Maxon 80 SERIES (80-4) Maintenance Manual

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Maxon 80 SERIES (80-4) Maintenance Manual | Manualzz
M-97-29
REV. D
MAR. 2000
MAINTENANCE
MANUAL
80-4 LM
11921 Slauson Avenue.
Santa Fe Springs, CA. 90670
(800) 227-4116
C
MAXON Lift Corp. 2000
LIFT CORP.
11921 Slauson Ave.
Santa Fe Springs, CA. 90670
CUSTOMER SERVICE:
TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116
FAX: (888) 771-7713
NOTE: Check with Customer Service for updated versions
of Manuals on an annual basis.
WARRANTY POLICY & PROCEDURE
NEW LIFTGATE WARRANTY
Term of Warranty: 2 Years from Date of In-Service
Type of Warranty: Full Parts and Labor
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 Labor
Schedule. (Call MAXON Customer Service for a copy).
All claims for warranty must be received within 30 Days of the repair date, and include the
following information:
1. Liftgate Model Number
2. Liftgate Serial Number
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.
All warranty repairs must be performed by an authorized MAXON warranty station. For major
repairs, MAXON Customer Service must be notified and an “Authorization Number” obtained. Major
repairs would generally be considered repairs made to the structural assembly of the liftgate and/or
repairs not outlined in the MAXON Liftgate Warranty Flat Rate Schedule.
Major components (i.e. hydraulic pumps, cylinders, valves, or failed structural parts) must be
returned, freight pre-paid, prior to the claim being processed. To ensure timely processing of these
warranty claims, an R.M.A. (Returned Merchandise Authorization) number must be obtained from
MAXON Customer Service prior to the return of any defective part. Defective Parts must be returned
within 60 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, defects due to misuse or abuse, or loss of income due to downtime.
Fabrication of 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.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase
Type of Warranty: Part Replacement
MAXON will guarantee all returned genuine replacement parts upon receipt and inspection of
parts and invoice.
Table of Contents
INTRODUCTION ........................................................................................................PAGE 4
WARNING .................................................................................................................. PAGE 5
PERIODIC MAINTENANCE CHECKLIST..................................................................PAGE 6
DECALS, 80 SERIES .................................................................................................PAGE 7
HYD. HOSE ROUTING, GRAVITY DOWN ................................................................PAGE 8
253171 PUMP, GRAVITY DOWN ............................................................................PAGE 10
CONTROL SWITCH GRAVITY DOWN ...................................................................PAGE 12
FUSED POWER CABLE..........................................................................................PAGE 13
WIRE CONNECTIONS GRAVITY DOWN ...............................................................PAGE 14
HYD. HOSE ROUTING, POWER DOWN ................................................................PAGE 15
CONTROL SWITCH, POWER DOWN ....................................................................PAGE 17
FUSED POWER CABLE..........................................................................................PAGE 18
WIRE CONNECTIONS, POWER DOWN ................................................................PAGE 19
253170 PUMP, POWER DOWN ..............................................................................PAGE 20
80-4LM ASSEMBLY .................................................................................................PAGE 22
PUMP PRESSURE ADJUST SETTING ...................................................................PAGE 24
TROUBLESHOOTING ............................................. PAGE 25
PLATFORM WILL NOT RAISE ................................................................................PAGE 26
PLATFORM RAISES BUT LEAKS DOWN ..............................................................PAGE 27
PLATFORM RAISES PARTIALLY AND STOPS ......................................................PAGE 28
LIFTGATE WILL NOT LIFT RATED CAPACITY ......................................................PAGE 29
PLATFORM RAISES SLOWLY ................................................................................PAGE 30
PUMP WILL NOT OPERATE ...................................................................................PAGE 31
PLATFORM LOWERS TOO FAST OR TOO SLOW ................................................PAGE 32
PLATFORM WILL NOT LOWER ..............................................................................PAGE 33
INTRODUCTION
This publication contains the information required to maintain the 80-4LM. If
there is any doubt regarding the suitability of these lifts being maintained on
it’s intended vehicle, or any portion of these instructions that you do not understand, please contact the MAXON Customer Service Department for
consultation.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Unauthorized modification to this equipment may cause premature failure or
create hazards in its use that are not foreseen at the time of installation.
These kinds of changes should be discussed with our Engineering Department before being undertaken.
PAGE 4
1.
Read the Maintenance Manual and understand it thoroughly before any maintenance of
this unit is done.
2.
Read the YELLOW urgent warning decal on the side of the vehicle close to the unit before
operating.
3.
If decals are dirty, clean them. If decals are defaced or missing, replace them. Free replacements are available from the manufacturer. See information at the end of the Warnings
4.
Be aware that the safety and location of other people or objects should be considered
before operation of this unit. Stand to one side of platform while operating this unit.
5.
Do not stand under, or have any foreign object under the Platform when lowering. Be sure
that the lowering of the Platform and/or Flipover will miss your feet!
6.
Keep fingers, hands, arms, legs, and feet clear of moving parts when operating this unit.
7.
If during your maintenance procedure, it becomes necessary to ride the platform, keep your
feet and any foreign objects clear of the rear edge of the platform. Otherwise your feet or
the foreign objects could become trapped between the edge of the platform and the vehicle
bed.
8.
Inspect all Roll Pins monthly, to insure that they are not broken. Replace if broken.
9.
Inspect all hydraulic hoses and fittings annually. Check for cracks and deterioration, and
replace if necessary.
10.
Disconnect battery when replacing parts or servicing.
11.
Do not allow children to ride, play with, or operate this unit.
12.
In the event of an emergency while operating the unit, release the toggle switch and the unit
will stop immediately.
13.
A properly installed Lift should operate smoothly and the only noise during the operation of
this unit should be from the Pump Unit during the raising of the Platform. Any scraping,
grating or audible indications of rough operation will need investigating. The cause will need
resolving before any further deterioration of performance occurs.
14.
Use only Maxon Authorized Parts for replacement. Replacement parts should be ordered
from:
MAXON LIFT CORP. Parts Department
11921 Slauson Ave., Santa Fe Springs, Ca. 90670
Phone: (800) 227-4116
PAGE 5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WARNING
PERIODIC MAINTENANCE CHECKLIST
Annually
Visually check the complete unit for excessive wear, worn parts or broken welds.
Check all Hinge Pins for excessive wear or broken welds. For parts replacement,
see the Assembly Breakdown Drawings.
Six Months
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Visually check the Platform Hinge Pins for excessive wear or broken welds. For
parts replacement, see the Assembly Breakdown Drawings.
Quarterly
Check the oil in the Pump Reservoir. The oil should be Grade ISO-(32) Hydraulic
Fluid. *See below for Cold Weather operation.
Check Hoses and Fittings for scuffing and leaks. Replace if necessary.
Check the electrical wiring for worn insulation, and the terminals for corrosion and
secure fit.
Check all bolts for tightness.
Check that all Warning Decals are in place and readable.
Check that all roll pins are properly installed. Replace if necessary.
Inspect the Hook & Chain Assembly for proper operation.
*
COLD WEATHER OPERATION
OIL SPECIFICATIONS:
Grade ISO-(32)
Gravity, API - 29.5 Degrees
Pour Point, F- (-54 Degrees)
PAGE 6
VISCOSITY:
@ 40 Degrees C - 31.2 cSt
@100 Degrees C - 6.2 cSt
VISCOSITY INDEX - 154 VI
Flash Point, F - 325 Degrees
DECALS, 80 SERIES
Operating Decal
P/N 262433
Capacity
Decal
Safety Hook Decal
P/N 263988
(Placed on both sides of
Extension Plate)
These Decals are located
on the rear corner post of the
vehicle, at the control position.
They should be read completely
and understood before operating
the Lift Gate. They should also be
kept clean and readable at all
times. If any decal should become
detatched from the vehicle, or
defaced, it must be replaced. Free
replacements are available from:
MAXON Lift Corp., Parts Dept.
Unhook Safety Chain
Before Lowering Liftgate
P/N 263998
THE MAXIMUM CAPACITY
OF THIS LIFT IS
4000
LBS.
WHEN THE LOAD IS
CENTERED ON THE LOAD
CARRYING PLATFORM
OPERATING INSTRUCTIONS
GPT & 80-3/4 Units
1
P/N 250993
P/N 220389
!
WARNING
READ CAREFULLY
Unhook Safety
Chain First.
2
!
• Improper operation of this Lift can result in serious personal injury.
Do not operate unless you have been properly instructed and have
read, and are familiar with the operating instructions. If you do not
have a copy of the instructions, please obtain them from your
employer, distributor, or lessor, before you attempt to operate Lift.
• Be certain that the vehicle is properly and securely braked before
using the Lift.
• Always inspect this Lift for maintenance or damage before using it. If
there are signs of improper maintenance, damage to vital parts, or
slippery Platform surface, do not use the Lift until these problems
have been corrected.
• Do not overload the Lift. The load limit is based on evenly distributed cargo over the entire Platform surface. If you are using a pallet
jack, be sure it can be maneuvered safely. Do not operate a forklift on
the Platform or travel with the platform in an open position at any time.
• Load should be placed in a stable position close to the edge of the
Platform nearest the truck. The heaviest portion of the load should
never be placed beyond the center of the Platform away from the
truck.
• Never allow yourself, a helper, or bystander to stand in a position
where a falling load could land on either of you. Also do not allow any
part of yours or your helper’s body to be placed under, within, or
around any portion of the moving liftgate, or it’s mechanisms, or in a
position that would trap them between the platform and the ground or
truck when the liftgate is operated.
• If a helper is riding the Platform with you, make sure you are both
doing so safely and that you are not in danger of coming in contact
with any moving or potentially moving obstacles. USE GOOD
COMMON SENSE. If load appears to be unsafe, do not lift or lower it.
MAXON LIFT CORP.
PART NO. 264081
Activate Toggle
Switch to Lower
Stowed Lift Gate
This point must
touch the ground
3
Open Platform
4
Open Flipover
5
6
Activate Toggle
Switch to Raise or
Lower Platform
To Tuck Unit Away after Use,
Reverse Steps 1 thru 4
P/N 251838
PAGE 7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Warning Decal
P/N 260008
HYD. HOSE ROUTING, GRAVITY DOWN
253352 Flow Control
Valve, 3/8 NPT
054036 Elbow,
Swivel
226948-24 Hose Asy.
H.P. 3/8”x 29” Lg.
202406 Elbow, 1/4”
&
800183 Bushing, 3/8” x 1/4”
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
To
L
253342-01
Pump Asy. G.D.
224370-14 Hose,
Plastic, 1/4”x 25” Lg.
202386 Fitting, 1/4”x 1/4”
ow
er
Tee
801292 Nipple
Close, 3/8 NPT
To
U
pp
er
Tee
262437
Cyl. Hose Clamp
040395
Elbow,
3/8 NPT
x #8 JIC
264806 3-1/2” x 10” Cylinder, 80-4
224370-12
Hose Plastic
1/4”x 55”Lg.
202406 Elbow, 1/4”
&
800183 Bushing,
3/8”x 1/4”
253715-01 Hose Asy.
H.P. 3/8”x 27” Lg.
PAGE 8
224370-12 Hose
Plastic 1/4”x 55”Lg.
260144 Connector,
JIC #8 x 3/8 NPT
224370-13 Hose
Plastic 1/4”x 75”Lg.
227001-01 Pipe,
Thd’d. 22” Lg.
227001-03 Pipe,
Thd’d. 42” Lg.
253715-01 Hose Asy.
H.P. 3/8” x 27” Lg.
202376
Brass Tee, 1/4”F
227003 Tee, 3/8”F
&
228151 Swivel 3/8 Str.
253715-01 Hose Asy.
H.P. 3/8”x 27” Lg.
224370-14 Hose,
Plastic, 1/4”x 25” Lg.
PAGE 9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYD. HOSE ROUTING, GRAVITY DOWN
253171 PUMP, GRAVITY DOWN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
QTY.
PART NUMB ER
1
1
250093
MOTOR, HEAVY DUTY 12 VOLTS DC
2
1
253353
VALVE, SOL ENOID 2-WAY
*2a
1
226594
O-RING K IT, 2-WAY VALVE
3
1
229200
COUPL ING
4
1
251885
CHECK VALVE K IT
4a
4a
1
260257
S TE E L B A L L
4b
4b
1
260254
SPRING
4c
4c
1
260258
PL U G
4d
4d
1
260255
RETAINER
4e
4e
1
260256
SOCK ET HEAD CAPSCREW
1
260229
REL IEF VALVE K IT
5a
5a
1
260231
SPRING
5b
5b
1
260235
O-RING
5c
5c
1
260234
VALVE CAP
5d
5d
1
260232
ADJ USTING SCREW
5e
5e
1
260233
SPRING GUIDE
5f
5f
1
260230
S TE E L B A L L
6
1
260847
FIL L ER/B REATHER CAP
7
1
251882
RESERVOIR, 3 QT.
8
1
260250
FILTER
9
1
260236
PUMP ASSEMB LY
10
10
1
251884
0-RING
11
11
1
260252
DRIVEPL ATE ASSEMB LY 5"
12
12
1
260261
OIL SEAL
13
13
1
229199
B U S B AR
14
14
1
260270
SOL ENOID SWITCH
*15
4
229202
CAPSCREW, HEX. WASHER HD.
5
DESCRIPTION
PAGE 10
4
4b
4a
4e
13
12
8
PAGE 11
5
4c
4d
5c
5b
5a
5d
2
5e
1
5f
3
14
6
11
10
9
7,15
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
253171 PUMP, GRAVITY DOWN
CONTROL SWITCH GRAVITY DOWN
Assemble Switch in Mount Bracket as shown. When mounting the
bracket to the Channel, note the location of the Wht. & Blk. wires to ensure
proper wiring to match the “UP/DOWN” Decal.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
226889
Switch
251711
Guard
250876
Switch Boot
Seal
250916-01
Switch & Harness
Assembly
030029
Screws
051076-105
Harness
Corner
Post
Looking at Switch from the Platform, the Wht.
Wire must be on the left or “Door” side.
251028
Channel
Wht.
Grn.
1
Battery Cable
2
250993
Decal
Blk. ( Key Side
of Switch)
3
Corner Post
Grn.
Wht.
Pump Unit Motor Solenoid
PAGE 12
Extension Plate
051076-105
Harness to Pump Unit
250993
Short End to
Vehicle Battery
Battery Cable Assembly (32’ Std.)
(Includes Replacement Fuse Kit)
P/N 264422
200AMP Replacement Fuse
Kit (P/N 264687)
WARNING
Do not attach cable to
battery until liftgate is
completely installed.
Long End to Motor
Solenoid
ADDITIONAL AVAIL IAB L E B ATTERY CAB L E K ITS
PART
NUMB ER
40' CAB L E ASSEMB LY
264848
10' EXTENSION CAB L E ASSEMB LY
264849
PAGE 13
Cable Assembly
Extension Cable Assembly
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FUSED POWER CABLE
WIRE CONNECTIONS GRAVITY DOWN
Toggle Switch
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Black
Green
White
To Battery
(+)
Ground
Wire
1234567890123
1234567890123
1234567890123
1234567890123
1234567890123
1234567890123
POWER TO
UP
WHT.
DOWN
BLK.
PAGE 14
253755 Adaptor,
SAE #8 x 3/8 NPT
050207
Elbow, Swivel
260184
Pump Asy. P.D.
253755 Adaptor,
SAE #8 x 3/8 NPT
228151 Swivel,
3/8 NPT (M-F)
227003 Tee,
3/8 NPT
260490 Needle
Valve, 3/8 NPT
226948-09 Hose Asy.
H.P. 1/4”x 18-1/2” Lg.
To
U
227382 Adaptor,
1/4 NPT x 3/8 NPT
260490 Needle
Valve, 3/8 NPT
pp
er
Tee
To
L
ow
er
Tee
030283 Nipple, 3/8
NPT x 1-1/2” LG
227004 Elbow,
3/8 NPT (M-F)
226948-24 Hose Asy.
H.P. 3/8”x 29” Lg.
262437
Cyl. Hose Clamp
040395 Elbow,
3/8 NPT x #8 JIC
264806 3-1/2” x 10” Cylinder, 80-4
253715-01 Hose Asy.
H.P. 3/8”x 27” Lg.
253715-02 Hose Asy.
H.P. 3/8” x 31” Lg.
PAGE 15
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYD. HOSE ROUTING, POWER DOWN
HYD. HOSE ROUTING, POWER DOWN
260144 Connector,
JIC #8 x 3/8 NPT
227001-03 Pipe,
Thd’d. 42” Lg.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
253715-02 Hose Asy.
H.P. 3/8” x 31” Lg.
253715-01 Hose Asy.
H.P. 3/8”x 27” Lg.
227001-10 Pipe,
Thd’d. 20-3/4” Lg.
227001-09 Pipe,
Thd’d. 23-3/4” Lg.
226948-24 Hose Asy.
H.P. 3/8”x 29” Lg.
227003 Tee, 3/8”F
PAGE 16
250876
SWITCH BOOT
SEAL
224849
SWITCH
252561
SWITCH &
HARNESS ASY.
030029
SCREWS
CORNER POST
252527-01
HARNESS
LOOKING AT SWITCH FROM THE PLATFORM, THE
RED WIRE MUST BE ON THE LEFT OR DOOR SIDE.
4 5
RED
1
224845-03
JUMPER
250993
DECAL
251868
CHANNEL
BLK
GRN
WHT
6
2 3
CORNER POST
BATTERY
CABLE
EXTENSION PLATE
GRN WIRE
WHT WIRE
PUMP UNIT MOTOR
SOLENOID
HARNESS TO
PUMP UNIT
250993
PAGE 17
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL SWITCH, POWER DOWN
FUSED POWER CABLE
Short End to
Vehicle Battery
Battery Cable Assembly (32’ Std.)
(Includes Replacement Fuse Kit)
P/N 264422
200AMP Replacement Fuse
Kit (P/N 264687)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WARNING
Do not attach cable to
battery until liftgate is
completely installed.
Long End to Motor
Solenoid
ADDITIONAL AVAIL IAB L E B ATTERY CAB L E K ITS
PART
NUMB ER
40' CAB L E ASSEMB LY
264848
10' EXTENSION CAB L E ASSEMB LY
264849
PAGE 18
Cable Assembly
Extension Cable Assembly
TOGGLE SWITCH
Black
Red
Green
White
TO BATTERY
(+)
Ground
Wire
123456789012345678
123456789012345678
123456789012345678
123456789012345678
123456789012345678
POWER TO
UP
WHT, RED
DOWN
WHT, BLK
PAGE 19
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WIRE CONNECTIONS, POWER DOWN
253170 PUMP, POWER DOWN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
250093
HEAVY DUTY MOTOR, 12 VDC
2
1
260276
VALVE, SOL ENOID 4-WAY
*2a
1
226595
O-RING K IT, 4-WAY VALVE
3
1
253353
VALVE, SOL ENOID 2-WAY
*3a
1
226594
O-RING K IT, 2-WAY VALVE
4
1
260275
MANIFOL D B L OCK ASSEMB LY
5
1
260229
REL IEF VALVE K IT
5a
5a
1
260230
S TE E L B A L L
5b
5b
1
260231
SPRING
5c
5c
1
260235
O-RING
5d
5d
1
260234
VALVE CAP
5e
5e
1
260232
ADJ USTING SCREW
5f
5f
1
260233
SPRING GUIDE
6
1
261106
RESERVOIR, 2.5 GAL . W/.75 B REATHER
7
1
260847
FIL L ER/B REATHER CAP
8
1
260250
FILTER
9
1
260236
PUMP ASSEMB LY
10
10
1
251884
O-RING
11
11
1
260274
DRIVEPL ATE ASSEMB LY, 5"
12
12
1
260261
OIL SEAL
13
13
1
229200
COUPL ING
14
14
1
229199
B U S B AR
15
15
1
260270
SOL ENOID SWITCH
*16
4
229202
CAPSCREW, HEX HD. WASHER
*NOT SHOWN
PAGE 20
___________________________________________________________
5
5b
3
5c
5a
2
5d
4
1
5f
5e
15
6,16
7
13
14
12
11
10
9
PAGE 21
8
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
253170 PUMP, POWER DOWN
80-4LM ASSEMBLY
1
1c
1b 1a
1d
2
1e
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
7
5
8, 9
6
7
5
13
25
3
20
6
12, 12a
1
24
10
11
21
13
22
23
15
17
11
6
16
18
17
14
25
19
PAGE 22
ITEM
QTY.
PART NUMB ER
DESCRIPTION
1
2
203410
K IT, RUB B ER DOCK B UMPER (OPTIONAL )
1a
1a
4
030323
NUT, HEX, 1/2-20 UNF
1b
1b
4
030567
L OCK WASHER, 1/2"
1c
1c
2
222988
RUB ER B UMPER PAD
1d
1d
4
030566
FL ATWASHER, 1/2"
1e
1e
4
030083
B OLT, 1/2-20 UNF x 2" L ONG
2
1
226355
EXTENSION PL ATE WEL DMENT
3
2
262462
PIN WEL DMENT, CYL . 1.375 DIA.
4
2
262490
SADDL E ASSEMB LY
5
2
261806-01
PL ATFORM OPENER
6
4
226358
PIN WEL DMENT
7
2
226856
DOCK B UMPER ANGL E
8
1
253170
PUMP ASSEMB LY
9
1
260157
PUMP B OX ASSEMB LY
10
10
1
262429
MAINFRAME WEL DMENT
11
11
2
226372
ROUND TUB E x 1/4"
12
12
2
264806
CYL INDER, 3" x 10"
2
264807
SEAL K IT
13
13
2
261785-01
PARAL L EL ARM WEL DMENT
14
14
1
261797-02
SHACK L E WEL DMENT RH
15
15
1
261800-01
L IFTFRAME WEL DMENT
16
16
1
226363-01
TORSION SPRING RH
17
17
2
226364
PIN, SPRING
18
18
1
050175
NAMEPL ATE
19
19
1
20
20
12a
262356-01
FL IPOVER WEL DMENT 24"
262356-02
FL IPOVER WEL DMENT 30"
1
261797-01
SHACK L E WEL DMENT L H
21
21
1
226363-02
TORSION SPRING, L H
22
22
2
226375
23
23
1
24
24
2
262435
PIN WEL DMENT, CYL . 1.375 DIA.
25
25
2
226365
PIN, SHACK L E
ROL L ER x 1"
262338-01
PL ATFORM WEL DMENT 24"
262338-02
PL ATFORM WEL DMENT 30"
PAGE 23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
80-4LM ASSEMBLY
PUMP PRESSURE ADJUST SETTING
PUMP BLOCK
Lower the Platform to the ground to relieve
any pressure on the hoses. Remove the
existing hose and swivel assembly from
Port “B” (3/8” NPT). Install a 0-3000 PSI
Gauge, to port “B”.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Remove the Valve Cap, from the Pump
Block. Using the Raise/Lower Switch on
the Curb side of the vehicle, actuate the
motor and check the gauge reading. Adjust
the relief valve to a pressure setting of
2750 PSI.
GAUGE
PORT
“B”
REDUCE
PRESSURE
INCREASE
PRESSURE
VALVE
CAP
FIGURE 1
Activate the Raise/Lower Switch several times to verify that the pressure
shown on the gauge will remain at the proper setting. (Ref. Fig. 1).
WARNING!
Setting the pressure higher than recommended
could cause damage to lift components.
If the unit does not maintain the pressure
reading, it may be necessary to remove
and inspect the relief valve components
(Ref. Fig. 2).
Check for nicks or cuts on the Spring, and
Ball. Replace any damaged parts before
reassembling the unit.
Upon reassembly, you will have to seat
the Ball by inserting a 3/16” diameter rod
through the Spring and tapping the Ball
against the seat with a hammer.
SPRING
BALL
FIGURE 2
PAGE 24
TROUBLESHOOTING
PAGE 25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
___________________________________________________________
PLATFORM WILL NOT RAISE
1.
Verify that power is being supplied to the Solenoid Terminal “A”.
Recharge the battery if less than 12 volts.
2.
Fill Reservoir to within 1” below the top with the recommended
hydraulic fluid.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3.
Touch a jumper wire to terminals “A” & “C”. If motor runs, check
Switch, Switch connections, and White wire. Correct the 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.
5.
Check for structural damage. Replace worn parts.
6.
Check filter in the pump Reservoir. Replace if necessary.
7.
Check for a broken motor-to-pump coupler. Replace if necessary.
A worn pump is extremely noisy, and needs replacement.
Terminal “A”
Terminal “A”
Battery
Cable
Battery Cable
Terminal “C”
White Wire
Terminal “B”
White Wire
GRAVITY DOWN
Terminal
“C”
Terminal “B”
POWER DOWN
PAGE 26
1/4”
1.
Check Solenoid Valves for electrical shorts
by holding a screwdriver approximately 1/4” from
the top nut of the Solenoid. (See Fig. 1). The
solenoid should not draw the screwdriver to the
nut with a magnetic force, unless the toggle
switch is actuated. The Coil can be replaced by
removing the Nut and Wires.
Coil
FIGURE 1
2.
Check the Valve Stem by removing the
Coil Assembly, (Item 1, Fig. 2). 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 paper clip in
the end. If the Plunger does not move freely
approximately 1/8”, replace the Valve Stem.
2
1
1/8”
FIGURE 2
3.
Check the Hydraulic Cylinder. With the
Platform on the ground, remove the Breather
Plug or Vent Line from the Vent Port of the
Cylinder. Raise the Platform to be level with
the bed. If hydraulic fluid streams from the
Vent Port, the Piston Seals are worn. Replace
the Seals. (See Fig. 3).
Pressure Port
Vent Port
FIGURE 3
PAGE 27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES BUT LEAKS DOWN
PLATFORM RAISES PARTIALLY AND STOPS
1.
Lower the opened Platform to the ground. Fill the Reservoir to within 1”
from the top with the recommended Hydraulic Fluid.
2.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Verify that the Battery shows 12 volts or better under load from pump
motor. The use of a voltage load tester is recommended.
3.
Check for Structural damage, or lack of lubrication. Replace worn parts.
4.
Check Filter in the Pump Reservoir. Replace if necessary.
5.
Check for a broken motor-to-pump coupler. Replace if necessary. A
worn pump is extremely noisy, and needs replacement.
PAGE 28
1. Verify that the Battery shows 12 volts or better under load from pump
motor. The use of a voltage load tester is recommended.
2. Check for Structural damage or lack of lubrication.Replace worn parts.
3. Check the Hydraulic Cylinder.
Pressure Port
GRAVITY DOWN UNITS: With the Platform
on the ground, remove the Breather Plug
or Vent Line from the Vent Port of the Cylinder. Raise the Platform. If hydraulic fluid
streams from the Vent Port, the Piston
Seals are worn. Replace the Seals.
POWER DOWN UNITS: Remove the
Power Down Hose from the cylinder. Raise
the Platform. If hydraulic fluid streams from
the Power Down Port, the Piston Seals are
worn. Replace the Seals.
Vent or
Power
Down Port
FIGURE 1
4. 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 switch in the “UP” position. Adjust the Relief Valve on the side of the
Pump until the gauge shows 2800 to 3000 PSI . (See Fig. 2)
5. If Pump cannot produce 2800-3000 PSI with a minimum of 12 Volts
available, the Pump is worn and needs to be replaced.
FIGURE 2
Decrease
Increase
PAGE 29
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATE WILL NOT LIFT RATED CAPACITY
PLATFORM RAISES SLOWLY
1. Verify that power is being supplied to Terminal “A”.
Terminal “A”
Recharge the battery if less than 12 Volts registers on the
Voltage Tester. (See Fig. 1)
Battery
Cable
2. Lower the opened Platform to the ground. Fill the Pump
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Reservoir to within 1” from the top with the recommended
hydraulic fluid (for Gravity Down Units only).
White Wire
3. Verify the Pump Motor is grounded to the vehicle frame.
FIGURE 1
4. Check for leaking hoses and fittings. Tighten or replace
as required.
5. Check for structural damage or lack of lubrication.
Replace worn parts.
Decrease
6. Check the Filter in the Pump Reservoir. Replace if necessary.
Increase
FIGURE 2
7. 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 switch in the “UP”
position. Adjust the Relief Valve on the side of the Pump until the gauge shows 2800
to 3000 PSI . (See Fig. 2)
8. With the Platform on the ground, remove breather plug or vent line from vent port
of cylinder. Raise the Platform to bed level. If hydraulic fluid streams from the Vent
Port, the Piston Seals are worn. (See Fig. 3) Replace the Seals.
9. Check the Flow Control Valve. The arrow on the valve shows the direction of flow
that is restricted, and Must point back to the Reservoir. (See Fig. 4)
PRESSURE PORT
VENT PORT
FIGURE 4
FIGURE 3
PAGE 30
FLOW
CONTROL
VALVE
1.
Verify that power is being supplied to the Solenoid Terminal “A”
(Ref. Fig. 1). Recharge the battery if less than 12 volts.
2.
Touch a jumper wire to terminals “A” & “C” (Ref. Fig. 1). If motor runs,
check Switch, Switch connections, and White wire. Correct the connections or
replace the Switch.
3.
Touch heavy jumper cables to terminals “A” & “B” (Ref. Fig. 1).
a. If motor runs, replace the motor solenoid.
b. If motor does not run, repair or replace the pump motor.
4.
Check for a broken Pump Shaft or motor-to-pump coupler. Replace if
necessary. A worn pump is extremely noisy, and needs replacement.
(Tractor/Trailer Vehicles) Check electrical connections to Tractor.
Terminal “A”
Battery Cable
White Wire
Terminal “C”
Terminal “B”
FIGURE 1
PAGE 31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP WILL NOT OPERATE
PLATFORM LOWERS TOO FAST OR TOO SLOW
1. Check the Flow Control Valve. The Arrow on the valve shows the direction
of flow that is restricted and must point back to the Reservoir. (See Fig. 1)
2. Too Fast:
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
GRAVITY DOWN
The Flow Control Valve could be fully open. To slow the flow, turn the
knob in a clockwise direction to restrict the flow through the valve. (See
Fig. 1)
POWER DOWN
The Flow Control Valve could be closed. To increase the flow through
the valve, turn the knob in a counter-clockwise direction. (See Fig. 1)
3. Too Slow:
GRAVITY DOWN
The Flow Control Valve could be closed. To increase the flow through
the valve, turn the knob in a counter-clockwise direction. (See Fig. 1)
POWER DOWN
The Flow Control Valve could be fully open. To slow the flow, turn the
knob in a clockwise direction to restrict the flow through the valve. (See
Fig. 1)
4. Check for structural damage or lack of lubrication. Replace worn parts.
5. Check the Filter in the Pump Reservoir. Replace if necessary. A worn
Pump is extremely noisy, and needs replacement.
Flow
Control
Valve
FIGURE 1
PAGE 32
Terminal “A”
1.
Verify that power is being supplied
to the Solenoid Terminal “A”
(Ref. Fig. 1). Recharge the battery if
less than 12 volts.
Battery Cable
White Wire
2.
Check for structural damage or
lack of lubrication. Replace worn parts.
FIGURE 1
3.
Check Solenoid Valve for power by holding a screwdriver approximately
1/4” from the top nut of the Solenoid. Energize the unit. (See Fig. 2). A good
solenoid will draw the screwdriver to the nut by a magnetic force. The Coil can
be replaced by removing the Nut and Wires.
4.
Check the Valve Stem by removing the Coil Assembly, (Item 1, Fig. 3).
Unscrew the Valve Stem, (Item 2, Fig. 3), from the Pump. Push on the
plunger that is located inside the Valve Stem by inserting a paper clip in the
end. If the Plunger does not move freely approximately 1/8”, replace the Valve
Stem.
”
1/4
2
Coil
1
FIGURE 2
1/8”
FIGURE 3
PAGE 33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT LOWER
LIQUID SEALANT APPLICATION
1. Clean all threads with a soft brush and a suitable cleaning solvent.
2. Dry threads thoroughly with compressed air or shop towel.
3. Apply the Liquid Sealant (Compound PLS 2), to the external threads of
the Male Connector.
4. Assemble the fitting and torque it to the prescribed value.
5. Check for leakage. If leakage exists, remove the fitting and return to
Step # 1.
6. If fitting is loosened or removed, return to Step # 1.
P/N 260798-02
CAUTION
Due to the 80% lead content in PLS 2, follow these safety and first aid
precautions:
Eye Contact - Flush eyes immediately with large quantities of water,
lifting the upper and lower eyelids occasionally. If irritation persists, consult a physician.
Skin Contact - Flush the contaminated skin and wash with soap and
water.
Ingestion - If person is conscious, give large quantities of water to drink
and induce vomiting. Consult a physician immediately.

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