GPT SERIES (2005 Release, After October 1, 2005)

GPT SERIES (2005 Release, After October 1, 2005)
M-97-15
REV. H
OCTOBER 2005
© MAXON Lift Corp. 2005
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 on-line at www.maxonlift.com. On-line claims will be given priority processing.
All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s
Warranty Department within 30 days of repair date.
All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior
written approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with
original invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized
returns will be refused and will become the responsibility of the returnee.
Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in
plain view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned
parts are subject to no credit and returned back to the customer.
Defective Parts requested for return must be returned within 30 days of the claim date for consideration to:
MAXON Lift Corp.
16205 Distribution Way, Cerritos, CA 90703
Attn: RMA#__
MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income
due to downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.
MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.
All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not
returned in new condition will be subject to an additional reworking charge which will be based upon the labor and material cost required to return
the Liftgate or component to new condition.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase.
Type of Warranty: Part replacement only
MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts and original invoice.
All warranty replacements parts will be sent out via ground freight. If a Rush Shipment is requested all freight charges will be billed to the
requesting party.
TABLE OF CONTENTS
WARNINGS ...................................................................................................... 6
LIFTGATE TERMINOLOGY ................................................................................................... 7
SERVICE TIME CHART ........................................................................................................ 8
PERIODIC MAINTENANCE CHECKLIST ................................................... 10
CHANGING HYDRAULIC FLUID ......................................................................................... 11
ADJUSTMENTS ........................................................................................... 13
SADDLE ADJUSTMENT .................................................................................................... 14
REPLACING PLATFORM TORSION SPRING .................................................................... 15
PLATFORM ADJUSTMENT ................................................................................................ 16
PARTS BREAKDOWN .................................................................................. 18
GPT ASSEMBLY ................................................................................................................ 19
GPT-25/-3 MAIN FRAME ASSEMBLY................................................................................. 20
GPT-4/-5 MAIN FRAME ASSEMBLY................................................................................... 22
PLATFORM & FLIPOVER ASSY (NO CART STOP) ........................................................... 24
PLATFORM & FLIPOVER ASSY (SINGLE CART STOP) ................................................... 25
FLIPOVER (SINGLE CART STOP) ..................................................................................... 26
PLATFORM & FLIPOVER ASSY (DUAL CART STOP) ....................................................... 27
DOCK BUMPER ................................................................................................................. 29
HYDRAULIC COMPONENTS - POWER DOWN ................................................................. 30
PUMP ASSEMBLY - POWER DOWN ................................................................................. 32
PUMP BOX ASSEMBLY - POWER DOWN ........................................................................ 34
CONTROL SWITCH AND POWER CABLE ........................................................................ 35
DECALS ............................................................................................................................ 36
TABLE OF CONTENTS - Continued
SYSTEM DIAGRAMS ................................................................................... 39
HYDRAULIC SCHEMATIC - POWER DOWN ..................................................................... 39
ELECTRICAL SCHEMATIC - POWER DOWN.................................................................... 40
TROUBLESHOOTING .................................................................................. 41
PLATFORM WILL NOT RAISE ............................................................................................ 41
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 42
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 43
LIFTGATE WILL NOT LIFT RATED CAPACITY ................................................................... 44
PLATFORM RAISES SLOWLY ........................................................................................... 45
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS TOO QUICKLY .. 47
Comply with the following WARNINGS while maintaining Liftgates. See Operation Manual
M-97-16 for operating safety requirements.
!
WARNINGS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• Read and understand the instructions in this Maintenance Manual before performing maintenance on the Liftgate.
• Before operating the Liftgate, read and understand the operating instructions in Operation Manual
M-97-16.
• Comply with all WARNING and instruction decals attached to the Liftgate.
• Keep decals clean and legible. If decals are defaced or missing, replace them. Free replacement
decals are available from Maxon Parts Department.
• Consider the safety and location of bystanders and location of nearby objects when operating the
Liftgate. Stand to one side of the platform while operating the Liftgate
• Do not allow untrained persons to operate the Liftgate.
• Do not stand under, or allow obstructions under the platform when lowering the Liftgate. Be sure
your feet are clear of the Liftgate.
• Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.
• Wear apppropriate safety equipment such as protective eyeglasses, faceshield and clothing while
performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.
• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no flames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek first aid. If acid gets on your
skin, immediately wash it off with soap and water.
• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the control
Toggle Switch and the Liftgate will stop.
• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the pump unit while the platform is raised. Listen for scraping, grating
and binding noises and correct the problem before continuing to operate Liftgate.
• If it is necessary to stand on the platform while maintaining the Liftgate, keep your feet and any
objects clear of the inboard edge of the platform. Your feet or objects on the platform could be
trapped between the platform and the Liftgate extension plate.
• Never perform unauthorized modifications on the Liftgate. Modifications may result in early failure of
the Liftgate and may create hazards for Liftgate operators and maintainers.
• Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial
number information with your parts order. Order replacement parts from:
MAXON LIFT CORP. Customer Service
11921 Slauson Ave., Santa Fe Springs, CA 90670
Phone: (800) 227-4116
• To order parts by e-mail, submit orders to [email protected]
6
CONTROL
SWITCH
EXTENSION
PLATE
SADDLE
MAIN FRAME
PLATFORM
OPENER
DOCK
BUMPER
LIFT
CYLINDERS
PUMP BOX
PLATFORM
FLIPOVER
LIFT
ARM
PARALLEL
ARM
CART STOP
(SINGLE SHOWN)
7
LIFT
FRAME
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATE TERMINOLOGY
(GPT SERIES)
SERVICE TIME CHART
STRUCTURAL SERVICE TO BE PERFORMED
CHANGE PLATFORM PINS (EACH)
TIME REQ'D.
(HOURS)
.50
CHANGE ALL PINS
3.00
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CHANGE GREASELESS BUSHINGS (EACH)
.25
CHANGE PLATFORM TORSION SPRING
1.00
CHANGE EXTENSION PLATE
1.50
CHANGE LIFTFRAME ASSEMBLY
1.00
CHANGE PARALLEL ARM (EACH)
.50
CHANGE SHACKLES (EACH)
.50
CHANGE PLATFORM OPENER
.50
CHANGE PLATFORM LOCKING LATCH
.50
CHANGE ENTIRE PLATFORM
2.00
CHANGE PLATFORM MAIN SECTION
1.50
CHANGE PLATFORM FOLDING SECTION (ALUMINUM)
1.00
REPLACE FOLDING SECTION HINGE PIN (ALUMINUM)
2.00
ADJUST PLATFORM SLOPE
.50
ELECTRICAL SERVICE TO BE PERFORMED
TIME REQ'D.
(HOURS)
CHANGE MOTOR
1.00
CHANGE MOTOR SOLENOID
.50
CHANGE SOLENOID VALVE COIL (EACH)
.50
CHANGE POWER PACK, COMPLETE
1.00
CHANGE OUTSIDE SWITCH ASSEMBLY
.50
CHANGE CIRCUIT BREAKER
.50
CHANGE TOGGLE SWITCH (EACH)
.50
C HANGE WIRING HARNESS OUTSIDE
1.00
8
TIME REQ'D.
(HOURS)
CHANGE PUMP ASSEMBLY
1.00
CHANGE PUMP RESERVOIR
1.00
CHANGE AUXILIARY HAND PUMP
1.00
RESET PUMP AND RELIEF VALVE PRESSURE
.50
ADJUST LOWERING SPEED
.25
CHANGE EXTERNAL FLOW CONTROL VALVE
.50
CHANGE/CLEAN CARTRIDGE VALVE
1.00
CHANGE LIFT CYLINDER (EACH)
1.00
CHANGE EXTERNAL HYDRAULIC HOSES (EACH)
.25
CHANGE RETURN LINE (EACH)
.50
9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SERVICE TO BE PERFORMED
PERIODIC MAINTENANCE CHECKLIST
! WARNING
Never operate the Liftgate if parts are loose or missing.
NOTE: Make sure Vehicle is parked on level ground while performing the
maintenance checks.
Annually
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Visually check the entire Liftgate for excessively worn parts and broken welds, especially the
Hinge Pins. See PARTS BREAKDOWN section for replacement parts. Also, do the Semiannual and Quarterly Maintenance checks.
Semi-annually
Visually check the Platform Hinge Pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly Maintenance checks.
Quarterly
Check the Hydraulic Fluid level in the Pump Reservoir. If hydraulic fluid must be added, refer to
CHANGING HYDRAULIC FLUID procedure on following page for the correct fluid to use.
If Hydraulic Fluid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure on following page.
Keep track of the grade of Hydraulic Fluid in the Pump Reservoir and never mix two different
grades of fluid.
Check all Hoses and Fittings for chaffing and fluid leaks. Replace if necessary.
Check electrical wiring for chaffing and make sure wiring connections are tight and free of
corrosion.
Check that all WARNING and instruction decals are in place and legible.
Check that all roll pins are in place and protrude evenly from both sides of Hinge Pin collar.
Replace roll pins if necessary.
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.
10
CHANGING HYDRAULIC FLUID
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic
lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
NOTE: Use correct grade of hydraulic fluid for your location.
+70 to +140 Degrees F - Grade ISO 32
+40 to +105 Degrees F - Grade ISO 15
Below + 70 Degrees F
- Grade ISO 10 or MIL-H-5606
See TABLES 12-1, 12-2, & 12-3 on following page for recommended brands.
NOTE: To prevent spills, drain used hydraulic fluid through a funnel into waste fluid container.
1. Place empty 5 Gallon Bucket under Drain Plug.
PUMP BOX
2. Open and raise Platform to vehicle bed height.
Remove the Drain Plug (FIG. 11-1). Drain
hydraulic fluid.
3. Disconnect the White Wire (FIG. 11-2) from
Motor Solenoid. Lower the Platform while draining
the remaining hydraulic fluid from system. Reinstall Drain Plug. Reconnect the White Wire to
Motor Solenoid.
DRAIN
PLUG
4. Remove Filler Cap (FIG. 11-2) and refill
reservoir to the level shown on decal.
FIG. 11-1
FILLER
CAP
5. Raise Platform to vehicle bed height.
Check hydraulic fluid again and, if
needed, add more hydraulic fluid
MOTOR
(FIG. 11-2).
SOLENOID
6. Reinstall Filler Cap (FIG. 11-2).
WHITE WIRE
DECAL
(FLUID LEVEL)
FIG. 11-2
11
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CAUTION
CHANGING HYDRAULIC FLUID - Continued
ISO 32 HYDRAULIC OIL
RECOMMENDED BRANDS
PART NUMBER
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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 12-1
ISO 15 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
TABLE 12-2
ISO-10 OR MIL-H-5606 HYDRAULIC FLUID
RECOMMENDED BRANDS
PART NUMBER
AMSOIL
N/A
CHEVRON
FLUID A, FLUID G
KENDALL
GLACIAL BLU
SHELL
AEROSHELL FLUID-41
EXXON
UNIVIS HVI-13
MOBIL
AERO HFA
TABLE 12-3
12
13
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ADJUSTMENTS
SADDLE ADJUSTMENT
1. Make sure Platform is at ground level.
2. Remove bolts, lock nuts (FIG. 14-1B), and Saddle from Right Hand side (RH) Mounting
Plate. Repeat step for Left Hand (LH) side.
MOUNTING
PLATE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BOLTS &
LOCK NUTS
SADDLE
PLATFORM
LIFT GATE - SIDE VIEW (RH SIDE SHOWN)
FIG. 14-1
3. Stow the Platform as shown in FIG. 14-2A. Use floor jack positioned at center of Platform
(near hinge) to raise Platform 1/8” above Roller (FIG. 14-2B). Reinstall Saddle, Bolts and
Locknuts on RH side Mounting Plate (FIG. 14-2A). Repeat for Saddle on LH side. Butt each
Saddle against Platform, and tighten lock nuts.
ROLLER
LIFTING FRAME
BRACKET
PLATFORM
HINGE
SADDLE
1/8”
GAP
GAP BETWEEN PLATFORM & ROLLER
FIG. 14-2B
14
MOUNTING
PLATE
BOLTS &
LOCK NUTS
STOWED LIFTGATE - SIDE VIEW
(RH SIDE SHOWN)
FIG. 14-2A
REPLACING PLATFORM TORSION SPRING
2. Raise Platform to a convenient work height PLATFORM
to gain access and release tension on the (REFERENCE)
Torsion Spring.
HINGE PIN
TORSION
SPRING
HINGE
BRACKET
! CAUTION
To prevent injury and equipment damage,
make sure there is no tension on torsion
spring before removing hinge pin.
LOCK
NUT
BOLT
3. Unbolt Hinge Pin from Hinge Bracket
(FIG. 15-1). Remove bolt and lock nut.
Drive the Hinge Pin inboard toward the
Shackle with a hammer and pin punch, just
enough to free the torsion spring (FIG. 151). Remove spring from Shackle.
FIG. 15-1
4. Install the Torsion Spring as shown in FIG.
15-2. Make sure the long leg of the spring is
inserted in the bracket located on Shackle
(FIG. 15-2). Make sure the short end of the
spring is visible and resting against the edge
of the Hinge Bracket (FIG. 15-2).
5. Drive the Hinge Pin into correct
position (FIG. 5) through the
Hinge Bracket with a hammer
and pin punch. Line up the bolt
hole in the Hinge Pin with the
hole in the Hinge Bracket. Bolt
the Hinge Pin to Hinge Bracket
with bolt and lock nut (FIG. 5).
SHACKLE
HINGE PIN
PLATFORM
(REFERENCE)
BOLT &
LOCK NUT
BRACKET
HINGE
BRACKET
LONG
LEG
SHORT
LEG
SHACKLE
FIG. 15-2
6. Operate the Liftgate to make
sure it operates correctly.
15
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1. Manually fold Flipover onto Platform.
PLATFORM ADJUSTMENT
NOTE: Before doing the following procedure,
make sure vehicle is parked on level ground.
LEVEL LINE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Make sure Platform is at ground level. Unfold
the Platform and Flipover. The Shackles and
PLATFORM EDGE ABOVE BED LEVEL
the outboard edge of Platform must touch the
FIG. 16-1
ground at the same time as shown in FIG. 7.
If the Shackles and the outboard edge of Platform are touching the ground, RAISE Platform
to bed height. Outboard edge of Platform
should be above bed level (FIG. 16-1). If indications are correct (FIGS. 16-1 & 16-2), Liftgate
is
installed correctly and no adjustment is needed.
PLATFORM & SHACKLES
YES
If indications are incorrect, continue
with instrucTOUCH GROUND
tion 2.
FIG. 16-2
2. If the platform is level at bed level (FIG. 16-3),
if Shackles do not touch the ground (FIG. 164), or if edge of Platform does not touch the
ground (FIG. 16-5), inspect each of the Hinge LEVEL LINE
Pins for visible wear before adjusting the
Platform. Replace Hinge Pins that are visibly
worn. Refer to Parts Breakdown section of
PLATFORM EDGE AT BED LEVEL
this manual for repair parts.
FIG. 16-3
3. Check Liftgate for structural damage that may
cause incorrect platform positioning. Repair
structural damage.
“A”
(TABLE 1)
NOTE: If the Platform is like FIG. 16-2 and
there is no structural damage or damaged
hinge pins, do instruction 4. If the Shackle
touches and the Platform edge does not
(FIG. 16-4), skip 4 and do 5.
SHACKLES DO NOT TOUCH GROUND
FIG. 16-4
4. Make sure Platform is still at ground level. If the
Shackle is not touching the ground, measure
and compare distance “A” (FIG. 16-4) with
TABLE 17-1 to determine the correct shim.
Make shims as needed (FIG. 17-1). Weld shim
as shown in FIG. 17-2.
“B”
(TABLE 2)
PLATFORM DOES NOT
TOUCH GROUND
FIG. 16-5
16
5. Make sure Platform is still at ground
level. If edge of the Platform is not
touching the round, measure and compare distance “B” (FIG. 16-5) with
TABLE 17-2 to determine how much
to grind from the Platform Stops
(FIG. 17-3). Grind correct amount of
metal (TABLE 17-2) from Platform
Stop as shown in FIG. 17-3 .
REQUIRED SHIM
THICKNESS
1"
1/16"
1/16"
2"
1/8"
1/8"
3"
3/16"
3/16"
4"
1/4"
1/4"
WELD SIZE
1”
SHIM (1/16”, 1/8”, or 1/4”) MADE
FROM STEEL FLAT
FIG. 17-1
SHACKLE
"W"
NEW SHIM
(TABLE 1)
2 PLACES
TABLE 17-1
LOWER PLATFORM
EDGE (OUTBOARD)
THIS DISTANCE("B")
GRIND METAL FROM
PLATFORM STOP
1"
1/16"
2"
1/8"
3"
3/16"
4"
1/4"
“W”
(TABLE 1)
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 17-2
TABLE 17-2
SHACKLE
(REF)
6. RAISE the Platform, then LOWER it
to the ground. Platform and Shackle
should touch the ground at the same
time as shown in FIG. 16-2.
GRIND THIS FACE
(SEE TABLE 2)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 17-3
17
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RAISE PLATFORM
EDGE (OUTBOARD)
THIS DISTANCE ("A")
2-1/2”
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PARTS BREAKDOWN
18
GPT ASSEMBLY
REFER TO HYDRAULIC COMPONENTS
& PUMP BOX ASSEMBLY
4
2
REFER TO MAIN
FRAME ASSEMBLY
8B
6
8A
8C
8
7
7
3
1
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
226938
EYE,DROP FORGED PAD 3/4" X 1-1/2"
2
1
227700
HOOK ASSEMBLY
3
4
900014-4
BOLT, HEX HEAD 3/8-16 X 1"
4
2
901011-5
NUT, HEX HEAD 3/8-16 UNC-2B
5
1
226355
6
2
902001-2
WASHER, FLAT 3/8" X 1/16"
7
4
902011-4
WASHER, LOCK 3/8" X 15/16"
8
1
265994-01
OPENER ASSEMBLY
8A
1
030805
COTTER PIN 1/8" X 1"
8B
1
280082-01
ROLLER
8C
1
905202-03
PIN
EXTENSION PLATE
19
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5
GPT-25/-3 MAIN FRAME ASSEMBLY
24
29
24
15B
29
3
28
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
7 31
32
15
11
26
28
13
2
27
26
3 26
15
17
15A
13
12
33
11
11
21
14B
32
1
1
20
5
14C
14A
25
32
2
5
20 1
14A 14C 14B 21
14
11
9
22
7
1
19
10 11
18
2
23A
2
11
10
8
6
20
23
16
12
32
19A
4
31
11
19A
16
15B
11
14
1
1 30 22A 11
27
30 1
15A
33
11 1
GPT-25/-3 MAIN FRAME ASSEMBLY
QTY.
PART NO.
1
8
30034
BOLT, 3/8-24 X 1"
2
4
30035
BOLT 3/8-24 X 1-1/4"
3
2
040103-5
4
1
50175
PLATE, MAXON HORIZONTAL
5
2
907026
PIN, ROLL 3/16" DIA. X 2-1/4" LG
6
6
207644
RIVET, POP 3/16" X 13/32"
7
2
221416
PIN, ROLL 3/8" X 2"
8
1
226363-01
SPRING, TORSION 1/2" X 5-3/4" RH
9
1
226363-02
SPRING, TORSION 1/2" X 5-3/4" LH
10
2
226364
SUPPORT PIN WELDMENT
11
10
226941
NUT, NYLON LOCK 3/8-24 THIN
12
2
229657
PIN WELDMENT
13
2
250310
PIN WELDMENT
14
2
253085-01
14A
1
221416
14B
1
261793-01
14C
1
264272
15
DESCRIPTION
LOOM, SPLIT 1/2" X 5" LG
ROLLER PIN, ASSEMBLY
PIN, ROLL 3/8" X 2"
ROLLER
FLAT, WASHER 2-1/4"
2
261788-01
PARALLEL ARM ASSEMBLY
15A
2
905112-05
BEARING, SELF LUBE 1-3/8" X 1-5/8"
15B
2
905114-04
BEARING, SELF LUBE 1-1/4" X 1-1/2"
16
2
262280
17
1
262322-01
LIFT, ARM WELDMENT L/H
18
1
262322-02
LIFT, ARM WELDMENT R/H
19
1
262396
LIFT FRAME WELDMENT ASSEMBLY
2
263473
ROLLER, KNUCKLE DOWN
20
2
262437
BUSHING WELDMENT HOSE CLAMP
21
2
262440
PIN, 1-3/8" X 3-3/8" LG
22
1
265815-01
SHACKLE ASSEMBLY, LEFT HAND
2
905112-06
BEARING SELF LUBE 1-3/8" X 3/8"
1
265815-02
SHACKLE ASSEMBLY, RIGHT HAND
2
905112-06
BEARING SELF LUBE 1-3/8" X 3/8"
24
2
265849-01
SADDLE, LOW PROFILE HINGE
25
1
265865-01
MAIN FRAME WELDMENT
26
14
205780
27
2
266035-01
28
4
901023
29
4
901024-3
BOLT, HEX FRAME 2-1/4" LG
30
6
902011-4
WASHER, LOCK 3/8" X 15/16" ZC
31
2
902013-20
WASHER, FLAT 1-1/4" ZC
32
4
905114-04
BEARING, SELF LUBE 1-1/4" X 1-1/2"
33
2
905115-02
BEARING, SELF LUBE 1-1/2" X 1-1/2"
19A
2 2A
23
23A
PIN, WELDMENT LIFT FRAME/SHACKLE
PLASTIC TIE, 7" LG.
PIN, WELDMENT UNDERRIDE
FLANGE LOCK NUT
21
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
GPT-4/-5 MAIN FRAME ASSEMBLY
28
33
28
18A
33
9
35
30
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
17
18
36
31
5
10
32
3
30
5
19
18A
14
10
16 15
31
7
17
2
17
1
26A
34
22
17 24
36
2
23 4
29
2
36
2
22 15
2
12
9
18A
3
23
18
24
17
16
1
26 16
17
4
25
13
30
32
21
35 9
17
11
27A
17
1
17
25
34
9
16
6
8
22
27
36
18A
20
7
17
13
1
14
2
GPT-4/-5 MAIN FRAME ASSEMBLY
QTY.
PART NO.
1
4
30034
BOLT, 3/8-24 X 1"
2
6
30035
BOLT 3/8-24 X 1-1/4"
3
2
30038
BOLT, 3/8-24 X 1-1/2"
4
2
30414
PIN, COTTER 1/8" X 2-1/2"
5
2
040103-5
LOOM, SPLIT 1/2" X 5" LG
6
1
50175
7
2
905113-03
8
6
207644
RIVET, POP 3/16" X 13/32"
9
4
221416
PIN, ROLL 3/8" X 2" ZINC
10
2
226358
PIN WELDMENT
11
1
226363-01
SPRING, TORSION 1/2" X 5-3/4" RH
12
1
226363-02
SPRING, TORSION 1/2" X 5-3/4" LH
13
2
226365
PIN, SHACKLE WELDMENT
14
2
226368
LOWER ARM PIN WELDMENT
15
2
2263 72
ROUND TUBE X 1/4" (2" X 5/16"W)
16
4
226375
ROLLER X 1"
17
10
226941
NUT, NYLON LOCK 3/8-24 THIN
18
2
261785-01
ARM, PARLLEL WELDMENT
4
905112-07
BEARING, SELF LUBE 1-3/8" X 1-3/4"
19
1
262332-01
LIFT ARM WELDMENT R/H
20
1
262332-02
LIFT ARM WELDMENT L/H
21
1
262397
LIFT FRAME WELDMENT ASSEMBLY
22
2
262435
PIN WELDMENT, CYLINDER 1-3/8" DIA.
23
2
262437
BUSHING WELDMENT HOSE CLAMP
24
2
26246 2
PIN WELDMENT, CYLINDER 1-3/8" DIA.
25
2
265807-01
PIN WELDMENT, PLATFORM
26
1
265813-01
SHACKLE ASSEMBLY, LEFT HAND
2
905112-06
BEARING SELF LUBE 1-3/8" X 3/8"
1
265813-02
SHACKLE ASSEMBLY, RIGHT HAND
2
905112-06
BEARING, SELF LUBE 1-3/8" X 3/8"
28
2
265849-01
SADDLE, LOW PROFILE HINGE
29
1
265866-01
MAIN FRAME WELDMENT
30
14
205780
31
2
266033-01
32
4
901023
33
4
901024-3
BOLT, HEX FRAME 2-1/4" LG
34
2
902011-4
WASHER, LOCK 3/8" X 15/16"
35
2
902013-21
WASHER, FLAT 1-3/8"
36
4
905112-07
BEARING, SELF LUBE 1-3/8" X1-3/4"
18A
26A
27
27A
DESCRIPTION
PLATE, MAXON HORIZONTAL
BEARING, SELF LUBE 1-3/4" X1-3/4"
PLASTIC TIE, 7" LG.
PIN, WELDMENT UNDERRIDE
FLANGE LOCK NUT
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
PLATFORM & FLIPOVER ASSY
(NO CART STOP)
P/N 265204-01
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1
5
3
6
4
1
4
4
5
2
6
2A
ITEM
QTY.
PART NO.
1
2
263456-04
HINGE ROD 1/2" DIA X 80-13/16" LG
2
1
263665-01
FLIPOVER WELDMENT, ALUMINUM, 30"
1
265819-01
HANDLE WELDMENT
3
1
265203-01
PLATFORM WELDMENT, ALUMINUM, 30"
4
16
280109
HINGE ASSEMBLY
5
2
280110
HINGE ASSEMBLY
6
4
905015-1
2A
DESCRIPTION
ROLL PIN, 3/16" X 3/4"
24
4
1
2
5
3
1
3
3
4
5
REFER TO FLIPOVER
(SINGLE CART STOP)
ITEM
QTY.
PART NO.
DESCRIPTION
1
2
263456-04
HINGE ROD 1/2" DIA X 80-13/16" LG
2
1
265203-01
PLATFORM WELDMENT, ALUMINUM, 30"
3
16
280109
HINGE ASSEMBLY
4
2
280110
HINGE ASSEMBLY
5
4
905015-1
ROLL PIN, 3/16" X 3/4"
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM & FLIPOVER ASSY
(SINGLE CART STOP)
P/N 265462-01
FLIPOVER (SINGLE CART STOP)
P/N 265457-01
4
13 5
3
14
6
12
3
13
7
8
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
11
9
4
12
2
10
1
1A
ITEM
QTY.
PART NO.
1
1
263670-01
FLIPOVER WELDMENT, ALUMINUM
1
265819-01
HANDLE WELDMENT
2
1
030406
ROLL PIN, 1/8" X 1"
3
2
030805
COTTER PIN 1/8" X 1"
4
6
253542
BEARING, SELF LUBE 1/2" X 1/2"
5
1
262481-02
ARM, OPENING AND CLOSING, RH
6
1
262508-01
RAMP WELDMENT, SINGLE CART STOP
7
1
262513-01
PIN, 1/2" DIA X 80-39/64" LG
8
1
262514
GAS SPRING
9
2
262515
METAL EYELET END FITING
10
1
26 2536
SPRING, TORSION, 1/8"
11
1
900047
SCREW,SHOULDER, 1/2" X 3/4" LG
12
2
902022
FLAT WASHER, 1/2"
13
2
905122-02
14
2
905135
1A
DESCRIPTION
BEARING, SELF LUBE 1/2" X 5/16"
PIN, CLEVIS 5/16" X 7/8"
26
4
1
2
5
3
1
4
3
4
5
REFER TO FLIPOVER
(DUAL CART STOP)
ITEM
QTY.
PART NO.
DESCRIPTION
1
2
263456-04
HINGE ROD, 1/2" DIA X 80-13/16" LG
2
1
265203-01
PLATFORM WELDMENT, ALUMINUM, 30"
3
16
280109
HINGE ASSEMBLY
4
2
280110
HINGE ASSEMBLY
5
4
905015-1
ROLL PIN, 3/16" X 3/4"
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM & FLIPOVER ASSY
(DUAL CART STOP)
P/N 265463-01
FLIPOVER (DUAL CART STOP)
P/N 265459-01
7
4
13
8
14
3
15
9
6
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
10
11
4
13
2
14 5
12
11
10
1
14
3
15
1A
ITEM
QTY.
PART NO.
1
1
263670-02
FLIPOVER ASSEMBLY, ALUMINUM
1
265819-01
HANDLE WELDMENT
2
1
030406
ROLL PIN, 1/8" X 1"
3
4
030805
COTTER PIN 1/8" X 1"
4
6
253542
BEARING, SELF LUBE 1/2" X 1/2"
5
1
262481-01
ARM, OPENING AND CLOSING LH
6
1
262481-02
ARM, OPENING AND CLOSING RH
7
1
262509-03
RAMP WELDMENT, DUAL CART STOP, LH
8
1
262509-04
RAMP WELDMENT, DUAL CART STOP, RH
9
1
262513-01
PIN, 1/2" DIA X 80 39/64" LG
10
2
262514
GAS SPRING
11
4
262515
METAL EYELET END FITING
12
2
900047
SCREW, SHOULDER, 1/2" X 3/4" LG
13
2
9020 22
FLAT WASHER, 1/2"
14
4
905122-02
15
4
905135
1A
DESCRIPTION
BEARING, SELF LUBE 1/2" X 5/16"
PIN, CLEVIS 5/16" X 7/8"
28
14
12
EXTENSION PLATE
(REFERENCE)
MAIN FRAME
(REFERENCE)
1
2
1
ITEM
QTY.
PART NO.
DESCRIPTION
1
2
226856
2
1
266019-01
BRACE ANGLE L/H
3
1
266019-02
BRACE ANGLE R/H
DOCK BUMPER ANGLE X 23-1/2"
29
3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DOCK BUMPER
HYDRAULIC COMPONENTS - POWER DOWN
REFER TO
PUMP ASSEMBLY
(POWER DOWN)
11
17
18
21
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
8
1
20
1
22
19
23
14
13
13
15
15
3
2
16
4
16
10
10
RH
LH
6
15 9
15
12
30
7
5
QTY.
PART NO.
2
266037-01
CYLINDER, 2-3/4" x 10"
2
266038-01
CYLINDER, 3" x 10"
2
1
265846-01
HOSE ASSY, 3/8"HP SAE#8F,#6M, 21" LG.
3
1
265863-01
HOSE ASSY, 3/8"HP SAE#6- #8 F-F, 26" LG.
4
1
265888-01
HOSE ASSY, 3/8"HP SAE#8 F-F, 57" LG.
5
1
265888-02
HOSE ASSY, 3/8"HP SAE#8 F-F, 83" LG.
6
1
265889-01
HOSE ASSY, 3/8"HP SAE#6 F-F, 55" LG.
7
1
265889-02
HOSE ASSY, 3/8"HP SAE#6 F-F, 77" LG.
8
1
906709-01
VALVE,FLOW REGULATOR #6 SAE, 4 GPM
9
1
905150
10
2
906704-01
ELBOW, STRAIGHT THR. #8 F/S O-RING M-M
11
1
906771-01
CONNECTOR, STRAIGHT, #6 - #8, M-M, O-RING F/S
12
1
906706-01
TEE, UNION SAE#8 F/S M-M
13
2
906707-01
ELBOW, STRAIGHT THD. #6F/S O-RING M-M
14
1
906770-01
ELBOW, MALE PIPE, #8 O-RING FS-NPTF
15
6
906712-02
O-RING #6 (3/8" FACE SEAL TUBE-END)
16
5
906712-03
O-RING #8 (1/2" FACE SEAL TUBE-END)
17
1
050207
18
1
226948-09
19
1
260490
NEEDLE VALVE, F-F 3/8" NPTF
20
1
800183
BUSHING, 3/8"-1/4"
21
1
906751-01
FITTING, STRAIGHT O-RING, SAE#6 M (WITH SWIVEL)
22
1
906769-01
BRANCH TEE, SWIVEL NUT, SAE#8 M-M/F
23
1
906772-01
CONNECTOR, STRAIGHT SWIVEL, #8, M-F, O-RING F/S
1
DESCRIPTION
TEE, UNION, 3/8" F/S MALE,6-JLO
FITTING, SWIVEL ELBOW
HOSE ASSY, 1/4" HP X 18-1/2" LG., M-M 1/4" NPTF
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
PUMP ASSEMBLY - POWER DOWN
5A
2
13
32
5D
4
5E
1
5F
15
16
6
7
12
11
10
9
8
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
14
5C
5
5B
3
QTY.
PART NO.
1
1
250093
MOTOR, HEAVY DUTY, 12 VDC
2
1
260276
VALVE, 4-WAY SOLENOID
1
226595
O-RING KIT, 4-WAY VALVE (NOT SHOWN)
1
253353
VALVE, 2-WAY SOLENOID
1
226594
O-RING KIT, 2-WAY VALVE (NOT SHOWN)
4
1
260275
MANIFOLD BLOCK
5
1
260229
RELIEF VALVE KIT
5A
1
260230
STEEL BALL
5B
1
260231
SPRING
5C
1
260235
O-RING
5D
1
260234
VALVE CUP
5E
1
260232
ADJUSTING SCREW
5F
1
260233
SPRING GUIDE
6
1
260263
RESERVOIR, 2.5 GAL.
7
1
229193
FILLER/BREATHER CAP
8
1
260250
FILTER
9
1
290003
3-PIECE GEAR PUMP
10
1
251884
O-RING
11
1
260252
PORT PLATE ASSY, 5"
12
1
260261
OIL SEAL
13
1
229200
COUPLING
14
1
262966
BUS BAR
15
1
262939
STARTER SWITCH, 12 VDC, 3 TERMINAL
16
4
229202
CAP SCREW (NOT SHOWN)
2A
3
3A
DESCRIPTION
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
PUMP BOX ASSEMBLY - POWER DOWN
2A
(LATCH)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
2A
(LATCH)
2
1
2A
(CATCH)
3
4
REFER TO
DECALS
2A
(CATCH)
REFER TO
PUMP ASSY
ITEM
QTY.
PART NO.
R EF
1
260157
PUMP BOX ASSEMBLY
1
1
260156
PUMP BOX WELDMENT
2
1
229383
PUMP BOX COVER
2
215139
CATCH & FASTENER
3
1
251097
RUBBER GROMMET, 7/8" I.D., 1-5/8" O.D.
4
1
093209-10
2A
DESCRIPTION
EDGE TRIM, 8-1/2" LG.
34
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.
RED
(FOR REFERENCESEE DECALS)
(TO PUMP BOX)
BLACK
3
GREEN
2
WHITE
1
FIG. 35-1
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
264951-01
SWITCH & CABLE ASSEMBLY
2
2
900057-5
SCREW, SELF-TAPPING #10-24 X 1" LG.
3
1
905206
SWITCH BOOT SEAL
4
1
264422
CABLE ASSEMBLY, 200 AMPS, 38' LG.
5
1
264687
KIT, MEGAFUSE (200 AMP FUSE & HEATSHRINK TUBING)
TABLE 35-1
SHORT END TO
VEHICLE BATTERY
5
4
!
LONG END TO PUMP
MOTOR SOLENOID
WARNING
Do not attach cable to battery until
liftgate repairs are completed.
FIG. 35-2
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL SWITCH AND POWER CABLE
DECALS
INSTRUCTION DECAL
P/N 251838
(REFERENCE)
CAPACITY DECAL
P/N 264081
(REFERENCE)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION DECAL
P/N 263998
WARNING DECAL
P/N 264081
FIG. 36-1
36
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WARNING DECAL
P/N 264081
(REFERENCE)
CAUTION DECAL
P/N 263998
(REFERENCE)
CAPACITY DECAL (SEE TABLE 1)
P/N 264081
LIFT CAPACITY DECALS
CAPACITY
PART NO.
2500 LBS.
220382
3000 LBS.
220388
4000 LBS.
220389
5000 LBS.
220390
INSTRUCTION DECAL
P/N 251838
TABLE 1
FIG. 37-1
37
DECALS - Continued
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FLUID LEVEL DECAL
P/N 265330-03
FIG. 38-1
38
SYSTEM DIAGRAMS
HYDRAULIC CYLINDERS
4 GPM FLOW
CONTROL VALVE
ADJUSTABLE
NEEDLE VALVE
FILL HOLE
(PLUGGED)
PORT ARAISE VALVE “A”
PORT BLOWER
(PWR DN)
FILTER
VALVE “E”
CHECK VALVE
MOTOR
(REFERENCE)
HAND PUMP
PORT
RELIEF
VALVE
(SET AT
2200 PSI)
M
PUMP
HAND PUMP
PORT
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 39-1
39
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC - POWER DOWN
ELECTRICAL SCHEMATIC - POWER DOWN
GREEN
CONTROL SWITCH
RED
BLACK
CABLE
ASSEMBLY
WHITE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
SOLENOID,
VALVE A
SOLENOID,
VALVE E
MOTOR
STARTER
SOLENOID
CABLE WITH
200 AMP FUSE
BATTERY
FIG. 40-1
40
TROUBLESHOOTING
1. Connect voltmeter between Motor Solenoid Terminal “A” and Bracket (FIG. 41-1) to verify
that battery power is getting to “A”. Recharge the battery if voltmeter indicates less than
12.6 Volts DC.
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
2. Fill Reservoir to fill line shown on decal, with the hydraulic fluid recommended in the
Periodic Maintenance Checklist.
3. Touch a jumper wire to terminals “A” & “C” (FIG. 41-1). If motor runs check Switch, the
switch connections, and White wire. Check and correct wiring connections or replace the
Switch.
4. Touch heavy jumper cables to terminals “A” & “B” (FIG. 41-1).
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 t ime 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.
MOTOR SOLENOID
BRACKET
(VOLTMETER
- LEAD )
TERMINAL “B”
TERMINAL “C”
MOTOR
SOLENOID
FIG. 41-1
41
TERMINAL “A”
(VOLTMETER
+ LEAD )
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT RAISE
PLATFORM RAISES BUT LEAKS DOWN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Check if Lowering Solenoid Valve is
constantly energized. Connect voltmeter negative (-) lead to Motor Solenoid
bracket and positive (+) lead to Motor
Solenoid terminal “C” (FIG. 42-1). If
voltmeter reads battery voltage (+12.6
Volts DC minimum) without pushing
the toggle switch, the control circuit is
operating incorrectly. Check if toggle
switch, wiring or coil are faulty.
LOWERING
SOLENOID
VALVE
MOTOR
MOTOR SOLENOID
TERMINAL “C”
(VOLTMETER
+ LEAD )
MOTOR SOLENOID
BRACKET (VOLTMETER
- LEAD )
FIG. 42-1
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to manually bleed Hydraulic System by
correctly positioning Liftgate Platform before disconnecting any Lifting Cylinder high pressure Hydraulic Lines. The following procedure can save t ime and prevent accidental fluid
spills and hazards.
2. Check the Valve Stem by removing the Coil
Assembly (Item 1, FIG. 42-2). With platform on
ground, unscrew the Valve Stem, (Item 2,
FIG. 42-2) 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 Down Port of the Cylinder (FIG. 423). Raise the Platform even with the bed.
Allow pump motor to run two seconds more
while you watch for hydraulic fluid at the Down
Port. A few drops of hydraulic fluid escaping
the Down Port is normal; however, if it streams
from the Down Port, Piston Seals are worn.
Replace Seals.
42
2
1
1/8”
FIG. 42-2
DOWN PORT
RAISE
PORT
FIG. 42-3
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
1. Lower the opened Platform to the ground. Fill the Pump Reservoir on Gravity-Down
Liftgates to within 1/2” below the top with hydraulic fluid recommended in Periodic
Maintenance Checklist.
2. Use voltmeter to verify that the Battery shows 12.6 volts or more.
3. Check for Structural damage, or poor lubrication. Replace worn parts.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
4. Check the Hydraulic Cylinder. With the Platform on the
ground, remove the Breather Plug or Vent Line from
the Vent Port of the Cylinder (FIG. 43-1). Raise the
Platform even with the bed. Allow pump motor to run
two seconds more while you watch for hydraulic fluid at
the Vent Port. A few drops of hydraulic fluid escaping
the Vent Port is normal; however, if it streams from the
Vent Port, Piston Seals are worn. Replace Seals.
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.
43
DOWN PORT
RAISE
PORT
FIG. 43-1
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES PARTIALLY AND STOPS
LIFTGATE WILL NOT LIFT RATED CAPACITY
1. Use voltmeter to verify that the Battery shows 12.6 volts or more under load from pump
motor.
2. Check for Structural damage or lack of lubrication.Replace worn parts.
! CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
3. With Platform on the ground, remove the pressure
hose and fitting from the Pump and replace it with a 03000 PSI Pressure Gauge. Hold the switch in the “UP”
position. Adjust the Relief Valve on the side of the
Pump until the gauge shows 2200 PSI (FIG. 44-2).
Remove guage and reinstall pressure hose.
DOWN PORT
RAISE
PORT
4. Check for dirty pump motor relief valve. Clean if
necessary. Replace any worn out relief valve parts.
FIG. 44-1
5. Check the Hydraulic Cylinder. With the Platform on the
ground, remove the hydraulic line from the Down Port
of the Cylinder (FIG. 44-1). Raise the Platform even
with the bed. Allow pump motor to run two seconds
more while you watch for hydraulic fluid at the Down
Port. A few drops of hydraulic fluid escaping the
Down Port is normal; however, if it streams from the
Down Port, Piston Seals are worn. Replace Seals.
6. If Pump cannot produce 2200 PSI with a minimum of
12.6 Volts available, the Pump is worn and needs to
be replaced.
RELIEF VALVE
ADJUST SCREW
PRESSURE
GAUGE
DECREASE
INCREASE
ADJUSTMENT
COVER
FIG. 44-2
44
1. Connect voltmeter between Motor Solenoid Terminal
“A” and Bracket (FIG. 45-1) to verify that battery
power is getting to “A”. Recharge the battery if
voltmeter indicates less than 12.6 Volts DC.
MOTOR SOLENOID
BRACKET (VOLTMETER - LEAD)
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.
TERMINAL “A”
(VOLTMETER + LEAD )
FIG. 45-1
2. Check the Hydraulic Cylinder. With the Platform on the ground, remove the hydraulic line
from the Down Port of the Cylinder (FIG. 45-2). Raise the Platform even with the bed. Allow
pump motor to run two seconds more while you watch for hydraulic fluid at the Down Port.
A few drops of hydraulic fluid escaping the Down Port is normal; however, if it streams from
the Down Port, Piston Seals are worn. Replace Seals.
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 (FIG. 45-3) in high
pressure hydraulic line connected to Pump. When installing Flow Control Valve make sure arrow on valve is oriented as shown in FIG. 45-3.
4. Lower the opened Platform to the ground. Fill the
Pump Reservoir on Gravity-Down Liftgates to within
1/2” below the top with hydraulic fluid recommended
in Periodic Maintenance Checklist.
5. Verify the Pump Motor is grounded to vehicle frame.
DOWN PORT
RAISE
PORT
FIG. 45-2
FLOW CONTROL
VALVE
6. Check for leaking hoses and fittings. Tighten or
replace as required.
7. Check for structural damage or poor lubrication. Replace worn parts.
8. Check the Filter in the Pump Reservoir. Replace if
necessary.
45
FIG. 45-3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES SLOWLY
PLATFORM RAISES SLOWLY - Continued
9. With Platform on the ground, remove the pressure
RELIEF VALVE
ADJUST SCREW
hose and fitting from the Pump and replace it with
a 0-3000 PSI Pressure Gauge. Hold the Control
switch in the “RAISE” position. Adjust the Relief
Valve on the side of the Pump until the gauge
shows 2200 PSI (FIG. 46-1). Remove guage
and reinstall pressure hose.
PRESSURE
GAUGE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECREASE
INCREASE
ADJUSTMENT
COVER
FIG. 46-1
46
1. Connect voltmeter between Motor Solenoid
Terminal “A” and Bracket (FIG. 47-1) to verify
that battery power is getting to “A”. Recharge
the battery if voltmeter indicates less than
12.6 Volts DC.
LOWERING
SOLENOID
VALVE
MOTOR
2. Check for structural damage or poor
lubrication. Replace worn parts.
3. Check if Lowering Solenoid Valve is
getting power. Connect voltmeter between Motor Solenoid Bracket and Motor
MOTOR SOLENOID
Solenoid terminal “C” (FIG. 47-1). Push MOTOR SOLENOID
BRACKET
TERMINAL “C”
(VOLTMETER - LEAD )
Control Switch to “LOWER” position to
(VOLTMETER
energize Lowering Solenoid. If voltmeter
TERMINAL “A”
+ LEAD )
(VOLTMETER + LEAD )
reads battery voltage (+12.6 Volts DC
minimum), control circuit is operating
FIG. 47-1
correctly (replace Lowering Solenoid).
If voltmeter reads 0 Volts, check if toggle
switch and wiring are faulty.
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. 47-2). With platform supported,
unscrew the Valve Stem (Item 2, FIG. 47-2) 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
5. Check if filtering screen on solenoid valve is
plugged. Clean carefully if required.
47
1/8”
FIG. 47-2
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS
TOO QUICKLY
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS
TOO QUICKLY - Continued
6. Check and clean Flow Control Valve (FIG.
48-1) in the high pressure hydraulic line
connected to Pump.
FLOW CONTROL
VALVE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
7. Check if Flow Control Valve (FIG. 48-1) is pointing to
the direction of restricted fluid flow (back toward pump).
If required, remove Flow Control Valve and install it
correctly (FIG. 48-1).
FIG. 48-1
48
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