72-25/30 l
M-03-07
REV. B
APRIL 2009
MAINTENANCE MANUAL
72-25 & 72-30
© 2009 MAXON LIFT CORP.
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 of all Manuals (and replacements), download the
Manuals from Maxon’s website at www.maxonlift.com.
WARRANTY/ RMA POLICY & PROCEDURE
LIFTGATE WARRANTY
Type of Warranty:
Full Parts and Labor
Term of Warranty:
Standard Liftgates - 2 years from ship date or 6,000 cycles
Premium Liftgates - 2 years from ship date or 10,000 cycles
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 online at www.maxonlift.com. Online 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.
10321 Greenleaf Avenue, Santa Fe Springs, CA 90670
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 72-25 & 72-30 .......................................................................... 9
PERIODIC MAINTENANCE................................................................................................ 10
PERIODIC MAINTENANCE CHECKS ................................................................................ 10
PERIODIC MAINTENANCE CHECKLIST ............................................................................11
CHECKING HYDRAULIC FLUID ........................................................................................ 12
CHANGING HYDRAULIC FLUID ........................................................................................ 14
PLATFORM ADJUSTMENT ................................................................................................ 16
REPLACING PLATFORM TORSION SPRING ................................................................... 18
SAFETY HOOK MAINTENANCE ....................................................................................... 20
PARTS BREAKDOWNS ..................................................................................................... 21
72-25 & 72-30 MAIN ASSEMBLY ........................................................................................ 21
EXTENSION PLATE ASSEMBLY ........................................................................................ 22
LIFT FRAME & PARALLEL ARMS ...................................................................................... 23
PLATFORM & FLIPOVER ASSEMBLY (RAMP) ................................................................. 24
PLATFORM & FLIPOVER ASSEMBLY (WEDGE) .............................................................. 25
PLATFORM & FLIPOVER ASSEMBLY (SPECIAL PROFILE) ............................................ 26
PUMP COVER & MOUNTING PLATE ASSEMBLY (GRAVITY DOWN) ............................. 27
PUMP COVER & MOUNTING PLATE ASSEMBLY (POWER DOWN) ............................... 28
GRAVITY DOWN HYDRAULIC COMPONENTS ................................................................ 29
12 VDC POWER UNIT (GRAVITY DOWN) ......................................................................... 30
24 VDC POWER UNIT (GRAVITY DOWN) ......................................................................... 32
POWER DOWN HYDRAULIC COMPONENTS .................................................................. 35
12 VDC POWER UNIT (POWER DOWN)........................................................................... 36
DECALS .............................................................................................................................. 38
CONTROL SWITCH AND POWER CABLE ........................................................................ 39
HYDRAULIC SYSTEM DIAGRAMS ................................................................................... 40
HYDRAULIC SCHEMATIC (GRAVITY DOWN)................................................................... 40
HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 41
ELECTRICAL SYSTEM DIAGRAMS ................................................................................. 42
ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 42
ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 43
TROUBLESHOOTING ........................................................................................................ 44
PLATFORM WILL NOT RAISE............................................................................................ 44
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 45
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 46
LIFTGATE WILL NOT LIFT RATED CAPACITY .................................................................. 47
PLATFORM RAISES SLOWLY ........................................................................................... 48
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY ..................... 49
Comply with the following WARNINGS while maintaining Liftgates. See Operation Manual
for operating safety requirements.
WARNINGS
!
WARNING
• 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.
• Comply with all WARNING and instruction decals attached to the Liftgate.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement
decals are available from Maxon Customer Service.
• 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, 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 switch to stop the Liftgate.
• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the power 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.
6
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]
• Recommended practices for welding on steel parts are contained in the current AWS (American
Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and
personal injury could result from welds that are done incorrectly.
• Recommended practices for welding on aluminum parts are contained in the current AWS
(American Welding Society) D2.1 Structural Welding Code - Aluminum. Damage to Liftgate
and/or vehicle, and personal injury could result from welds that are done incorrectly.
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial number information with your parts order. Order replacement parts from:
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
8
EXTENSION
PLATE
CONTROL
SWITCH
CONTROL
HANDLE
MAIN FRAME
PARALLEL
ARM
PLATFORM
LIFT
CYLINDER
PUMP BOX
LIFT FRAME
RAMP FLIPOVER
WEDGE FLIPOVER
SPECIAL PROFILE
FLIPOVER
9
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LIFTGATE TERMINOLOGY
72-25 & 72-30
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHECKS
!
WARNING
Never operate the Liftgate with parts loose or missing.
NOTE: Make sure vehicle is parked on level ground while performing the maintenance checks.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Quarterly or 1250 Cycles (whichever occurs first)
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 chafing and fluid leaks. Tighten loose fittings or replace
parts as required.
Check electrical wiring for chafing and make sure wiring connections are tight and free of
corrosion. Use dielectric grease to protect electrical connections.
Check that all WARNING and instruction decals are in place. Also, make sure decals are
legible and decals are clean and undamaged.
Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate or if the Liftgate
is dirty, clean it off. Touch up the paint where bare metal is showing.
Semi-annually or 2500 Cycles (whichever occurs first)
Visually check the platform hinge pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly or 1250 Cycles maintenance checks.
10
NOTE: Make sure vehicle is parked on level ground while performing the maintenance
checks.
Quarterly or 1250 Cycles (whichever occurs first)
Check the level and condition of the hydraulic fluid.
Visually check all hoses for chafing and fluid leaks. Tighten loose fittings or replace
parts as required.
Check electrical wiring for chafing and make sure wiring connections are tights and free
of corrosion. Use dielectric grease to protect electrical connections.
Check that all WARNING and instruction decals are in place. Also, make sure decals
are legible and decals are clean and undamaged.
Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.
CAUTION
Damaged cylinder seals and contaminated hydraulic fluid can result from
painting the polished portion of the cylinder rod. To prevent damage, protect
the exposed polished portion of the cylinder rod while painting.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate or if the Liftgate is dirty, clean it off. Touch up the paint where bare metal is showing.
Semi-annually or 2500 Cycles (whichever occurs first)
Visually check the platform hinge pins for excessive wear and broken welds.
Do the Quarterly or 1250 Cycles Checks on this checklist.
11
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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.
NOTE: Use correct grade of hydraulic fluid for your location.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 13-2 and 13-3 for recommended brands.
1. Unbolt & remove pump cover (FIG. 8-1).
FLAT WASHERS
(5 PLACES)
POWER UNIT
(REF)
NOTE: If the hydraulic fluid in the
reservoir is contaminated, do
the CHANGING HYDRAULIC
FLUID procedure in this section.
NOTE: If you have a power down
power unit, skip instructions
2 & 3.
2. For gravity down power unit, check the
hydraulic fluid level “H” in reservoir (FIG.
12-2 and TABLE 12-1). If needed,
add fluid to the reservoir as follows.
PLATFORM POSITION
PUMP COVER
UNBOLTING / BOLTING PUMP COVER
FIG. 12-1
FLUID LEVEL
“H”
STOWED
1-7/8” to 2-3/8”
VEHICLE BED HEIGHT
1-7/8” to 2-3/8”
ON THE GROUND
CAP SCREWS
(5 PLACES)
3-1/2” to 4”
RESERVOIR
GRAVITY DOWN FLUID LEVEL
TABLE 12-1
3. Pull out (no threads) filler cap (FIG. 12-2).
Fill the reservoir with hydraulic fluid to level
“H” shown in FIG. 12-2 and TABLE 121. Reinstall filler cap (FIG. 12-2)
“H”
FILLER CAP
GRAVITY DOWN POWER UNIT
FIG. 12-2
12
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 13-1
POWER DOWN POWER UNIT
FIG. 13-1
5. Pull out (no threads) filler cap (FIG.
13-1). Fill the reservoir with hydraulic
fluid to level “H” shown in FIG. 13-1
and TABLE 13-1. Reinstall filler cap
(FIG. 13-1).
ISO 32 HYDRAULIC OIL
RECOMMENDED
BRANDS
6. Bolt on the pump cover (FIG. 10-1).
Torque the bolts (cap screws) to
10 - 14 lbs.- in.
PART NUMBER
AMSOIL
AWH-05
CHEVRON
HIPERSYN 32
KENDALL
GOLDEN MV
SHELL
TELLUS T-32
EXXON
UNIVIS N-32
MOBIL
DTE-13M, DTE-24,
HYDRAULIC OIL-13
TABLE 13-2
ISO 15 OR MIL-H-5606 HYDRAULIC OIL
RECOMMENDED
BRANDS
PART NUMBER
AMSOIL
AWF-05
CHEVRON
FLUID A, AW-MV-15
KENDALL
GLACIAL BLU
SHELL
TELLUS T-15
EXXON
UNIVIS HVI-13
MOBIL
DTE-11M
ROSEMEAD
THS FLUID 17111
TABLE 13-3
13
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4. For power down power unit, check the hydraulic
fluid level “H” in reservoir (FIG. 13-1 and TABLE
13-1). 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.
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 13-2 and 13-3 for recommended brands.
GRAVITY DOWN LIFTGATES
1. Remove the pump cover (FIG. 13-1). Place emp-
ty 5 gallon bucket under drain plug (FIG. 14-1).
2. Lower platform to ground. Pull out (no threads)
drain plug (FIG. 14-1). Drain hydraulic fluid
from system. Reinstall drain plug.
3. Pull out (no threads) filler cap (FIG. 14-1) and
refill reservoir with hydraulic fluid to level shown in
FIG. 14-1. Reinstall filler cap (FIG. 14-1).
4. Bolt on the pump cover as shown in FIG. 13-1
Torque the bolts (cap screws) to 10 - 14 lbs.- in.
RESERVOIR
3-1/2” - 4”
DRAIN
PLUG
FILLER CAP
LIFTGATE SHOWN WITH GRAVITY
DOWN PUMP & MOTOR
1. Remove the pump cover (FIG. 15-1). Place empFIG. 14-1
ty 5 gallon bucket under drain plug (FIG. 14-1).
POWER DOWN LIFTGATES
2. Open and raise platform to vehicle bed height. Pull
out (no threads) drain plug (FIG. 14-1). Drain hydraulic fluid.
3. Disconnect the motor power cable (FIG. 142) from starter solenoid. Lower the platform
while draining the remaining hydraulic fluid from
system. Reinstall drain plug. Reconnect the
motor power cable to starter solenoid.
4. Pull out (no threads) filler cap (FIG. 14-1) and
refill reservoir with hydraulic fluid to level shown
in FIG. 14-1. Reinstall filler cap (FIG. 14-1).
14
STARTER
SOLENOID
MOTOR
POWER
CABLE
POWER DOWN PUMP
FIG. 14-2
POWER UNIT
(REF)
CAP SCREWS
(5 PLACES)
FLAT WASHERS
(5 PLACES)
PUMP COVER
UNBOLTING / BOLTING PUMP COVER
FIG. 15-1
15
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5. Bolt on the pump cover as shown in
FIG. 15-1. 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.
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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. 16-1). If the
shackles and the tip of flipover touch the ground
at the same time, RAISE platform to bed height.
Outboard edge on top of flipover should be above
bed level (FIG. 16-2). If indications are correct
in both cases (FIGS. 16-1 & 16-2), Liftgate is
installed correctly and no adjustment is needed. If
indications are incorrect, continue to instruction 2.
TIP OF
FLIPOVER
FLIPOVER & SHACKLES
TOUCH GROUND
FIG. 16-1
OUTBOARD
EDGE
LEVEL LINE
NOTE: If tip of flipover touches first (FIG.
16-3), do instruction 2. If the shackle
touches first (FIG. 12-1), skip instruction 2 and do 3.
FLIPOVER EDGE ABOVE
BED LEVEL
FIG. 16-2
2. Make sure platform is still at ground level. If
the shackle is not touching the ground, measure and compare distance “A” (FIG. 16-3)
with TABLE 16-1 to determine the correct
shim. Make shims as needed (FIG. 16-5).
Weld shim as shown in FIG. 16-4.
RAISE TIP OF
FLIPOVER
THIS DISTANCE “A”
“A”
(TABLE 16-1)
REQUIRED SHIM
WELD SIZE “W”
THICKNESS
7/8”
1/16”
1/16”
1-3/4”
1/8”
1/8”
2-5/8”
3/16”
3/16”
3-1/2”
1/4”
1/4”
SHACKLES DO NOT TOUCH
GROUND
FIG. 16-3
EXISTING STOP
TABLE 16-1
1-1/2”
2-1/4”
NEW SHIM
SHACKLE
“W”
TABLE 16-1
SHIM (1/16”, 1/8”, 3/16”, or 1/4”)
MADE FROM STEEL FLAT
FIG. 16-5
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 16-4
16
LOWER TIP OF
FLIPOVER
THIS DISTANCE “B”
GRIND METAL FROM
PLATFORM STOP
7/8”
1/16”
1-3/4”
1/8”
2-5/8”
3/16”
3-1/2”
1/4”
TIP OF
FLIPOVER
PLATFORM DOES NOT
TOUCH GROUND
FIG. 17-1
TABLE 17-1
4. RAISE the platform, then LOWER it to
the ground. As the platform first touches
the ground, the tip of flipover and shackles should touch at the same time as
shown in FIG. 16-1.
EXISTING
STOP
GRIND
THIS EDGE
SHACKLE
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 17-2
17
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3. Make sure platform is still at ground
level. If the tip of flipover is not touching the ground, measure and compare
distance “B” (FIG. 17-1) with TABLE
17-1 to determine how much to grind
from the platform stops (FIG. 17-2).
Grind correct amount of metal (TABLE
“B”
17-1) from platform stop as shown in (TABLE 17-1)
FIG. 17-2.
PERIODIC MAINTENANCE
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.
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TORSION
SPRING
ROLL PIN
(REMOVED)
PIN
COLLAR
! CAUTION
PLATFORM
HINGE PIN
To prevent injury and equipment damage,
make sure there is no tension on torsion
spring before removing hinge pin.
SHACKLE
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. 181). Remove spring from shackle.
FIG. 18-1
PLATFORM HINGE
BRACKET
LONG LEG
4. Install the torsion spring as shown in
FIG. 18-2. 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, as
shown in FIG. 18-2.
SHACKLE
SHORT LEG
BRACKET
FIG. 18-2
18
PLATFORM HINGE
BRACKET
ROLL PIN
(INSTALLED)
PLATFORM
HINGE PIN
PIN COLLAR
6. Operate the Liftgate according to
instructions in Operation Manual
to make sure it operates correctly.
FIG. 19-1
19
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5. Drive platform hinge pin inboard to
correct position through the platform
hinge bracket (FIG. 19-1). 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. 19-1).
PERIODIC MAINTENANCE
SAFETY HOOK MAINTENANCE
CHECK SAFETY HOOK FUNCTION
1. When raising platform to stowed position,
listen for sound of safety hook engaging
platform loop.
EXTENSION
PLATE
CORRECT
POSITION
PLATFORM LOOP
(WRONG POSITION)
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2. When the Liftgate is stowed, see if platform loop is positioned above the safety
hook as shown in FIG. 20-1.
BEND IN
THIS
DIRECTION
SAFETY
HOOK
LOOP ADJUSTMENT
PLATFORM
1. If the safety hook is not positioned correctly,
LOWER platform to ground level (Operation
Manual).
FIG. 20-1
2. Adjust by bending the platform loop as shown
in FIG. 20-1.
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. 20-2) is lubricated
with automotive grease. Apply
grease if required.
CONTROL HANDLE ROD
(TYPICAL LUBE POINT) BRACKETS
2. Make sure control handle rod
(FIG. 20-2) is lubricated where
it has contact with brackets. Apply
automotive grease if required.
SAFETY HOOK FRONT SURFACE
FIG. 20-2
20
PARTS BREAKDOWNS
REFER TO EXTENSION
PLATE ASSEMBLY
2
1
3
REFER TO LIFT FRAME
& PARALLEL ARMS
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
(RAMP FLIPOVER SHOWN)
REFER TO PUMP
COVER, HYDRAULIC
COMPONENTS, &
POWER UNITS
ITEM QTY. PART NO.
DESCRIPTION
1
1
221416
ROLL PIN, 3/8” X 2” LG.
2
1
260368-03
PIN, 1” DIA X 3-1/2” LG.
3
1
266415-01
MAIN FRAME 72-25 & 72-30
21
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72-25 & 72-30 MAIN ASSEMBLY
EXTENSION PLATE ASSEMBLY
REFER TO EXTENSION
PLATE ASSEMBLY
4
3B
3C
3A
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
5
3D
6
2
3
7
1 (6 PLACES)
ITEM QTY. PART NO.
DESCRIPTION
1
6
207644
RIVET , 3/16” DIA. X .402” LG.
2
1
050175
MAXON PLATE
3
1
262999
EXTENSION PLATE WELDMENT
3A
1
215342
SPRING LEVER, 2-1/2” LG
3B
1
215341
SAFETY HOOK WELDMENT
3C
1
201606
HOOK RELEASE HANDLE, 5/8” X 52-3/4” LG
3D
2
201015
FLAT, 1/4” X 1/2” X 1” LG
4
1
215345
EXTENSION SPRING
5
1
203417
RENTAL LOCK BRACKET, 6-1/2” LG (OPTIONAL)
6
1
055011
HANDLE, RUBBER
7
1
203570
INNER BRACKET, 1” LG (FOR OPTIONAL RENTAL LOCK)
22
5
5
3
6
4
3
2
7
9
5
1
11
5
3
2
5
2
2
3
5
11
9
2
10
4
3
5
12
8
13
5
3
5
ITEM QTY. PART NO.
DESCRIPTION
1
1
260315
LIFT FRAME ASSEMBLY
2
8
260363
SELF LUBE BEARING, 1” X 1-1/2”
3
6
260368-03
PIN, 1” DIA X 3-1/2” LG
4
2
260368-04
PIN, 1” DIA X 4-1/2” LG
5
12
221416
ROLL PIN, 3/8” X 2” LG
6
1
260369
SELF LUBE BEARING, 1-1/8” X 2”
7
1
260368-05
PIN, 1” DIA X 5” LG
8
1
260368-02
PIN, 1” DIA X 11-1/4” LG
9
2
221867
ROLLER, 3/4”
10
1
201640
TORSION SPRING, PLATFORM
11
2
263325
PARALLEL ARM ASSEMBLY
12
1
280347-01
SHACKLE, LH
13
1
280347-02
SHACKLE, RH
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFT FRAME & PARALLEL ARMS
PLATFORM & FLIPOVER ASSEMBLY (RAMP)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
3
2
1
3
2
ITEM QTY. PART NO.
DESCRIPTION
1
1
201629
FLIPOVER WELDMENT (RAMP)
2
2
203405-05
PIN, 1” DIA X 3-1/4” LG
3
2
221416
ROLL PIN, 3/8” X 2” LG
4
1
280369
PLATFORM WELDMENT
24
4
3
2
1
3
2
ITEM QTY. PART NO.
DESCRIPTION
1
1
213085
FLIPOVER WELDMENT (WEDGE)
2
2
203405-05
PIN, 1” DIA X 3-1/4” LG
3
2
221416
ROLL PIN, 3/8” X 2” LG
4
1
280369
PLATFORM WELDMENT
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM & FLIPOVER ASSEMBLY (WEDGE)
PLATFORM & FLIPOVER ASSEMBLY (SPECIAL PROFILE)
15
16
14
17
9
4
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
11
5
3
4
4
3
3
13
7
10
3
4
6
4
5
12
4
3
3
8
1
2
6
2
ITEM QTY. PART NO.
DESCRIPTION
1
1
253875
ALUMINUM RAMP, 3/8” X 10” X 69” LG
2
4
900061-5
FLAT HEAD SOCKET SCREW, 3/8”-16 X 1-1/4” LG
3
6
902001-2
FLAT WASHER, 3/8”
4
6
901002
LOCK NUT, 3/8”-16 NYLON
5
2
253516
RUBBER BUMPER, 1” HEIGHT
6
2
900061-6
FLAT HEAD SOCKET SCREW, 3/8”-16 X 1-1/2” LG
7
1
253876
HINGE ASSEMBLY, LH
8
1
253877
HINGE ASSEMBLY, RH
9
1
280548-01
PLATFORM WELDMENT - SPECIAL PROFILE
10
1
225985
PIPE-SCHED 80, 3/4” X 60” LG
11
1
201680-01
FLIPOVER ASSEMBLY, BUTT END
12
1
203405-05
PIN , 1” DIA X 3-1/4” LG
13
1
221416
ROLL PIN, 3/8” X 2” LG
14
1
253805
PIN WELDMENT, TORSION BAR
15
1
905033-1
ROLL PIN, 1/4” X 1-1/2” LG
16
1
253808
BUSHING SPACER, 1/4”
17
1
253173
TORSION BAR
26
2
7
4
12
8
6
(5 PLACES)
10
4
9
(5 PLACES)
11
3
5
MAIN FRAME (REF)
12 VDC POWER UNIT
OR
24 VDC POWER UNIT
(REF, GRAVITY DOWN)
1A
1
ITEM QTY. PART NO.
1B
DESCRIPTION
266406-01
PUMP ASSEMBLY, STANDARD TUK-A-WAY
266406-02
PUMP ASSEMBLY, STANDARD TUK-A-WAY (24 VOLT)
1
266419-01
COVER ASSY
1A
1
093201-01
GASKET, RUBBER CHANNEL, 57-1/2” LG.
1B
1
261740
LABEL, OIL LEVEL
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
900009-3
SCREW, CAP 5/16”-18 X 3/4” LG, GRADE 8
7
2
900014-4
SCREW, CAP 3/8”-16 X 1” LG, GRADE 8
8
1
902011-4
LOCK WASHER, 3/8”
9
5
902002-1
FLAT WASHER, 5/16”
10
1
902013-11
FLAT WASHER, 3/8”
11
1
903400-02
LOCK WASHER, EXTERNAL TOOTH, 3/8”
12
1
908022-02
PLUG, FLEXIBLE
REF
1
1
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP COVER & MOUNTING PLATE ASSEMBLY (GRAVITY DOWN)
PUMP COVER & MOUNTING PLATE ASSEMBLY (POWER DOWN)
2
7
3
8
10
4
6
(5 PLACES)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
11
9
(5 PLACES)
5
5
MAIN FRAME (REF)
12 VDC POWER UNIT
(REF, POWER DOWN)
1A
1
ITEM QTY. PART NO.
DESCRIPTION
REF
1
268180-01
PUMP ASSEMBLY, POWER DOWN TUK-A-WAY
1
1
266419-01
COVER ASSY
1A
1
093201-01
GASKET, RUBBER CHANNEL, 57-1/2” LG.
1B
1
261740
LABEL, OIL LEVEL
2
1
268179-01
PLATE, PUMP MOUNT
3
1
908022-02
PLUG, FLEXIBLE
4
3
266428-02
GROMMET, 1/4”HOLE
5
2
266428-06
GROMMET, 9/16” HOLE
6
5
900009-3
SCREW, CAP 5/16”-18 X 3/4” LG, GRADE 8
7
2
900014-4
SCREW, CAP 3/8”-16 X 1” LG, GRADE 8
8
1
902011-4
LOCK WASHER, 3/8”
9
5
902002-1
FLAT WASHER, 5/16”
10
1
902013-11
FLAT WASHER, 3/8”
11
1
903400-02
LOCK WASHER, EXTERNAL TOOTH, 3/8”
28
1B
SEE 12 VDC POWER UNIT
(GRAVITY DOWN)
8
1
1A
3
6
7
5
2
4
ITEM QTY.
PART NO.
DESCRIPTION
266401-01
CYLINDER, 3” DIA X 10” STROKE (72-25)
266401-02
CYLINDER, 3-1/2” DIA X 10” STROKE (72-30)
1
260916-03
BEARING, SELF LUBE
2
1
906722-01
ELBOW, 90 DEG O-RING, #6 M-M
3
1
906709-02
FLOW REGULATOR VALVE, 2 GPM
4
1
280635-01
HOSE ASSY, 3/8” HP, 54” LG.
5
1
224370-07
HOSE, PLASTIC 60-1/2” LG.
6
1
228012
ADAPTER, STRAIGHT THREAD, 9/16”-18 M - 1/4” F
7
1
202406
ELBOW, BRASS 1/4” x 1/4”
8
1
906728-01
DUAL BARBED FITTING, 1/64” I.D.
1
1A
1
29
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)
CAUTION
To prevent damage to metal case starter solenoid, hold bottom terminal
nut securely when loosening and tightening top terminal nut. Do not
over-tighten the terminal nuts. For the 5/16” load terminals, torque nuts
35-40 lbs.-in. Torque the nuts on #10-32 control terminals 15-20 lbs.-in.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
To prevent damage when installing 2-way valves, torque valve cartridge
nut to 30 lbs.-in. max.
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
3
12
15
9
4
13
10
CONTROL SWITCH
WIRING HARNESS
(REF. CONTROL SWITCH
& POWER CABLE)
5
1A,1B
2
6
1
14
7
11
8
30
BARB FITTING
(REF. GRAVITY
DOWN HYDRAULIC
COMPONENTS)
DESCRIPTION
REF
1
268070-01
12 VDC POWER UNIT (GRAVITY DOWN)
1
1
290002
3-PIECE GEAR PUMP
1A
1
226594
OIL SEAL KIT
1B
1
290020
O-RING
2
1
268027-01
WIRE ASSEMBLY, 18 GA, #10 RING - 5/16” RING
3
1
280404
CABLE ASSEMBLY
4
1
268029-01
SOLENOID SWITCH
5
1
905152
ELBOW, 90 DEG, O-RING
6
1
280806-01
FILLER CAP
7
1
267733-11
RESERVOIR, 3 QT, VERTICAL WITH VENT
8
1
908017-01
DRAIN PLUG
9
1
280416
WIRE ASSEMBLY
10
1
290043
VALVE ASSEMBLY, 2 WAY
11
1
908018-01
GROMMET, 5/16” I.D.
12
1
280374
MOTOR, 12 VOLT DC
13
1
906740-01
RELIEF VALVE (RED SPRING)
14
1
908016-01
GROMMET, 3/4” I.D.
15
1
268024-01
WIRE ASSY, 16GA WHITE, 3” LG
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
24 VDC POWER UNIT (GRAVITY DOWN)
CAUTION
To prevent damage when installing 2-way valves, torque valve cartridge
nut to 30 lbs.-in. max.
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
12
3
2
CONTROL SWITCH
WIRING HARNESS
(REF)
4
9
13
10
5
6
11
14
1
7
8
32
15
DESCRIPTION
REF
1
280610-24
24 VDC POWER UNIT (GRAVITY DOWN)
1
1
290065
3-PIECE GEAR PUMP
2
1
280566-01
WIRE ASSEMBLY, 16 GA, GREEN
3
1
280404
CABLE ASSEMBLY
4
1
281571-01
MOTOR STARTER SOLENOID, 24 VOLT DC
5
1
905152
90 DEG 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
281572-01
24 VDC COIL
11
1
906719-01
VALVE
12
1
281573-01
MOTOR, 24 VOLT DC
13
1
906737-01
RELIEF VALVE
14
1
908016-01
GROMMET, 19/32”
15
1
908018-01
GROMMET, 5/16”
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
34
SEE 12 VDC POWER UNIT
(POWER DOWN)
3
4
2
5
6
1A
ITEM QTY.
1
PART NO.
DESCRIPTION
266401-01
CYLINDER, 3” DIA X 10” STROKE (72-25)
266401-02
CYLINDER, 3-1/2” DIA X 10” STROKE (72-30)
1
260916-03
BEARING, SELF LUBE
2
1
906722-01
ELBOW, 90 DEG, O-RING, #6 M-M
3
1
906709-02
FLOW REGULATOR VALVE, 2 GPM
4
1
280635-01
HOSE ASSEMBLY, 3/8”HP, 54” LG
5
1
905152
ELBOW, 90 DEG, SAE #6-JIC37 #6
6
1
280634-01
HOSE ASSEMBLY, 3/8”HP, 50” LG
1
1A
1
35
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)
CAUTION
To prevent damage to plastic case starter solenoid, do not over-tighten
the terminal nuts. For the 5/16” load terminals, torque nuts 35-40 lbs.-in.
Torque the nuts on #10-32 control terminals 15-20 lbs.-in.
CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
To prevent damage when installing 2-way valves, torque valve cartridge
nut to 30 lbs.-in. max.
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
7
1
15
2
CONTROL SWITCH
WIRING HARNESS
(REF. CONTROL SWITCH
& POWER CABLE)
15
13
6
14
3
3B
4B
4
5
3A
4A
9
15
8
10
12
11
36
QTY
PART NO.
DESCRIPTION
REF
1
268181-01
12 VDC POWER UNIT (POWER DOWN)
1
1
268176-01
MOTOR, 12 VDC
2
1
268029-01
SWITCH, SOLENOID
3
1
906821-01
2P2W VALVE & COIL ASSEMBLY, 4 WAY, DOUBLE SPADE
3A
1
906822-01
2P2W VALVE
3B
1
290045
COIL, DOUBLE SPADE, 2 WAY
4
1
290046
VALVE ASSEMBLY, 4 WAY, DOUBLE SPADE
4A
1
290047
VALVE CARTRIDGE, 4 WAY
4B
1
290048
COIL, DOUBLE SPADE, 3 OR 4 WAY
5
2
280416
WIRE ASSEMBLY
6
1
268079-01
WIRE ASSEMBLY, 18 GA, #10 RING - 5/16” RING
7
1
280404
CABLE ASSEMBLY
8
1
267733-01
RESERVOIR, 3 QT, VERTICAL WITH VENT
9
1
280806-01
FILLER CAP
10
1
908016-01
GROMMET, 3/4” I.D.
11
1
908017-01
DRAIN PLUG
12
1
908018-01
GROMMET, 5/16” I.D.
13
1
906738-02
RELIEF VALVE, ADJUST, 3200PSI
14
1
268174-01
RELIEF VALVE, ADJUST, 1100PSI
15
2
905152
ELBOW, 90 DEG, O-RING
37
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
DECALS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
UP/DOWN DECAL
P/N 264507
CAPACITY DECAL
P/N 220382
CAPACITY DECAL
P/N 220388
WARNING DECAL
(2 PLACES, LH SIDE NOT SHOWN)
P/N 265736-03
INSTRUCTION DECAL
P/N 251867-05
WARNING DECAL
P/N 264081
FIG. 38-1
38
NOTE: Use switch to RAISE and LOWER Liftgate to make sure switch
operates as shown on the decal.
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
BLACK
WHITE
(FOR REFERENCESEE DECALS)
(TO
POWER
UNIT)
BLACK
WHITE
2
1
GREEN
4
GREEN
RED
(POWER DOWN
VERSION ONLY)
3
ITEM QTY. PART NO.
1
1
DESCRIPTION
268025-01
CABLE ASSEMBLY, 85” LG (12 VDC GRAVITY DOWN)
280637-01
CABLE ASSEMBLY, 84” LG (24 VDC GRAVITY DOWN)
268170-01
CABLE ASSEMBLY, 85” LG (POWER DOWN)
267959-01
MOLDED SWITCH ASSEMBLY (GRAVITY DOWN)
264951-04
MOLDED SWITCH ASSEMBLY (POWER DOWN)
2
1
3
2
900057-5
SCREW, SELF-TAPPING #10-24 X 1” LG.
4
1
905206
SWITCH BOOT SEAL
5
1
264422
CABLE ASSEMBLY, 200 AMPS, 38’ LG
6
1
264687
KIT, MEGAFUSE (200 AMP FUSE & HEATSHRINK TUBING)
SHORT END TO
VEHICLE BATTERY
6
5
! WARNING
Do not attach cable to battery until
Liftgate repairs are completed.
LONG END TO PUMP
MOTOR SOLENOID
39
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL SWITCH AND POWER CABLE
HYDRAULIC SYSTEM DIAGRAMS
HYDRAULIC SCHEMATIC (GRAVITY DOWN)
HYDRAULIC CYLINDER
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
2 GPM FLOW
CONTROL VALVE
RETURN PORT
(PLUGGED)
VENT PORT
PRESSURE PORT
VALVE A
RELIEF VALVE
(SET AT 3250 PSI)
CHECK VALVE
AUX. HAND
PUMP PORT
(PLUGGED)
PUMP
M
MOTOR
(REFERENCE)
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 40-1
40
FILLER HOLE
(PLUGGED)
HYDRAULIC CYLINDER
2 GPM FLOW
CONTROL
VALVE
PORT B - LOWER
(POWER DOWN)
PORT A - RAISE
VALVE A
RELIEF VALVE 2
(SET AT 1100 PSI)
VALVE E
RELIEF VALVE 1
(SET AT 3200 PSI)
MOTOR
(REF)
PUMP
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 41-1
41
AUX. HAND
PUMP PORT
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC (POWER DOWN)
ELECTRICAL SYSTEM DIAGRAMS
ELECTRICAL SCHEMATIC (GRAVITY DOWN)
CONTROL SWITCH
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WHITE
GREEN BLACK
WHITE
GREEN BLACK
CABLE
ASSEMBLY
THERMAL
SWITCH
(IN MOTOR
CASING)
SOLENOID,
VALVE A
STARTER
SOLENOID
CABLE WITH
200 AMP FUSE
MOTOR
BATTERY
FIG. 42-1
42
RED
BLACK
(DOWN)
(UP)
WHITE
CONTROL SWITCH
BLACK
WHITE
GREEN
RED
GREEN
CABLE
ASSEMBLY
THERMAL
SWITCH
(IN MOTOR
CASING)
STARTER
SOLENOID
SOLENOID,
VALVE A
GREEN
CABLE WITH
200 AMP FUSE
BATTERY
FIG. 43-1
43
SOLENOID,
VALVE E
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SCHEMATIC (POWER DOWN)
TROUBLESHOOTING
PLATFORM WILL NOT RAISE
1. Use voltmeter to verify power is being supplied to solenoid terminal “B”
(FIG. 44-1). Recharge the battery if there is less than 12.6 volts.
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.
2. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
3. Touch a jumper wire to terminals “B” & “D” (FIG. 44-1). 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. 44-1).
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 manually bleed hydraulic system by
correctly positioning Liftgate platform before disconnecting any lifting cylinder high pressure hydraulic lines. The following procedure can save time 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.
STARTER
SOLENOID
TERMINAL “A”
MOTOR (+)
TERMINAL “C”
GROUND (-)
TERMINAL “D”
SWITCHED
BATTERY (+)
TERMINAL “B”
BATTERY (+)
LOWERING
SOLENOID
FIG. 44-1
44
1. Check if solenoid valves are constantly energized by touching a screwdriver to the top nut of the solenoid (FIG. 451). 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
FIG. 45-1
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 time and
prevent accidental fluid spills and hazards.
2. Check the valve stem by removing the coil assembly (Item 1, FIG. 45-2). With platform on
ground, unscrew the valve stem, (Item 2, FIG.
45-2) 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 reinstalling 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 vent/down port of the cylinder (FIG. 453). Raise the platform even with the bed. Allow
pump motor to run two seconds more while
you watch for hydraulic fluid at the vent/down
port. A few drops of hydraulic fluid escaping
the vent/down port is normal; however, if it
streams from the vent/down port, piston seals
are worn. Replace seals.
45
2
1
1/8”
FIG. 45-2
VENT/DOWN PORT
RAISE PORT
FIG. 45-3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES BUT LEAKS DOWN
TROUBLESHOOTING
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.
1. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
2. Use voltmeter to verify the battery shows 12.6 volts or more.
3. Check for structural damage and 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/down port of the cylinder (FIG. 46-1). Raise the platform even with
the bed. Allow pump motor to run two seconds
more while you watch for hydraulic fluid at the
vent/down port. A few drops of hydraulic fluid
escaping the vent/down port is normal; however, if it streams from the vent/down 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.
46
VENT/DOWN PORT
PRESSURE
PORT
FIG. 46-1
1. Use voltmeter to verify the battery shows 12.6 volts or more under load from pump motor.
2. Check for structural damage and 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 0-4000 PSI pressure gauge. Hold the switch in
the “UP” position. Adjust the relief valve on the
side of the pump until the gauge shows 3250 PSI
(FIG. 47-2). Remove guage and reinstall pressure hose.
VENT/DOWN PORT
PRESSURE
PORT
4. Check for dirty pump motor relief valve. Clean if
necessary. Replace any worn out relief valve
parts.
FIG. 47-1
5. Check the hydraulic cylinder. With the platform
on the ground, remove the breather plug or vent
line from the vent/down port of the cylinder (FIG.
47-1). Raise the platform even with the bed.
Allow pump motor to run two seconds more while
you watch for hydraulic fluid at the vent/down port.
A few drops of hydraulic fluid escaping the vent/
down port is normal; however, if it streams from
the vent/down port, piston seals are worn. Replace seals.
RELIEF
VALVE
ADJUST
SCREW
(REMOVE
PLUG)
6. If pump cannot produce 3250 PSI can’t lift load
capacity with a minimum of 12.6 volts available,
the pump is worn and needs to be replaced.
PRESSURE
GAUGE
47
FIG. 47-2
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATE WILL NOT LIFT RATED CAPACITY
TROUBLESHOOTING
PLATFORM RAISES SLOWLY
1. Use voltmeter to verify power is being supplied to
solenoid terminal “B”. Recharge the battery if voltmeter indicates less than 12.6 volts (FIG. 48-1).
TERMINAL
“B”
BATTERY (+)
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.
FIG. 48-1
2. Check the hydraulic cylinder. With the platform on the ground, remove the breather plug
or vent line from the vent/down port of the cylinder (FIG. 48-3). Raise the platform even
with the bed. Allow pump motor to run two seconds more while you watch for hydraulic
fluid at the vent/down port. A few drops of hydraulic fluid escaping the vent/down port is
normal; however, if it streams from the vent/down 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. 48-3.
4. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
5. Verify the pump motor is grounded to the vehicle frame.
6. Check for leaking hoses and fittings. Tighten or replace
as required.
PRESSURE
GAUGE
RELIEF
VALVE
ADJUST
SCREW
(REMOVE
PLUG)
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 0-4000
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 3250 PSI (FIG. 48-2).
Remove guage and reinstall pressure hose.
FIG. 48-2
VENT/DOWN
PORT
PRESSURE
PORT
FLOW
CONTROL
VALVE
FIG. 48-3
48
1. Use voltmeter to verify power is being supplied to
solenoid terminal “B”. Recharge the battery if voltmeter displays less than 12.6 volts ( FIG. 49-1).
TERMINAL
“B”
BATTERY (+)
2. Check for structural damage or poor lubrication.
Replace worn parts.
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. 49-2). A good solenoid will attract
(magnetically) the screwdriver to the nut and make it
difficult to pull the screwdriver away from the nut.
FIG. 49-1
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. 49-2). With platform supported,
unscrew the valve stem (Item 2, FIG. 49-2) 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. 49-2
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. 49-3) is
pointing to the direction of restricted fluid
flow (back toward pump). If required, remove
flow control valve and install it correctly (FIG.
49-3).
49
VENT/DOWN PORT
(REF)
RAISE PORT
(REF)
FLOW
CONTROL
VALVE
FIG. 49-3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY
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