.
PAR T N O.
1
1
266419-01
C OVER ASSY
1
093201-01
GASKET, RUBBER C HANNEL, 57-1/2" LG.
2
1
266427-01
PLATE, PUMP MOUNT
3
1
266428-01
GROMMET, 3/16" HOLE
4
3
266428-02
GROMMET, 1/4"HOLE
5
1
266428-06
GROMMET, 9/16" HOLE
6
5
900009-1
SC REW, C AP 5/16"-18 X 5/8" LG, GRAD E 8
7
2
900014-4
BOLT, HEX HEAD , 3/8"-16 X 1 LG, GRAD E 8
8
1
902011-4
LOC K WASHER, 3/8"
9
5
902013-10
FLAT WASHER, 5/16"
10
1
902013-11
FLAT WASHER, 3/8"
11
1
903400-02
LOC K WASHER, EXTERNAL TOOTH
12
3
908022-02
PLUG, FLEXIBLE
13
2
908022-03
PLUG, FLEXIBLE
1A
D ESC R IPTION
22
SEE 12 VDC POWER UNIT
(GRAVITY DOWN)
1
3
4
1A
7
8
2
6
5
ITEM
QTY.
PART NO.
1
1
266401-02
CYLINDER
1
260916-03
BEARING, SELF LUBE
2
1
906722-01
ELBOW, 90° O-RING, #6 M-M
3
1
906728-01
DUAL BARBED FITTING, 1/64" I.D.
4
1
224370-07
HOSE, PLASTIC 60-1/2" LG.
5
1
906709-02
FLOW REGULATOR VALVE
6
1
280635-01
HOSE ASSY, 3/8" HP, 54" LG.
7
1
228012
ADAPTER, STRAIGHT THREAD, 9/16"-18 M - 1/4" F
8
1
202406
ELBOW, BRASS 1/4" x 1/4"
1A
DESCRIPTION
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
GRAVITY DOWN HYDRAULIC COMPONENTS
12 VDC POWER UNIT (GRAVITY DOWN)
12
3
2
CONTROL SWITCH
WIRING HARNESS
(REF)
9
4
13
10
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1
5
6
11
14
7
8
ITEM
15
QTY.
PART NO.
DESCRIPTION
R EF
280610-01
1
1
290065
2
1
280566-01
3
1
280404
CABLE ASSEMBLY
4
1
280394
MOTOR STARTER SOLENOID, 12 VOLTS DC
5
1
905152
90° ELBOW
6
1
280806-01
FILLER CAP
7
1
280589-01
RESERVOIR
8
1
908017-01
DRAIN PLUG
9
1
280416
WIRE ASSEMBLY
10
1
280372
12 VDC COIL
11
1
906719-01
12
1
280374
13
1
906737-01
RELIEF VALVE
14
1
908016-01
GROMMET, 19/32"
15
1
908018-01
GROMMET, 5/16"
12 VDC POWER UNIT (GRAVITY DOWN)
PORT PLATE & PUMP ASSEMBLY (GRAVITY DOWN)
WIRE ASSEMBLY, 16 GA, GREEN
VALVE
MOTOR, 12 VOLTS DC
24
SEE 12 VDC POWER UNIT
(POWER DOWN)
1
1A
4
5
3
2
6
ITEM
QTY.
PART NO.
1
1
266401-02
CYLINDER
1
260916-03
BEARING, SELF LUBE
2
1
905152
3
1
280634-01
HOSE ASSEMBLY, 3/8"HP, 50"LG.
4
1
906722-01
ELBOW, 90 DEG, O-RING, #6 M-M
5
1
906709-02
FLOW REGULATOR VALVE
6
1
280635-01
HOSE ASSEMBLY, 3/8"HP, 54"LG.
1A
DESCRIPTION
ELBOW, 90° SAE #6-JIC37 #6
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
POWER DOWN HYDRAULIC COMPONENTS
12 VDC POWER UNIT (POWER DOWN)
13
1
4
6
16
4
5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
12
CONTROL SWITCH
WIRING HARNESS
(REF)
2
11
8
3
14
7
9
10
ITEM
QTY.
PART NO.
R EF
280600-01
15
DESCRIPTION
12 VDC POWER UNIT (POWER DOWN)
1
1
280381
MOTOR, 12 VOLTS DC
2
1
290066
PORT PLATE & PUMP ASSEMBLY (POWER DOWN)
3
2
906733-01
4
2
280404
CABLE ASSEMBLY
5
1
280543
CABLE ASSEMBLY
6
2
906720-01
10 VDC COIL
7
2
906719-01
VALVE
8
1
280806-01
FILLER CAP
ELBOW, 90°
9
1
280639-01
RESERVOIR
10
1
908017-01
DRAIN PLUG
11
1
906738-02
RELIEF VALVE, HP
12
1
906738-01
RELIEF VALVE, LP
13
1
280566-01
WIRE ASSEMBLY, 16 GA, GREEN
14
1
908016-01
GROMMET, 19/32"
15
1
908018-01
GROMMET, 5/16"
16
2
280394
MOTOR STARTER SOLENOID, 12 VOLTS DC
26
DECAL
P/N 264507
CAUTION DECAL
P/N 265736-01
DECAL
P/N 220382
INSTRUCTION DECAL
P/N 251867-03
DECAL
P/N 264081
FIG. 27-1
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECALS
CONTROL SWITCH AND POWER CABLE
NOTE: Use Switch to RAISE and LOWER Liftgate to make sure Switch
operates as shown on the decal.
BLACK
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
(FOR REFERENCESEE DECALS)
(TO
POWER
UNIT)
4
YELLOW
1
3
WHITE
GREEN
WHITE
RED
2
ITEM
QTY.
1
1
PART NO.
DESCRIPTION
280637-01
HARNESS ASSEMBLY, 84" LG. (GRAVITY DOWN)
280638-01
HARNESS ASSEMBLY, 84" LG. (POWER DOWN)
2
1
264346
3
2
900057-5
4
1
905206
SWITCH BOOT SEAL
5
1
264422
CABLE ASSEMBLY, 200 AMPS, 38' LG.
SWITCH & CABLE
SCREW, SELF-TAPPING #10-24 X 1" LG.
SHORT END TO
VEHICLE BATTERY
5
!
WARNING
Do not attach cable to battery until
liftgate repairs are completed.
LONG END TO PUMP
MOTOR SOLENOID
28
HYDRAULIC SYSTEM DIAGRAMS
HYDRAULIC CYLINDER
2 GPM FLOW
CONTROL VALVE
RETURN PORT
PRESSURE PORT
VALVE A
RELIEF VALVE
(SET AT 3250 PSI)
PUMP
CHECK VALVE
M
MOTOR
(REFERENCE)
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
29
FILLER HOLE
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC (TKL-25 GRAVITY DOWN)
HYDRAULIC SYSTEM DIAGRAMS
HYDRAULIC SCHEMATIC (TKL-25 POWER DOWN)
HYDRAULIC CYLINDER
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
2 GPM FLOW
CONTROL VALVE
PORT B - LOWER
(POWER DOWN)
PORT A - RAISE
VALVE
A
CHECK VALVE
VALVE
B
MOTOR
(REFERENCE)
CHECK VALVE
M
RELIEF VALVE
(SET AT
3250 PSI)
PUMP
CHECK VALVES
RELIEF VALVE
(SET AT
400 PSI)
FILTERS
RESERVOIR
DRAIN HOLE
(PLUGGED)
30
FILL HOLE
(PLUGGED)
ELECTRICAL SYSTEM DIAGRAMS
CONTROL SWITCH
WHITE
WHITE
RED
YELLOW
GREEN
BLACK
CABLE
ASSEMBLY
SOLENOID,
VALVE A
THERMAL
SWITCH
(IN MOTOR
CASING)
STARTER
SOLENOID
CABLE WITH
200 AMP FUSE
MOTOR
BATTERY
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SCHEMATIC (TKL-25 GRAVITY DOWN)
ELECTRICAL SYSTEM DIAGRAMS
ELECTRICAL SCHEMATIC (TKL-25 POWER DOWN)
CONTROL SWITCH
CABLE
ASSEMBLY
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
YELLOW
WHITE
RED
BLACK
WHITE
GREEN
THERMAL
SWITCH
(IN MOTOR
CASING)
SOLENOID,
VALVE B
BOTTOM
STARTER
SOLENOID
(LOWERING)
TOP
STARTER
SOLENOID
(RAISING)
MOTOR
CABLE WITH
200 AMP FUSE
BATTERY
32
SOLENOID,
VALVE A
TROUBLESHOOTING
1. Use voltmeter to verify that power is being supplied to Solenoid Terminal “A”
(FIG. 33-1.) Recharge the battery if less than 12.6 volts.
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
2. Fill Reservoir to within 1/2” below the top with the hydraulic fluid recommended in the
Periodic Maintenance Checklist.
3. Touch a jumper wire to terminals “A” & “C” (FIG. 33-1). If motor runs check Switch,
switch connections, and White wire. Check and correct wiring connections or replace the
Switch.
4. Touch heavy jumper cables to terminals “A” & “B” (FIG. 33-1).
a. If motor runs, replace the motor solenoid.
b. If motor does not run, repair or replace the pump motor.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
5. Check for structural damage and replace worn parts.
6. Check filter in the pump Reservoir. Replace filter if necessary.
7. Check for dirty pump motor relief valve. Clean if necessary.
Replace any worn out relief valve parts.
TERMINAL “B”
TERMINAL “C”
TERMINAL “A”
STARTER
SOLENOID
LOWERING
SOLENOID
FIG. 33-1
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT RAISE
TROUBLESHOOTING
PLATFORM RAISES BUT LEAKS DOWN
1. Check if Solenoid Valves are constantly energized by touching a screwdriver to the top nut of the Solenoid (FIG. 34-1).
Try pulling the screwdriver away from the solenoid. If the
solenoid nut attracts the screwdriver (magnetically) without
pushing the toggle switch, the control circuit is operating
incorrectly. Check if toggle switch, wiring or coil are faulty.
COIL
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FIG. 34-1
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to manually bleed Hydraulic System by
correctly positioning Liftgate Platform before disconnecting any Lifting Cylinder high pressure Hydraulic Lines. The following procedure can save t ime and prevent accidental fluid
spills and hazards.
2. Check the Valve Stem by removing the Coil
Assembly (Item 1, FIG. 34-2). With platform on
ground, unscrew the Valve Stem, (Item 2,
FIG. 34-2) from the Pump. Push on the plunger
that is located inside the Valve Stem by inserting a small screwdriver blade in the end. If the
Plunger does not move freely (approximately 1/
8”) replace the Valve Stem. When re-installing
valve stem, torque hex nut to 30 in-lbs.
3. Check the Hydraulic Cylinder. With the Platform
on the ground, remove the hydraulic line from the
Down Port of the Cylinder (FIG. 34-3). Raise
the Platform even with the bed. Allow pump
motor to run two seconds more while you watch
for hydraulic fluid at the Down Port. A few drops
of hydraulic fluid escaping the Down Port is
normal; however, if it streams from the Down
Port, Piston Seals are worn. Replace Seals.
2
1
1/8”
FIG. 34-2
DOWN PORT
RAISE PORT
FIG. 34-3
34
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
1. Lower the opened Platform to the ground. Fill the Pump Reservoir on Gravity-Down
Liftgates to within 1/2” below the top with hydraulic fluid recommended in Periodic
Maintenance Checklist.
2. Use voltmeter to verify that the Battery shows 12.6 volts or more.
3. Check for Structural damage, or poor lubrication. Replace worn parts.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
4. Check the Hydraulic Cylinder. With the Platform on the
ground, remove the Breather Plug or Vent Line from the
Vent Port of the Cylinder (FIG. 35-1). Raise the Platform
even with the bed. Allow pump motor to run two seconds
more while you watch for hydraulic fluid at the Vent Port.
A few drops of hydraulic fluid escaping the Vent Port is
normal; however, if it streams from the Vent Port, Piston
Seals are worn. Replace Seals.
VENT PORT
PRESSURE
PORT
FLOW
CONTROL
VALVE
FIG. 35-1
5. Check Filter in the Pump Reservoir. Replace filter if necessary.
6. Check for dirty pump motor relief valve. Clean if necessary. Replace any worn out relief
valve parts.
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES PARTIALLY AND STOPS
TROUBLESHOOTING
LIFTGATE WILL NOT LIFT RATED CAPACITY
1. Use voltmeter to verify that the Battery shows 12.6 volts or more under load from pump
motor.
2. Check for Structural damage or lack of lubrication.Replace worn parts.
! CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
3. With Platform on the ground, remove the pressure hose
and fitting from the Pump and replace it with a 0-3000
VENT PORT
PSI Pressure Gauge. Hold the switch in the “UP” position. Adjust the Relief Valve on the side of the Pump until
PRESSURE
the gauge shows 2800 to 3000 PSI (FIG. 36-2). RePORT
move guage and re-install pressure hose.
4. Check for dirty pump motor relief valve. Clean if
necessary. Replace any worn out relief valve parts.
5. Check the Hydraulic Cylinder. With the Platform on the
ground, remove the Breather Plug or Vent Line from the
Vent Port of the Cylinder (FIG. 36-1). Raise the
Platform even with the bed. Allow pump motor to run two
seconds more while you watch for hydraulic fluid at the
Vent Port. A few drops of hydraulic fluid escaping the
Vent Port is normal; however, if it streams from the Vent
Port, Piston Seals are worn. Replace Seals.
FIG. 36-1
RELIEF
VALVE
ADJUST
SCREW
6. If Pump cannot produce 2800-3000 PSI with a minimum
of 12.6 Volts available, the Pump is worn and needs to
be replaced.
PRESSURE
GAUGE
FIG. 36-2
36
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic TERMINAL
“A”
system. Before opening the hydraulic fluid reservoir filler cap, drain
plug and hydraulic lines, clean up contaminants that can get in the
FIG. 37-1
openings. Also, protect the openings from accidental contamination
during maintenance.
2. Check the Hydraulic Cylinder. With the Platform on the ground, remove the Breather Plug or
Vent Line from the Vent Port of the Cylinder (FIG. 37-3). Raise the Platform even with the
bed. Allow pump motor to run two seconds more while you watch for hydraulic fluid at the
Vent Port. A few drops of hydraulic fluid escaping the Vent Port is normal; however, if it
streams from the Vent Port, Piston Seals are worn. Replace Seals.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
3. Check and clean Flow Control Valve in high pressure hydraulic line attached to Cylinder.
When installing Flow Control Valve make sure arrow on valve is oriented as shown
in (FIG. 37-3).
4. Lower the opened Platform to the ground. Fill the Pump Reservoir on Gravity-Down
Liftgates to within 1/2” below the top with hydraulic fluid recommended in Periodic
Maintenance Checklist.
5. Verify the Pump Motor is grounded to the vehicle frame.
RELIEF
VALVE
ADJUST
SCREW
PRESSURE
GAUGE
6. Check for leaking hoses and fittings. Tighten or replace as
required.
7. Check for structural damage or poor lubrication. Replace
worn parts.
8. Check the Filter in the Pump Reservoir. Replace if necessary.
9. With Platform on the ground, remove the pressure hose
and fitting from the Pump and replace it with a 0-3000 PSI
Pressure Gauge. Hold the Control switch in the “RAISE”
position. Adjust the Relief Valve on the side of the Pump
until the gauge shows 2800 to 3000 PSI (FIG. 37-2).
Remove guage and re-install pressure hose.
37
FIG. 37-2
VENT PORT
PRESSURE
PORT
FLOW
CONTROL
VALVE
FIG. 37-3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES SLOWLY
1. Use voltmeter to verify that power is being supplied to
Solenoid Terminal “A”. Recharge the battery if voltmeter indicates less than 12.6 Volts ( FIG. 37-1).
TROUBLESHOOTING
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS
TOO QUICKLY
1. Use voltmeter to verify that power is being supplied to
Solenoid Terminal “A”. Recharge the battery if voltmeter
indicates less than 12.6 Volts ( FIG. 38-1).
2. Check for structural damage or poor lubrication.
Replace worn parts.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3. Check if Solenoid Valve is getting power by holding a
screwdriver against the top nut of the Solenoid. Push
Control Switch to “LOWER” position to energize
solenoid (FIG. 38-2). A good solenoid will attract
(magnetically) the screwdriver to the nut and make it
difficult to pull the screwdriver away from the nut.
TERMINAL
“A”
FIG. 38-1
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
4. Check the Valve Stem by removing the Coil Assembly
(Item 1, FIG. 38-2). With platform supported, unscrew
the Valve Stem (Item 2, FIG. 38-2) from the Pump.
Push on the plunger located inside the Valve Stem by
inserting a small screwdriver blade in the end. If the
Plunger does not move freely (approximately 1/8”)
replace the Valve Stem.
2
1
1/8”
FIG. 38-2
5. Check if filtering screen on solenoid valve is
plugged. Clean carefully if required.
6. Check and clean Flow Control Valve in high
pressure hydraulic line attached to Cylinder.
7. Check if Flow Control Valve (FIG. 38-3) is
pointing to the direction of restricted fluid flow
(back toward pump). If required, remove Flow
Control Valve and install it correctly (FIG. 38-3).
DOWN PORT
(REF)
RAISE PORT
(REF)
FIG. 38-3
38
FLOW
CONTROL
VALVE
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