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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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