80 SERIES (2002 Release, Steel Platform)

80 SERIES (2002 Release, Steel Platform)
M-04-08
APRIL 2004
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 .......................................................................... 10
PERIODIC MAINTENANCE CHECKLIST ........................................................................... 10
CHECKING HYDRAULIC FLUID ......................................................................................... 11
CHANGING HYDRAULIC FLUID ......................................................................................... 12
PLATFORM ADJUSTMENT ................................................................................................ 14
SADDLE ADJUSTMENT .................................................................................................... 16
REPLACING PLATFORM TORSION SPRING .................................................................... 17
PARTS BREAKDOWN .................................................................................. 18
80 SERIES FINAL ASSEMBLY ........................................................................................... 19
80 SERIES MAIN FRAME & LIFTING FRAME .................................................................... 20
PLATFORM & FLIPOVER ASSY ........................................................................................ 22
GRAVITY DOWN HYDRAULIC COMPONENTS.................................................................. 24
PUMP BOX ASSEMBLY (GRAVITY DOWN) ....................................................................... 25
POWER DOWN HYDRAULIC COMPONENTS ................................................................... 26
PUMP BOX ASSEMBLY (POWER DOWN) ........................................................................ 27
CONTROL SWITCH AND POWER CABLE ........................................................................ 28
DECALS ............................................................................................................................ 29
HYDRAULIC SYSTEM DIAGRAMS ............................................................. 32
HYDRAULIC SCHEMATIC - GRAVITY DOWN .................................................................... 32
HYDRAULIC SCHEMATIC - POWER DOWN ..................................................................... 33
TABLE OF CONTENTS - Continued
ELECTRICAL SYSTEM DIAGRAMS .......................................................... 34
ELECTRICAL SCHEMATIC - GRAVITY DOWN .................................................................. 34
ELECTRICAL SCHEMATIC - POWER DOWN .................................................................... 35
TROUBLESHOOTING .................................................................................. 36
PLATFORM WILL NOT RAISE ............................................................................................ 36
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 37
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 38
LIFTGATE WILL NOT LIFT RATED CAPACITY ................................................................... 39
PLATFORM RAISES SLOWLY ........................................................................................... 40
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS TOO QUICKLY .. 41
Comply with the following WARNINGS while maintaining Liftgates. See Operation Manual
M-00-37 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-97-37.
• 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
3. Adobe Pag
gemaker 7.0
EXTENSION
PLATE
CONTROL
SWITCH
SADDLE
PUMP BOX
PLATFORM
OPENER
MAIN FRAME
PLATFORM
LIFT CYLINDERS
FLIPOVER
PARALLEL
ARM
LIFT
ARM
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATE TERMINOLOGY
(80 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
1.00
REPLACE FOLDING SECTION HINGE PIN
.50
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
CHANGE 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
PERIODIC MAINTENANCE CHECKLIST
!
WARNING
Never operate the Liftgate with
parts loose or missing.
Annually
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Visually check the entire Liftgate for excessively worn parts and broken welds, especially the
Hinge Pins. See PARTS BREAKDOWN section for replacement parts. Also, do the Semiannual and Quarterly Maintenance checks.
Semi-annually
Visually check the Platform Hinge Pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly Maintenance checks.
Quarterly
Check the Hydraulic Fluid level in the Pump Reservoir. Refer to the CHECKING HYDRAULIC
FLUID procedure in the PERIODIC MAINTENANCE section.
If Hydraulic Fluid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure in the PERIODIC MAINTENANCE section.
Keep track of the grade of Hydraulic Fluid in the Pump Reservoir and never mix two different
grades of fluid.
Check all Hoses and Fittings for 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, clean it off. Touch
up the paint where bare metal is showing.
10
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 11-1, 11-2, & 11-3 for recommended brands.
1. Remove the Filler Cap (FIG. 11-1).
ISO 32 HYDRAULIC OIL
RECOMMENDED BRANDS
PUMP
RESERVOIR
FILLER CAP
FILL LEVEL
PART NUMBER
AMSOIL
AWH-05
CHEVRON
HIPERSYN 32
KENDALL
GOLDEN MV
SHELL
TELLUS T-32
EXXON
UNIVIS N-32
MOBIL
DTE-13M, DTE-24,
HYDRAULIC OIL-13
TABLE 11-1
CHECKING HYDRAULIC
FLUID LEVEL
FIG. 11-1
2. Check the Hydraulic Fluid level in the
Pump Reservoir (FIG. 11-1). If fluid is
below FILL LEVEL shown on Pump
Reservoir (FIG. 11-1), add fluid to the
FILL LEVEL.
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 11-2
3. Reinstall the Filler Cap (FIG. 11-1).
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 11-3
11
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CHECKING HYDRAULIC FLUID
PERIODIC MAINTENANCE
CHANGING HYDRAULIC FLUID
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic
lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
NOTE: Use correct grade of hydraulic fluid for your location.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
+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 9-2, 9-3 & 9-4 on the next page for recommended brands.
GRAVITY DOWN LIFTGATES
PUMP BOX
1. Place empty 5 Gallon Bucket under Drain Plug.
2. Open and lower Platform to ground. Remove
the Drain Plug (FIG. 12-1). Drain hydraulic fluid
from system. Reinstall Drain Plug.
DRAIN
PLUG
3. Remove Filler Cap (FIG. 12-2). Refill reservoir
with hydraulic fluid to the top of FILL LEVEL
bar shown on decal (FIG. 12-2). Reinstall Filler
Cap (FIG. 12-2).
GRAVITY DOWN PUMP BOX
FIG. 12-1
POWER DOWN LIFTGATES
1. Place empty 5 Gallon Bucket under Drain Plug.
2. Open and raise Platform to vehicle bed height.
Remove the Drain Plug (FIG. 12-1). Drain
hydraulic fluid.
MOTOR POWER
CABLE
DECAL
3. Disconnect the Motor Power Cable (FIG. 12-2)
from Starter Solenoid next to pump. Lower the
Platform while draining the remaining hydraulic
fluid from system. Reinstall Drain Plug.
Reconnect the Motor Power Cable to Starter
Solenoid.
4. Remove Filler Cap (FIG. 12-2). Refill reservoir
with hydraulic fluid to the top of FILL LEVEL
bar shown on decal (FIG. 12-2). Reinstall Filler
Cap (FIG. 12-2).
12
FILLER CAP
STARTER SOLENOID
PUMP
POWER DOWN PUMP & MOTOR
FIG. 12-2
13
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THIS PAGE INTENTIONALLY LEFT BLANK
PERIODIC MAINTENANCE
PLATFORM ADJUSTMENT
NOTE: Before doing the following procedure,
make sure vehicle is parked on level ground.
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. As the Platform first touches
the ground, Shackles and tip of Flipover must touch
the ground at the same time (FIG. 14-1). If the
Shackles and the tip of Flipover touch the ground at
the same time, RAISE Platform to bed height. Tip of
Flipover should be above bed level (FIG. 14-2). If
indications are correct in both cases (FIGS. 14-1 &
14-2), Liftgate is installed correctly and no adjustment is needed. If indications are incorrect, continue
with instruction 2.
NOTE: If tip of Flipover touches first (FIG. 143), do instruction 2. If the Shackle touches first
(FIG. 11-1), skip instruction 2 and do 3.
TIP OF
FLIPOVER
PLATFORM & SHACKLES
TOUCH GROUND
FIG. 14-1
1” MAX.
TIP OF
FLIPOVER
LEVEL LINE
PLATFORM EDGE ABOVE
BED LEVEL
FIG. 14-2
2. Make sure Platform is still at ground level. If the
Shackle is not touching the ground, measure
and compare distance “A” (FIG. 14-3) with
TABLE 14-1 to determine the correct shim.
Make shims as needed (FIG. 14-5). Weld
shim as shown in FIG. 14-4.
RAISE TIP OF
FLIPOVER
THIS DISTANCE " A"
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
“A”
(TABLE 14-1)
SHACKLES DO NOT
TOUCH GROUND
FIG. 14-3
"W"
NEW SHIM
(TABLE 1)
TABLE 14-1
2 PLACES
“W”
(TABLE 1)
2-1/2”
1”
SHACKLE
SHIM (1/16”, 1/8”, or 1/4”) MADE
FROM STEEL FLAT
FIG. 14-5
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 14-4
14
LOWER TIP OF
FLIPOVER
THIS DISTANCE" B "
GRIND METAL FROM
PLATFORM STOP
1"
1/16"
2"
1/8"
3"
3/16"
4"
1/4"
“B”
(TABLE 15-1)
TIP OF
FLIPOVER
PLATFORM DOES NOT
TOUCH GROUND
FIG. 15-1
TABLE 15-1
4. RAISE the Platform, then LOWER it to the
ground. As the Platform first touches the
ground, the tip of Flipover and Shackle
should touch at the same time as shown in
FIG. 14-1.
GRIND THIS FACE
(SEE TABLE 2)
PLATFORM
SHACKLE
(REF)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 15-2
15
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3. Make sure Platform is still at ground level.
If the tip of Flipover is not touching the
ground, measure and compare distance
“B” (FIG. 15-1) with TABLE 15-1 to
determine how much to grind from the
Platform Stops (FIG. 15-2). Grind correct
amount of metal (TABLE 15-1) from
Platform Stop as shown in FIG. 15-2.
SADDLE ADJUSTMENT
1. Lower Platform to ground level.
2. Remove bolts, lock nuts, and Saddle
(FIG. 16-1B)from Right Hand (RH) side
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
BOLTING SADDLE
FIG. 16-1B
PLATFORM
(REF)
LIFT GATE - SIDE VIEW (RH SIDE SHOWN)
FIG. 16-1A
3. Stow the Platform as shown in FIG. 16-2A. Use floor jack positioned at center of Platform
(near hinge) to raise Platform 1/8” above Roller (FIG. 16-2B). Reinstall Saddle, bolts and
locknuts on RH side Mounting Plate (FIG. 16-2A). Repeat for Saddle on LH side. Butt each
Saddle against Platform, and tighten lock nuts.
SADDLE
ROLLER
LIFTING FRAME
BRACKET
PLATFORM
MOUNTING
PLATE
HINGE
BOLTS &
LOCK NUTS
STOWED LIFTGATE - SIDE VIEW
(RH SIDE SHOWN)
FIG. 16-2A
1/8”
GAP
GAP BETWEEN PLATFORM & ROLLER
FIG. 16-2B
16
NOTE: The following procedure shows how to replace Torsion Spring on RH side of
Platform. Use this procedure for replacing Torsion Spring on the LH Side.
1. Fold Flipover onto Platform.
2. Fold Platform.
PLATFORM
(REFERENCE)
3. Raise Liftgate to a convenient work height
to gain access and release tension on the
Torsion Spring.
! CAUTION
BOLT
SHACKLE
4. Unbolt Hinge Pin from Hinge Bracket
(FIG. 17-1). Remove bolt and lock nut. Drive
the Hinge Pin inboard toward the Shackle
just enough to free the torsion spring (FIG.
17-1). Remove the Torsion Spring.
6. Drive the Hinge Pin into correct
position through the Hinge
Bracket as shown in FIG. 17-2.
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. 17-2).
TORSION
SPRING
LOCK NUT
To prevent injury and equipment damage,
make sure there is no tension on torsion
spring before removing hinge pin.
5. Install the Torsion Spring as shown in FIG.
17-2. Make sure the long leg of the spring
is inserted in the bracket located on
Shackle (FIG. 17-2). Make sure the short
end of the spring is visible and resting
against the edge of the Hinge Bracket
(FIG. 17-2).
HINGE
BRACKET
HINGE PIN
REMOVING HINGE PIN
(RH SIDE OF PLATFORM SHOWN)
FIG. 17-1
PIN WELDMENT
PLATFORM
(REFERENCE)
BOLT &
LOCK NUT
SHORT LEG
HINGE
BRACKET
SHACKLE
LONG LEG
BRACKET
7. Operate the Liftgate according to
instructions in Operation Manual
M-97-37 to make sure it operates
correctly.
INSTALLING HINGE PIN
(RH SIDE OF PLATFORM SHOWN)
FIG. 17-2
17
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REPLACING PLATFORM TORSION SPRING
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PARTS BREAKDOWN
18
80 SERIES FINAL ASSEMBLY
REFER TO HYDRAULIC
COMPONENTS & PUMP
BOX ASSEMBLY
2
8
4
6
REFER TO
MAIN FRAME &
LIFTING FRAME
8
7
1
REFER TO PLATFORM
& FLIPOVER ASSEMBLY
3
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
5
1
226355
EXTENSION PLATE
6
2
902001-2
WASHER, FLAT 3/8"
7
4
902011-4
WASHER, LOCK 3/8"
8
2
266763-01
OPENER ASSEMBLY
19
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
5
80 SERIES MAIN FRAME & LIFTING FRAME
24
29
8
26
27
2
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
15
16A
30
25
7
16
5
20
24
3
1
11
28
2
12 19
15
10
7
27
3
17A
22
1
12
31
20
32
7
17B
21
13
18
15
2
34
17
5
9
16
17B
4
29
8
14
17B
15
33
34
16A
14
2
18 15
23
30
7
17B
17A
6
20
11
1
15
80 SERIES MAIN FRAME & LIFTING FRAME
QUANTITY
PART NO.
1
4
030034
BOLT, 3/8"-24 X 1" LG. GR8
2
4
030035
BOLT 3/8"-24 X 1-1/4" LG. GR8
3
2
030038
BOLT, 3/8"-24X1-1/2" LG. GR8
4
1
050175
PLATE, MAXON HORIZONTAL
5
4
905112-06
6
6
207644
POP RIVET, 3/16" X 25/64" LG.
7
4
221416
ROLL PIN, 3/8" X 2" LG.
8
2
226358
PIN WELDMENT
9
1
226363-01
TORSION SPRING, 1/2" X 5-3/4" LG. RH
10
1
226363-02
SPRING, TORSION, 1/2" X 5-3/4" LG. LH
11
2
226365
PIN WELDMENT, SHACKLE
12
2
907026
ROLL PIN, 3/16 X 2-1/4" LG.
13
2
226372
ROUND TUBE, 1/4" (2" X 5/16"W)
14
4
226375
ROLLER, 1"
15
8
226941
NYLON LOCK NUT, 3/8"-24 THIN
16
2
261785-01
PARALLEL ARM WELDMENT (WITH BEARINGS)
8
905112-07
BEARING, SELF-LUBE, 1-3/8" X 1-3/4" LG.
1
261800-01
LIFT FRAME WELDMENT
17A
4
915112-01
BEARING, SELF-LUBE, 1-3/8" X 3/4" LG.
17B
4
915112-02
BEARING, SELF-LUBE, 1-3/8" X 1" LG.
18
2
262435
PIN WELDMENT, CYLINDER 1-3/8" DIA
19
2
262437
BUSHING WELDMENT-CYL HOSE CLAMP
20
2
262462
PIN WELDMENT, CYL. 1-3/8" DIA
21
2
265807-01
PIN WELDMENT, PLATFORM 1-3/8" X 13-1/8" LG.
22
1
266762-01
SHACKLE ASSY, LH (WITH BEARINGS)
23
1
266762-02
SHACKLE ASSY, RH (WITH BEARINGS)
24
2
266675-01
SADDLE, STEEL PLATFORM
25
1
265866-01
MAIN FRAME WELDMENT
26
14
205780
27
2
266033-01
28
4
901023
29
4
901024-5
BOLT, HEX HEAD, 1/2"-13 X 2-1/4" LG.
30
2
902001-2
FLAT WASHER, 3/8"
31
2
902013-21
FLAT WASHER, 1-3/8"
32
2
905128-07
ROLL PIN 1/8" X 2-1/4" LG
33
2
040103-5
LOOM, SPLIT 1/2" X 5" LG
34
2
266676-01
ROLLER, STEEL 1"
16A
17
DESCRIPTION
BEARING, SELF LUBE, 1-3/8" X 3/8" LG.
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
PLATFORM & FLIPOVER ASSY
(WEDGE)
5
7
3
6
8
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
1
3
4
2
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
266652-01
PLATFORM WELDMENT, STEEL
2
1
266665-01
FLIPOVER WELDMENT, STEEL
3
2
251533
PIN, 2-3/8" LG.
4
2
221416
ROLL PIN
5
1
280749-03
ANCHOR BOLT WELDMENT, 1/2"-13
6
1
280751-01
TORSION BAR
7
1
902000-14
FLAT WASHER, 1/2"
8
1
901010
NYLON LOCK NUT, 1/2"-13
22
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
GRAVITY DOWN HYDRAULIC COMPONENTS
CYLINDER (REF)
CYLINDER (REF)
17
17
16 13
13
16
15
14
16
8
3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
11
1
1
1A
1A
6
12
5
2
16
16
10
RH
ITEM
4
16
9
LH
7
QTY.
PART NO.
2
266038-01
CYLINDER, 3" BORE (80-3)
2
266039-01
CYLINDER, 3.5" BORE (80-4)
1
266038SK-01
SEAL KIT (3" BORE CYLINDER)
1
266039SK-01
SEAL KIT (3.5" BORE CYLINDER)
2
1
265846-01
HOSE ASSY 3/8"HP SAE#8F,#6M 21" LG.
3
1
22437-17
PLASTIC HOSE, 14" X 30" LG
1
1A
DESCRIPTION
4
1
265888-01
HOSE ASSY, 3/8"HP, SAE#8 F-F 57" LG.
5
1
224370-13
PLASTIC HOSE, 14" X 75" LG.
6
1
224370-12
PLASTIC HOSE, 14" X 55" LG.
7
1
265888-02
HOSE ASSY, 3/8"HP, SAE#6 F-F, 77" LG.
8
1
215406
9
1
905150
10
2
906704-01
ELBOW, STRAIGHT THREAD #8 F/S O-R M-M
ELBOW, BRASS, 1/4" X 3/8"
TEE, UNION 3/8" F.S. MALE,6-JLO
11
2
906705-01
CONNECTOR, LONG, NPSC, SAE #6
12
1
906711-01
TEE, UNION AIRBRAKE, 1/4"
13
2
906707-01
ELBOW, STRAIGHT THREAD F/S O-R #6 M-M
14
1
906708-01
ELBOW, STRAIGHT THREAD F/S O-R #6 M-F SW
15
1
906709-01
VALVE,FLOW REGULATOR #6 SAE, 4GPM
16
8
906712-02
O-RING , #6 (3/8" FACE SEAL TUBE-END)
17
2
228012
AADAPTER, STRAIGHT THD. 9/16" TO 1/4" PIPE
24
10
REFER TO PUMP
BOX ASSEMBLY
-GRAVITY DOWN
2A
(LATCH)
2A
(LATCH)
2
CONTROL SWITCH
CABLE ASSEMBLY
(REF)
3
5
5G
5C
5B
1
2A
(CATCH)
2A
(CATCH)
4
5E
5A
5F
5H
5D
6
ITEM
QTY.
PART NO.
1
1
266016-01
2
1
229383
PUMP BOX COVER
2
215139
CATCH & FASTENER
3
1
205780
PLASTIC TIE
4
1
280566-01
GREEN WIRE ASSEMBLY, 16GA
5
1
266014-01
PUMP ASSEMBLY, GRAVITY DOWN
5A
1
280374
MOTOR, 12 VOLTS DC
5B
1
280372
SOLENOID VALVE, 12 VOLTS DC
5C
1
906721-01
5D
1
280394
MOTOR STARTER SOLENOID, 12 VOLTS DC
5E
1
280416
WIRE ASSEMBLY (16GA)
5F
1
280404
CABLE ASSEMBLY (2GA)
5G
1
229193
FILLER, BREATHER
5H
1
266030-01
1
REF
2A
6
DESCRIPTION
PUMP BOX WELDMENT
RESERVOIR
DRAIN PLUG
DECAL (SEE DECAL SECTION)
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP BOX ASSEMBLY (GRAVITY DOWN)
POWER DOWN HYDRAULIC COMPONENTS
15
3
1
REFER TO PUMP
BOX ASSEMBLY
-POWER DOWN
14
8
1
1A
1A
11
13
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
13
15
15
16
2
4
16
16
10
10
RH
ITEM
6
15 9
15
12
7
LH
5
QTY.
PART NO.
2
266038-01
CYLINDER, 3" BORE (80-3)
2
266039-01
CYLINDER, 3.5" BORE (80-4)
1
266038SK-01
SEAL KIT (3" BORE CYLINDER)
1
266039SK-01
SEAL KIT (3.5" BORE CYLINDER)
2
1
265846-01
HOSE ASSY, 3/8"HP SAE#8F,#6M, 21" LG.
3
1
265847-01
HOSE ASSY, 3/8"HP SAE#6 F-F, 28" 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, 4GPM
9
1
905150
10
2
906704-01
ELBOW, STRAIGHT THR. #8F/S O-RING M-M
11
2
906705-01
CONNECTOR, LONG STR, THD SAE #6
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
906708-01
ELBOW, STRAIGHT THD F/S O-RING #6M-F SW
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)
1
1A
DESCRIPTION
TEE, UNION, 3/8" F/S MALE,6-JLO
26
2A
(LATCH)
2A
(LATCH)
2
CONTROL SWITCH
CABLE ASSEMBLY
(REF)
4
5H
5E
5D
1
5F 5C
2A
(CATCH)
2A
(CATCH)
5F
5G
5A
5B
5
5I
3
ITEM
QTY.
PART NO.
1
1
266016-01
2
1
229383
PUMP BOX COVER
2
215139
CATCH & FASTENER
3
1
REF
4
1
205780
5
1
266030-01
5A
1
280381
MOTOR, 12 VOLTS DC
5B
2
280394
MOTOR STARTER SOLENOID, 12 VOLTS DC
5C
2
906719-01
VALVE
5D
2
906720-01
10 VDC COIL
5E
1
906721-01
RESERVOIR
5F
2
280402
CABLE ASSEMBLY (2 GA)
5G
1
280543
CABLE ASSEMBLY (2 GA)
5H
1
229193
FILLER-BREATHER
5I
1
REF
2A
DESCRIPTION
PUMP BOX WELDMENT
DECAL (SEE DECAL SECTION)
PLASTIC TIE
PUMP ASSEMBLY, POWER DOWN
DRAIN PLUG, 3/8"-18 NPTF
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP BOX ASSEMBLY (POWER DOWN)
CONTROL SWITCH AND POWER CABLE
NOTE: Use Switch to RAISE and LOWER Liftgate to make sure Switch
operates as shown on the decal.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BLACK
(FOR REFERENCESEE DECALS)
(TO
POWER
UNIT)
4
YELLOW
1
3
WHITE
GREEN
WHITE
RED
2
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
266032-01
2
1
264346
3
2
900057-5
4
1
905206
SWITCH BOOT SEAL
5
1
264422
CABLE ASSEMBLY, 200 AMPS, 38' LG.
CABLE ASSEMBLY, 16GA / 3 WIRE
SWITCH & CABLE
SCREW, SELF-TAPPING #10-24 X 1" LG.
SHORT END TO
VEHICLE BATTERY
5
!
WARNING
Do not attach cable to battery until
liftgate repairs are completed.
LONG END TO PUMP
MOTOR SOLENOID
28
INSTRUCTION DECAL
P/N 251838
(REFERENCE)
CAPACITY DECAL
P/N 264081
(REFERENCE)
CAUTION DECAL
P/N 263998
WARNING DECAL
P/N 264081
29
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECALS
DECALS - CONTINUED
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
UP/DOWN DECAL
P/N 264507
WARNING DECAL
P/N 264081
(REFERENCE)
CAUTION DECAL
P/N 263998
(REFERENCE)
CAPACITY DECAL (SEE TABLE 30-1)
LIFT CAPACITY DECALS
CAPACITY
PART NO.
2500 LBS.
220382
3000 LBS.
220388
4000 LBS.
220389
5000 LBS.
220390
INSTRUCTION DECAL
P/N 251838
TABLE 30-1
30
FLUID LEVEL DECAL
P/N 265330-03
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SYSTEM DIAGRAMS
HYDRAULIC SCHEMATIC - GRAVITY DOWN
HYDRAULIC CYLINDERS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4 GPM FLOW
CONTROL VALVE
PRESSURE PORT
RETURN PORT
VALVE A
RELIEF VALVE
(SET AT 3250 PSI)
PUMP
CHECK VALVE
M
MOTOR
(REFERENCE)
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
32
FILL HOLE
(PLUGGED)
HYDRAULIC CYLINDERS
4 GPM FLOW
CONTROL VALVE
PORT B - LOWER
(POWER DOWN)
PORT A - RAISE
VALVE
A
CHECK VALVE
VALVE
B
MOTOR
(REFERENCE)
CHECK VALVE
M
RELIEF VALVE
(SET AT
3250 PSI)
PUMP
CHECK VALVES
RELIEF VALVE
(SET AT
1000 PSI)
FILTERS
RESERVOIR
DRAIN HOLE
(PLUGGED)
33
FILL HOLE
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC - POWER DOWN
ELECTRICAL SYSTEM DIAGRAMS
ELECTRICAL SCHEMATIC - GRAVITY DOWN
CONTROL SWITCH
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WHITE
WHITE
RED
YELLOW
GREEN
BLACK
CABLE
ASSEMBLY
SOLENOID,
VALVE A
THERMAL
SWITCH
STARTER
SOLENOID
CABLE WITH
200 AMP FUSE
MOTOR
BATTERY
34
CABLE
ASSEMBLY
YELLOW
RED
WHITE
GREEN
WHITE
BLACK
THERMAL
SWITCH
SOLENOID,
VALVE B
STARTER
SOLENOID
(LOWER)
STARTER
SOLENOID
(RAISE)
MOTOR
CABLE WITH
200 AMP FUSE
BATTERY
35
SOLENOID,
VALVE A
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SCHEMATIC - POWER DOWN
TROUBLESHOOTING
PLATFORM WILL NOT RAISE
1. Connect voltmeter between Motor Solenoid Terminal “A” and Bracket (FIG. 36-1) to verify
that battery power is getting to “A”. Recharge the battery if voltmeter indicates less than 12.6
Volts DC.
CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
2. Fill Reservoir to within 1/2” below the top with the hydraulic fluid recommended in the
Periodic Maintenance Checklist.
3. Touch a jumper wire to terminals “A” & “C” (FIG. 36-1). If motor runs check Switch,
switch connections, and White wire. Check and correct wiring connections or replace the
Switch.
4. Touch heavy jumper cables to terminals “A” & “B” (FIG. 36-1).
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.
TERMINAL “A”
(VOLTMETER
+ LEAD )
6. Check filter in the pump Reservoir.
Replace filter if necessary.
MOTOR SOLENOID
BRACKET
(VOLTMETER
- LEAD )
7. Check for dirty pump motor relief
valve. Clean if necessary.
Replace any worn out relief valve
parts.
TERMINAL “C”
TERMINAL “B”
MOTOR
SOLENOID
FIG. 36-1
36
PLATFORM RAISES BUT LEAKS DOWN
MOTOR SOLENOID
BRACKET
(VOLTMETER - LEAD )
TERMINAL “C”
(VOLTMETER + LEAD)
FIG. 37-1
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 (FIG. 37-2, Item 1). With platform
supported, unscrew the Valve Stem (FIG. 37-2,
Item 2) from the Pump. Push on the plunger
located inside the Valve Stem with a small
screwdriver. If the Plunger does not move freely
(approximately 1/8”) replace the Valve Stem.
2
1
1/8”
FIG. 37-2
3. Check the Hydraulic Cylinder. With the Platform on
the ground, remove the Breather Plug or Line from
the Down Port of the Cylinder (FIG. 37-3). Raise
the Platform even with the bed. Allow pump motor
to run two seconds more while you watch for
hydraulic fluid at the Down Port. A few drops of
hydraulic fluid escaping the Down Port is normal;
however, if it streams from the Down Port, Piston
Seals are worn. Replace Seals.
DOWN
PORT
PRESSURE
PORT
FIG. 37-3
37
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LOWERING
1. Check if Lowering Solenoid Valve is
SOLENOID VALVE
constantly energized. Connect voltmeter negative (-) lead to Motor
MOTOR
Solenoid bracket and positive (+)
lead to Motor Solenoid terminal “C”
(FIG. 37-1). 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.
MOTOR SOLENOID
TROUBLESHOOTING
PLATFORM RAISES PARTIALLY AND STOPS
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Lower the opened Platform to the ground. Fill the Pump Reservoir on Gravity-Down
Liftgates to within 1/2” below the top with hydraulic fluid recommended in Periodic
Maintenance Checklist.
2. Use voltmeter to verify that the Battery shows 12.6 volts or more.
3. Check for Structural damage, or poor lubrication. Replace worn parts.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
4. Check the Hydraulic Cylinder. With the Platform on the ground, remove the Breather Plug or
Line from the Down Port of the Cylinder (FIG. 39-1). 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.
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.
38
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
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
3. With Platform on the ground, remove the pressure
hose and fitting from the Pump and replace it with a 03000 PSI Pressure Gauge. Hold the switch in the “UP”
position. Adjust the Relief Valve on the side of the
Pump until the gauge shows 2800 to 3000 PSI (FIG.
39-2). Remove guage and re-install pressure hose.
DOWN PORT
PRESSURE
PORT
4. Check for dirty pump motor relief valve. Clean if
necessary. Replace any worn out relief valve parts.
5. Check the Hydraulic Cylinder. With the Platform on the
ground, remove the Breather Plug or Line from the
Down Port of the Cylinder (FIG. 39-1). 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.
FIG. 39-1
PRESSURE
GAUGE
6. If Pump cannot produce 2800-3000 PSI with a minimum of 12.6 Volts available, the Pump is worn and
needs to be replaced.
FIG. 39-2
39
RELIEF VALVE
ADJUST SCREW
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATE WILL NOT LIFT RATED CAPACITY
TROUBLESHOOTING
PLATFORM RAISES SLOWLY
1. Connect voltmeter between Motor Solenoid Terminal
“A” and Bracket (FIG. 40-1) 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
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.
TERMINAL “A”
(VOLTMETER
+ LEAD )
FIG. 40-1
2. Check the Hydraulic Cylinder. With the Platform on the ground, remove the Breather Plug
or Line from the Down Port of the Cylinder (FIG. 40-3). Raise the Platform even with the
bed. Allow pump motor to run two seconds more while you watch for hydraulic fluid at the
Down Port. A few drops of hydraulic fluid escaping the Down Port is normal; however, if it
streams from the Down Port, Piston Seals are worn. Replace Seals.
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. 40-2) in high pressure hydraulic line attached to
Cylinder. When installing Flow Control Valve make sure arrow on valve is oriented as
shown in FIG. 40-2.
DOWN PORT
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 Mainte- PRESSURE
FLOW
PORT
nance Checklist.
CONTROL
VALVE
5. Verify the Pump Motor is grounded to the vehicle
frame.
6. Check for leaking hoses and fittings. Tighten or
replace as required.
7. Check for structural damage or poor lubrication. Replace
worn parts.
FIG. 40-2
PRESSURE
GAUGE
8. Check the Filter in the Pump Reservoir. Replace if
necessary.
9. With Platform on the ground, remove the pressure hose
and fitting from the Pump and replace it with a 0-3000 PSI
Pressure Gauge. Hold the Control switch in the “RAISE”
position. Adjust the Relief Valve on the side of the Pump
until the gauge shows 2800 to 3000 PSI (FIG. 40-3).
Remove guage and reinstall pressure hose.
40
RELIEF VALVE
ADJUST SCREW
FIG. 40-3
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.
TERMINAL “A”
LOWERING
SOLENOID VALVE
(VOLTMETER
2. Check for structural damage or poor
+ LEAD )
lubrication. Replace worn parts.
3. Check if Lowering Solenoid Valve is getting
power . Connect voltmeter between Motor
Solenoid Bracket and Motor Solenoid terminal
“C” (FIG. 41-1). Push Control Switch to
MOTOR
“LOWER” position to energize Lowering
MOTOR SOLENOID
Solenoid. If voltmeter reads battery voltage
MOTOR SOLENOID
BRACKET
(+12.6 Volts DC minimum), control circuit is
TERMINAL “C”
(VOLTMETER - LEAD )
(VOLTMETER + LEAD )
operating correctly (replace Lowering
Solenoid). If voltmeter reads 0 Volts, check
FIG. 41-1
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
(FIG. 41-2, Item 1). With platform supported, unscrew
the Valve Stem (FIG. 41-2, Item 2) from the Pump.
Push on the plunger located inside the Valve Stem with
a small screwdriver. If the Plunger does not move freely
(approximately 1/8”) replace the Valve Stem.
2
1
5. Check if filtering screen on solenoid valve is
plugged. Clean carefully if required.
6. Check and clean Flow Control Valve in high pressure
hydraulic line attached to Cylinder.
7. Check if Flow Control Valve (FIG. 41-3) is pointing to
the direction of restricted fluid flow (back toward
pump). If required, remove Flow Control Valve and
install it correctly (FIG. 41-3).
41
1/8”
FIG. 41-2
DOWN PORT
PRESSURE
PORT
FLOW
CONTROL
VALVE
FIG. 41-3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS
TOO QUICKLY
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