72-150/TE-20 (Short Arm)

72-150/TE-20 (Short Arm)
M-02-22
REV. (-01)
MARCH 2003
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 ...................................................................................................... 6
LIFTGATE TERMINOLOGY ................................................................................................... 7
PERIODIC MAINTENANCE CHECKLIST ............................................................................. 8
CHANGING HYDRAULIC FLUID ........................................................................................... 9
PLATFORM ADJUSTMENT ................................................................................................ 10
REPLACING PLATFORM TORSION SPRING .................................................................... 12
SAFETY HOOK MAINTENANCE ........................................................................................ 14
PARTS BREAKDOWN .................................................................................. 15
72-150SA/TE-20SA FINAL ASSEMBLY .............................................................................. 16
EXTENSION PLATE ASSEMBLY ....................................................................................... 17
LIFT FRAME & PARALLEL ARMS ...................................................................................... 18
PLATFORM & FLIPOVER ASSEMBLY ............................................................................... 20
PUMP COVER ................................................................................................................... 21
GRAVITY DOWN HYDRAULIC COMPONENTS.................................................................. 22
12 VDC POWER UNIT (GRAVITY DOWN) .......................................................................... 23
POWER DOWN HYDRAULIC COMPONENTS ................................................................... 24
12 VDC POWER UNIT (POWER DOWN) ........................................................................... 25
DECALS ............................................................................................................................ 26
CONTROL SWITCH AND POWER CABLE ........................................................................ 27
SCHEMATICS ............................................................................................... 28
HYDRAULIC SCHEMATIC (GRAVITY DOWN) .................................................................... 29
ELECTRICAL SCHEMATIC - GRAVITY DOWN .................................................................. 30
TABLE OF CONTENTS - Continued
HYDRAULIC SCHEMATIC - POWER DOWN ..................................................................... 31
ELECTRICAL SCHEMATIC - POWER DOWN ................................................................... 32
TROUBLESHOOTING .................................................................................. 33
PLATFORM WILL NOT RAISE ............................................................................................ 34
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 35
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 36
LIFTGATE WILL NOT LIFT RATED CAPACITY ................................................................... 37
PLATFORM RAISES SLOWLY ........................................................................................... 38
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS TOO QUICKLY .. 39
Comply with the following WARNINGS while maintaining Liftgates. See Operation Manual
M-02-21 for operating safety requirements.
!
WARNINGS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• 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-02-21.
• 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]
6
EXTENSION
PLATE
CONTROL
SWITCH
PUMP
ASSEMBLY
MAIN FRAME
PLATFORM
FLIPOVER
LIFT
CYLINDER
PARALLEL
ARM
OPENER
LIFT FRAME
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATE TERMINOLOGY
72-150SA & TE-20SA
PERIODIC MAINTENANCE CHECKLIST
!
WARNING
Never operate the Liftgate with parts loose or missing.
Annually
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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. If hydraulic fluid must be added, select
the correct grade of fluid to use at your location. Recommended hydraulic fluids are listed in
TABLE 1 and TABLE 2
+40 to +150 Degrees F
Below + 40 Degrees F
- Grade ISO 32
- Grade ISO 15
ISO 15 HYDRAULIC FLUID
ISO 32 HYDRAULIC FLUID
RECOMMENDED BRANDS
PART NUMBER
RECOMMENDED BRANDS
PART NUMBER
EXXON
UNIVIS J13
EXXON
MIL-L-5606 A
TELLUS T 32
CHEVRON
AVIATION
HYDRAULIC FLUID A
EXXON
UNIVIS N 32
SHELL
AEROSHELL FLUID 4
MOBIL
HYDRAULIC OIL 13
MOBIL
AERO HFA
ROSEMEAD
HYDRAULIM MV 150
CHEVRON
HYDRAULIC OIL AW MV 32
SHELL
TABLE 2
TABLE 1
If Hydraulic Fluid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure on following page.
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.
8
CHANGING HYDRAULIC FLUID
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.
GRAVITY DOWN LIFTGATES
1. Remove the Pump Cover. Place empty 5 Gallon
Bucket under Drain Plug (FIG. 1).
FILLER
CAP
2. Lower Platform to ground. Pull out (no threads)
Drain Plug (FIG. 1). Drain hydraulic fluid from
system. Re-install Drain Plug.
3. Pull out (no threads) Filler Cap (FIG. 1) and refill
reservoir with Hydraulic Fluid to 4” level shown in
FIG. 1. Use correct grade of hydraulic fluid for your
location. See TABLE 1 and TABLE 2 for
recommended fluids.
4” MIN
+40 to +150 Degrees F - Grade ISO 32
Below + 40 Degrees F - Grade ISO 15
RESERVOIR
DRAIN
PLUG
4. Reinstall Filler Cap (FIG. 1).
POWER DOWN LIFTGATES
1. Remove the Pump Cover. Place empty 5 Gallon
Bucket under Drain Plug (FIG. 1).
LIFTGATE SHOWN WITH
GRAVITY DOWN PUMP & MOTOR
FIG. 1
2. Open and raise Platform to vehicle bed height. Pull
out (no threads) Drain Plug (FIG. 1). Drain hydraulic
fluid.
3. Disconnect the Motor Power Cable (FIG. 2) from
bottom Starter Solenoid. Lower the Platform while
draining the remaining hydraulic fluid from
system. Reinstall Drain Plug. Reconnect the
Motor Power Cable to bottom Starter Solenoid.
4. Pull out (no threads) Filler Cap (FIG. 1) and refill
reservoir with Hydraulic Fluid to 4” level shown in
FIG. 1. Use correct grade of hydraulic fluid for your
location. See TABLE 1 and TABLE 2 for
recommended fluids.
BOTTOM
STARTER
SOLENOID
+40 to +150 Degrees F - Grade ISO 32
Below +40 Degrees F - Grade ISO 15
5. Raise Platform to vehicle bed height. Check hydraulic
fluid again and, if needed, add more hydraulic fluid
until Sight Glass (FIG. 1) is half full.
6. Reinstall Filler Cap (FIG. 1).
9
MOTOR POWER
CABLE
POWER DOWN PUMP
FIG. 2
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
PLATFORM ADJUSTMENT
NOTE: Before doing the following procedure,
make sure vehicle is parked on level ground.
LEVEL LINE
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. The Shackles and
PLATFORM EDGE ABOVE BED LEVEL
the outboard edge of Platform must touch the
FIG. 3
ground at the same time as shown in FIG. 4.
If the Shackles and the outboard edge of Platform are touching the ground, RAISE Platform
to bed height. Outboard edge of Platform
should be above bed level (FIG. 3). If indications
are correct (FIGS. 3 & 4), Liftgate is installed
correctly and no adjustment is needed. If indications are incorrect, continue with instruction 2.
PLATFORM & SHACKLES
TOUCH GROUND
NOTE: If the Platform is like FIG. 5, do instrucFIG. 4
tion 2. If the Platform touches and the Shackle
does not (FIG. 8), skip 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. 5) with
TABLE 3 to determine the correct shim. Make
shims as needed (FIG. 6). Weld shim as shown
in FIG. 7.
RAISE PLATFORM
EDGE (OUTBOARD)
THIS DISTANCE ("A")
REQUIRED SHIM
THICKNESS
11/16"
1/16"
1/16"
1-3/8"
1/8"
1/8"
2-1/16"
3/16"
3/16"
2-3/4"
1/4"
1/4"
WELD SIZE
“A”
(TABLE 3)
SHACKLES DO NOT TOUCH GROUND
FIG. 5
"W"
SHIM
(TABLE 3)
CENTERED
(TOP EDGES FLUSH)
PLATFORM
TABLE 3
1-1/2”
SHACKLE
(REF)
2-1/4”
“W”
(TABLE 3)
SHIM (1/16”, 1/8”, 3/16”, or 1/4”)
MADE FROM STEEL FLAT
FIG. 6
2 PLACES
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 7
10
3. Make sure Platform is still at ground level. If
the Platform is not touching the ground,
measure and compare distance “B” (FIG. 8)
with TABLE 4 to determine how much to grind
from the Platform Stops (FIG. 9). Grind
correct amount of metal (TABLE 4)
from Platform Stop as shown in FIG. 9.
“B”
(TABLE 4)
PLATFORM DOES NOT
TOUCH GROUND
FIG. 8
LOWER PLATFORM
EDGE (OUTBOARD)
THIS DISTANCE("B")
GRIND METAL FROM
PLATFORM STOP
11/16"
1/16"
1-3/8"
1/8"
2-1/16"
3/16"
2-3/4"
1/4"
PLATFORM
STOP
PLATFORM
TABLE 4
GRIND HERE
(TABLE 4)
4. RAISE the Platform, then LOWER it to the
ground. Platform and Shackle should touch the
ground at the same time as shown in FIG. 4.
11
SHACKLE
(REF)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM ADJUSTMENT - Continued
REPLACING PLATFORM TORSION SPRING
1. Manually fold Flipover onto Platform .
2. Raise Liftgate to a convenient work height
to gain access and release tension on the
Torsion Spring.
PIN
COLLAR
TORSION
SPRING
PLATFORM
HINGE PIN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
! CAUTION
To prevent injury and equipment damage,
make sure there is no tension on torsion
spring before removing hinge pin.
3. 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. 10).
Remove spring from Shackle.
SHACKLE
ROLL PIN
(REMOVED)
FIG. 10
4. Install the Torsion Spring as
shown in (FIG. 11). 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. 11).
BLOCK
SHORT LEG
LONG LEG
SHACKLE
PLATFORM
HINGE
BRACKET
BRACKET
FIG. 11
12
5. Drive Platform Hinge Pin inboard to correct position through the Platform Hinge Bracket
(FIG. 12). 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. 12).
6. Operate the Liftgate according to instructions in Operation Manual M-02-21 to make sure
it operates correctly.
PLATFORM
HINGE PIN
PIN
COLLAR
PLATFORM HINGE
BRACKET
FIG. 12
13
ROLL PIN
(INSTALLED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
REPLACING PLATFORM TORSION SPRING
-Continued
SAFETY HOOK MAINTENANCE
GREASE ALL HOLES THE
ROD PASSES THRU
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
GREASE FRONT SURFACE OF
HOOK WITH AUTOMOTIVE
GREASE
FIG. 13
CHECK SAFETY HOOK FUNCTION
1. When raising Platform to stowed position,
listen for sound of Platform Loop striking
Safety Hook.
EXTENSION
PLATE
2. When the Liftgate is stowed, see if Platform
Loop is positioned above the Safety Hook
as shown in FIG. 13.
CORRECT
POSITION
PLATFORM LOOP
(WRONG POSITION)
BEND IN
THIS
DIRECTION
LOOP ADJUSTMENT
1. If the Safety Hook is not positioned correctly,
LOWER Platform to ground level (Operation
Manual M-02-21).
2. Adjust by bending the Platform Loop as shown
in FIG. 14.
3. Stow the Platform and check for correct Safety
Hook position. Repeat adjustment if required.
14
SAFETY
HOOK
PLATFORM
FIG. 14
15
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PARTS BREAKDOWN
72-150SA/TE-20SA FINAL ASSEMBLY
REFER TO EXTENSION
PLATE ASSEMBLY
5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
7
2
1
6
3
2
3
3
REFER TO PUMP COVER,
HYDRUALIC COMPONENTS, &
POWER UNITS
REFER TO LIFT FRAME
& PARALLEL ARMS
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
203405-05
2
5
221416
ROLL PIN
3
4
252686
PIN, 4" LG.
4
1
253657
BEARING, SELF LUBE
5
2
900014-04
HEX HD BOLT, 3/8"-16 x 1" LG.
6
2
902011-04
LOCK WASHER, 3/8"
7
1
903400-02
LOCK WASHER, EXTERNAL TOOTH, 3/8"
PIN, 3-1/4" LG.
16
EXTENSION PLATE ASSEMBLY
3D
3A
3C
VIEWED FROM UNDER
EXTENSION PLATE
3B
5
3
2
1
ITEM
QTY.
PART NO.
DESCRIPTION
1
6
207644
RIVET
2
1
050175
MAXON PLATE
3
1
263000
EXTENSION PLATE
3A
1
201606
HANDLE
3B
2
201561
STOP BLOCK
3C
1
215342
LEVER, SPRING
3D
1
215341
SAFETY HOOK
4
1
215345
EXTENSION SPRING
5
1
055011
RUBBER HANDLE (GRIP)
17
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
LIFT FRAME & PARALLEL ARMS
15C
15D
15
16A
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
16
10
15A
15B
11
9
2
8B
8B
8A
8
13
5
14
1
4
12
8A
7
6
1
3
8B
2
18
11
14A
LIFT FRAME & PARALLEL ARMS
QTY.
PART NO.
1
5
221416
ROLL PIN
2
2
252686
PIN, 4" LG.
3
1
280052-01
SHACKLE WELDMENT (RH)
4
1
280052-02
SHACKLE WELDMENT (LH)
5
1
260830
PIN, 7-1/4" LG.
6
1
262981
PIN, 14" LG.
7
1
280849-01
8
1
280050
8A
2
261837-05
BUSHING, FLANGED - PLASTIC
8B
4
260916-03
BEARING, SELF LUBE
9
1
280093
PIN, CYLINDER
10
1
280087-02
PIN WELDMENT
11
2
905033-4
ROLL PIN
12
1
280087-01
PIN WELDMENT
13
1
280085
ROLLER
14
1
280048
PARALLEL ARM RH
2
260916-03
1
280078
OPENER
15A
1
280082-01
ROLLER
15B
1
900035-10
CAP SCREW, 1/2"-13 X 3-1/2" LG.
15C
1
902000-14
FLAT WASHER, 1/2"
15D
1
901010
LOCK NUT, 1/2"-13
1
280077
PARALLEL ARM LH
2
260916-03
14A
15
16
16A
DESCRIPTION
TORSION SPRING
LIFT FRAME
BEARING, SELF LUBE
BEARING, SELF LUBE
19
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
PLATFORM & FLIPOVER ASSEMBLY
4
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4A
3
2
2
3
1
ITEM
QTY.
PART NO.
DESCRIPTION
1
280038-01
FLIPOVER (72" WIDE)
1
280038-02
FLIPOVER (84" WIDE)
2
2
900033-2
CAP SCREW, 1/2"-20 x 1-1/4" LG.
3
2
901016-1
LOCK NUT, THIN HEAD, 1/2"-20
1
280043-01
PLATFORM (72" WIDE)
1
280043-02
PLATFORM (84" WIDE)
2
260916-03
BEARING, SELF LUBE
1
4
4A
20
5
4
1
4
5
3
3
2
2
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
280615
2
4
900005-3
BUTTON SCREW 1/4"-20 x 3/4" LG.
3
4
902013-09
FLAT WASHER, 1/4"
4
4
902011-2
LOCK WASHER, 1/4"
5
4
901011-1
HEX NUT, 1/4"-20
PUMP COVER
21
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP COVER
GRAVITY DOWN HYDRAULIC COMPONENTS
SEE 12 VDC POWER UNIT
(GRAVITY DOWN)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
9
1
2
4
8
5
6
7
3
ITEM
QTY.
1
1
PART NO.
DESCRIPTION
280140
CYLINDER (72-150SA)
280145
CYLINDER (TE-20SA)
ELBOW 90° SAE #6 - JIC37 #6
2
1
905152
3
1
260916-03
4
1
905181
5
1
906709-02
FLOW REGULATOR VALVE
6
1
280635-01
HOSE ASSY, 3/8" HP, 60" LG.
7
1
260121
ADAPTER, STRAIGHT THREAD, O-RING #6M - 3/8F
8
1
215406
ELBOW BRASS 1/4" x 3/8"
9
1
224370-07
HOSE, PLASTIC 60-1/2" LG.
BEARING, SELF LUBE
SWIVEL, O-RING, 3/8" x JIC#6F
22
CONTROL SWITCH
WIRING HARNESS
(REF)
3
11
4
10
9
5
12
1
6
2
7
8
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
280467
PORT PLATE, VERTICAL PUMP MOUNT (GD)
2
1
280466
PUMP, VERTICAL
3
1
280404
CABLE ASSEMBLY
4
1
280394
MOTOR STARTER SOLENOID, 12 VOLTS DC
5
1
906733-01
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
SOLENOID VALVE, 12 VOLTS DC
11
1
280374
MOTOR, 12 VOLTS DC
12
1
906737-01
RELIEF VALVE
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
12 VDC POWER UNIT (GRAVITY DOWN)
P/N 280610-01
POWER DOWN HYDRAULIC COMPONENTS
SEE 12 VDC POWER UNIT
(POWER DOWN)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
7
1
2
4
2
5
6
3
ITEM
QTY.
1
1
PART NO.
DESCRIPTION
280140
CYLINDER (72-150 SA)
280145
CYLINDER (TE-20 SA)
ELBOW, 90° SAE #6-JIC37 #6
2
2
905152
3
1
260916-03
4
1
905181
5
1
906709-02
FLOW REGULATOR VALVE
6
1
280635-01
HOSE ASSEMBLY, 3/8"HP, 60"LG.
7
1
280634-01
HOSE ASSEMBLY, 3/8"HP, 60"LG.
BEARING, SELF LUBE
SWIVEL, O-RING, 3/8"M-JIC#6F
24
1
CONTROL SWITCH
WIRING HARNESS
(REF)
4
6
4
5
12
2
11
3
8
7
9
10
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
280381
MOTOR, 12 VOLTS DC
2
1
290002
3 PIECE GEAR PUMP
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
9
1
280639-01
RESERVOIR
10
1
908017-01
DRAIN PLUG
11
2
906738-02
RELIEF VALVE HP
12
1
906738-01
RELIEF VALVE LP
ELBOW, 90°
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
12 VDC POWER UNIT (POWER DOWN)
P/N 280600-01
DECALS
DECAL
P/N 264507
DECAL
(LOCATED BY SERIAL PLATE)
P/N 265642
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECAL P/N 220386
(72-150SA ONLY)
DECAL P/N 220387
(TE-20SA ONLY)
DECAL
P/N 251867-04
DECAL
P/N 264081
26
BLACK
(For Reference Only)
WHITE
YELLOW
SWITCH BOOT SEAL
P/N 905206
(TO
POWER
UNIT)
SCREW, SELF-TAPPING
#10-24 X 1” LG.
P/N 900057-5
(2 PLACES)
GREEN
HARNESS ASSY, 74” LG.
P/N 280638-01
WHITE
RED
SWITCH & CABLE
ASSEMBLY
P/N 264346
NOTE: Use Switch to RAISE and LOWER Liftgate to make sure Switch
operates as shown on the decal.
SHORT END TO
VEHICLE BATTERY
FUSED BATTERY CABLE ASSY (38’ LG.)
P/N 264422
!
WARNING
Do not attach cable to battery until
liftgate repairs are completed.
LONG END TO PUMP
MOTOR SOLENOID
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL SWITCH AND POWER CABLE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
SCHEMATICS
28
HYDRAULIC CYLINDER
2 GPM FLOW
CONTROL VALVE
PRESSURE PORT
RETURN 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 (GRAVITY DOWN)
(72-150SA / TE-20SA)
ELECTRICAL SCHEMATIC - GRAVITY DOWN
(72-150SA / TE-20SA)
CONTROL SWITCH
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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
30
HYDRAULIC CYLINDER
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)
31
FILL HOLE
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC - POWER DOWN
(72-150SA / TE-20SA)
ELECTRICAL SCHEMATIC - POWER DOWN
(72-150SA / TE-20SA)
CONTROL SWITCH
CABLE
ASSEMBLY
YELLOW
WHITE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RED
BLACK
WHITE
GREEN
THERMAL
SWITCH
(IN MOTOR
CASING)
SOLENOID,
VALVE B
STARTER
SOLENOID
(RAISE)
STARTER
SOLENOID
(LOWER)
MOTOR
CABLE WITH
200 AMP FUSE
BATTERY
32
SOLENOID,
VALVE A
.........................................................................................................
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
TROUBLESHOOTING
PLATFORM WILL NOT RAISE
1. Use voltmeter to verify that power is being supplied to Solenoid Terminal “A”.
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.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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”. 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”.
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
34
PLATFORM RAISES BUT LEAKS DOWN
FIG. 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. 2). With platform on
ground, unscrew the Valve Stem, (Item 2,
FIG. 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. 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.
35
2
1
1/8”
FIG. 2
DOWN PORT
RAISE PORT
FIG. 3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
COIL
1. Check if Solenoid Valves are constantly energized by touching a screwdriver to the top nut of the Solenoid (FIG. 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.
PLATFORM RAISES PARTIALLY AND STOPS
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.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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. 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.
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.
36
LIFTGATE WILL NOT LIFT RATED CAPACITY
2. Check for Structural damage or lack of lubrication.Replace worn parts.
! 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.
3. With Platform on the ground, remove the pressure
hose and fitting from the Pump and replace it with a 03000 PSI Pressure Gauge. Hold the switch in the “UP”
position. Adjust the Relief Valve on the side of the
Pump until the gauge shows 2800 to 3000 PSI (FIG. 5).
Remove guage and re-install pressure hose.
VENT PORT
PRESSURE
PORT
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. 4). 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. 4
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
37
FIG. 5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Use voltmeter to verify that the Battery shows 12.6 volts or more under load from pump
motor.
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. 6).
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 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. 6
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. 8). 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. 8).
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. 7). Remove
guage and re-install pressure hose.
38
FIG. 7
VENT PORT
PRESSURE
PORT
FLOW
CONTROL
VALVE
FIG. 8
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. 9).
2. Check for structural damage or poor lubrication.
Replace worn parts.
TERMINAL
“A”
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. 10). A
good solenoid will attract (magnetically) the screwdriver to the nut
and make it difficult to pull the screwdriver away from the nut.
FIG. 9
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. 10). With platform supported, unscrew the Valve Stem (Item 2, FIG. 10) 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
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.
DOWN PORT
(REF)
RAISE PORT
(REF)
7. Check if Flow Control Valve (FIG. 11) is pointing to
the direction of restricted fluid flow (back toward pump).
If required, remove Flow Control Valve and install it
correctly (FIG. 11).
39
1/8”
FIG. 10
FLOW
CONTROL
VALVE
FIG. 11
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY,
OR LOWERS TOO QUICKLY
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