Maxon 72-150 / TE-20 Maintenance Manual

Maxon 72-150 / TE-20 Maintenance Manual
M-12-06
REV. A
JUNE 2014
MAINTENANCE MANUAL
TE-20, 72-150
© 2014 MAXON LIFT CORP.
11921 Slauson Ave.
Santa Fe Springs, CA. 90670
LIFT CORP.
CUSTOMER SERVICE:
TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116
FAX: (888) 771-7713
NOTE: For latest version of all Manuals (and replacements), download the
Manuals from Maxon’s website at www.maxonlift.com.
WARRANTY/ RMA POLICY & PROCEDURE
LIFTGATE WARRANTY
Type of Warranty:
Full Parts and Labor
Term of Warranty:
Standard Liftgates - 2 years from ship date or 6,000 cycles
Premium Liftgates - 2 years from ship date or 10,000 cycles
This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s specifications as set forth in
MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments, damage or
malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this warranty does not
cover equipment that has had unauthorized modifications or alterations made to the product.
MAXON agrees to replace any components which are found to be defective during the first 2 years of service, and will reimburse for labor based on
MAXON’s Liftgate Warranty Flat Rate Schedule. (Copy of the Flat Rate is available at www.maxonlift.com.)
All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and labor,
MAXON’s Technical Service Department must be notified and an “Authorization Number” obtained.
All claims for warranty must be received within 30 Days of the repair date, and include the following information:
1. Liftgate Model Number and Serial Number
2. The End User must be referenced on the claim
3. Detailed Description of Problem
4. Corrective Action Taken, and Date of Repair
5. Parts used for Repair, Including MAXON Part Number(s)
6. MAXON R.M.A. # and/or Authorization # if applicable (see below)
7. Person contacted at MAXON if applicable
8. Claim must show detailed information i.e. Labor rate and hours of work performed
Warranty claims can also be placed online at www.maxonlift.com. Online claims will be given priority processing.
All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s Warranty
Department within 30 days of repair date.
All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior written
approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with original
invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized returns will be
refused and will become the responsibility of the returnee.
Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in plain
view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned parts
are subject to no credit and returned back to the customer. Defective parts requested for return must be returned within 30 days of the claim date for
consideration to:
MAXON Lift Corp.
10321 Greenleaf Ave., Santa Fe Springs, CA 90670
Attn: RMA#__
MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income due to
downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.
MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.
All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not returned
in new condition will be subject to an additional reworking charge, which will be based upon the labor and material cost required to return the Liftgate or
component to new condition.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase.
Type of Warranty: Part replacement only. MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts
and original invoice.
All warranty replacements parts will be sent out via ground freight. If a rush shipment is requested, all freight charges will be billed to the requesting
party.
TABLE OF CONTENTS
SUMMARY OF CHANGES: M-12-06, REVISION A ............................................................. 6
WARNINGS & SAFETY INSTRUCTIONS ............................................................................ 7
LIFTGATE TERMINOLOGY (PAINTED) ............................................................................... 9
LIFTGATE TERMINOLOGY (GALVANIZED) ...................................................................... 10
PERIODIC MAINTENANCE................................................................................................ 11
PERIODIC MAINTENANCE CHECKS .................................................................................11
PERIODIC MAINTENANCE CHECKLIST ........................................................................... 12
CHECKING HYDRAULIC FLUID ........................................................................................ 14
CHANGING HYDRAULIC FLUID ........................................................................................ 16
REPLACING PLATFORM TORSION SPRING ................................................................... 21
SAFETY HOOK MAINTENANCE (IF EQUIPPED).............................................................. 23
PARTS BREAKDOWN ....................................................................................................... 24
72-150 & TE-20 MAIN ASSEMBLY (PAINTED)................................................................... 24
72-150 & TE-20 MAIN ASSEMBLY (GALVANIZED) ............................................................ 26
EXTENSION PLATE ASSEMBLY (PAINTED) ..................................................................... 28
BOLT-ON EXTENSION PLATE ASSEMBLY (GALVANIZED).............................................. 29
LIFT FRAME & PARALLEL ARMS ...................................................................................... 30
PLATFORM & FLIPOVER ASSEMBLY (RAMP) ................................................................. 32
PLATFORM & FLIPOVER ASSEMBLY (WEDGE) .............................................................. 33
SINGLE STEP ASSEMBLY (GALVANIZED, BOLT-ON) ...................................................... 34
DUAL STEP ASSEMBLY (GALVANIZED, BOLT ON) .......................................................... 36
PUMP COVER & MOUNTING PLATE ASSEMBLY (GRAVITY DOWN) ............................. 38
PUMP COVER & MOUNTING PLATE ASSEMBLY (POWER DOWN) ............................... 40
HYDRAULIC COMPONENTS (GRAVITY DOWN) .............................................................. 43
12 VDC POWER UNIT (GRAVITY DOWN) ......................................................................... 44
24 VDC POWER UNIT (GRAVITY DOWN) ......................................................................... 46
HYDRAULIC COMPONENTS (POWER DOWN)................................................................ 49
12 VDC POWER UNIT (POWER DOWN)........................................................................... 50
OPTIONAL BATTERY BOX ELECTRICAL COMPONENTS ............................................... 52
OPTIONAL BATTERY BOX ASSEMBLY ............................................................................. 54
OPTIONAL BATTERY BOX ................................................................................................. 56
DECALS .............................................................................................................................. 58
CONTROL SWITCH AND POWER CABLE ........................................................................ 60
HYDRAULIC SYSTEM DIAGRAMS ................................................................................... 61
HYDRAULIC SCHEMATIC (GRAVITY DOWN)................................................................... 61
HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 62
ELECTRICAL SYSTEM DIAGRAMS ................................................................................. 63
ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 63
ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 64
TROUBLESHOOTING ........................................................................................................ 65
PLATFORM WILL NOT RAISE............................................................................................ 65
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 66
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 67
LIFTGATE WILL NOT LIFT RATED CAPACITY .................................................................. 68
PLATFORM RAISES SLOWLY ........................................................................................... 69
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY ................ 71
SUMMARY OF CHANGES: M-12-06, REVISION A
PAGE
DESCRIPTION OF CHANGE
COVER
Updated REV and date of release.
6
Added SUMMARY OF CHANGES
44, 50
43, 49, 69, 71
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58
Clarified torque specs for electrical connections on starter solenoid
Updated flow regulator (control) valve P/N 906923-01, HP hose P/N 288241-01 and
description
Replaced Warning decal 282479-01 with Decal Sheet 282522-01.
6
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.
• Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your
feet are clear of the Liftgate.
• Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.
• 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 can become
trapped between the platform and the Liftgate extension plate.
• Recommended practices for welding on steel parts are contained in the current AWS (American
Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and
personal injury could result from welds that are done incorrectly.
• Recommended practices for welding on aluminum parts are contained in the current AWS
(American Welding Society) D1.2 Structural Welding Code - Aluminum. Damage to Liftgate
and/or vehicle, and personal injury could result from welds that are done incorrectly.
• Welding on galvanized parts gives off especially hazardous fumes. Comply with WARNING decal
on the galvanized part (FIG. 7-1). To minimize hazard remove galvanizing from weld area, provide
adequate ventilation, and wear suitable respirator.
FIG. 7-1
7
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WARNINGS & SAFETY
INSTRUCTIONS
! WARNING
SAFETY INSTRUCTIONS
• Read and understand the instructions in this Maintenance Manual before performing maintenance on the Liftgate.
• Before operating the Liftgate, read and understand the operating instructions in Operation
Manual.
• Comply with all WARNING and instruction decals attached to the Liftgate.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement
decals are available from Maxon Customer Service.
• Consider the safety and location of bystanders and location of nearby objects when operating the
Liftgate. Stand to one side of the platform while operating the Liftgate.
• Do not allow untrained persons to operate the Liftgate.
• Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while
performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.
• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no flames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek first aid. If acid gets on your
skin, immediately wash it off with soap and water.
• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the control switch to stop the Liftgate.
• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the power unit while the platform is raised. Listen for scraping, grating and binding noises and correct the problem before continuing to operate Liftgate.
• 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
Online: www.maxonlift.com
Express Parts Ordering: Phone (800) 227-4116 ext. 4345
Email: Ask your Customer Service representative
8
EXTENSION
PLATE
CONTROL
SWITCH
CONTROL
HANDLE
PLATFORM
OPENER
PARALLEL
ARM
PLATFORM
MAIN
FRAME
PUMP BOX
(COVER SHOWN)
LIFT
CYLINDER
RAMP FLIPOVER
(WEDGE IS AVAILABLE)
LIFT FRAME
9
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LIFTGATE TERMINOLOGY (PAINTED)
LIFTGATE TERMINOLOGY (GALVANIZED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
EXTENSION
PLATE
CONTROL
SWITCH
DOCK BUMPER
PLATFORM
OPENER
PARALLEL
ARM
PLATFORM
PUMP BOX
(COVER SHOWN)
STEP
LIFT
CYLINDER
LIFT FRAME
RAMP FLIPOVER
(WEDGE IS AVAILABLE)
10
PERIODIC MAINTENANCE
!
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.
Quarterly or 1250 Cycles (whichever occurs first)
Check the hydraulic fluid level in the pump reservoir. Refer to the CHECKING HYDRAULIC
FLUID procedure in the PERIODIC MAINTENANCE section.
If hydraulic fluid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure in the PERIODIC MAINTENANCE section.
Keep track of the grade of hydraulic fluid in the pump reservoir and never mix two different
grades of fluid.
Check all hoses and fittings for chafing and fluid leaks. Tighten loose fittings or replace
parts as required.
Check electrical wiring for chafing and make sure wiring connections are tight and free of
corrosion. Use dielectric grease to protect electrical connections.
Check that all WARNING and instruction decals are in place. Also, make sure decals are
legible, clean and undamaged.
Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.
Pump EP chassis grease in each lube fitting on the cylinders and arms until grease
starts oozing from ends of the bearings. The lubrication diagram on the PERIODIC
MAINTENANCE CHECKLIST SHEET shows where to find the lube fittings. Wipe off
excess grease with a clean lint-free cloth.
CAUTION
Damaged cylinder seals and contaminated hydraulic fluid can result from painting the polished portion of the cylinder rod. To prevent damage, protect the
exposed polished portion of the cylinder rod while painting.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it off.
Touch up the paint where bare metal is showing. MAXON recommends using the aluminum
primer touchup paint kit, P/N 908134-01.
Semi-annually or 2500 Cycles (whichever occurs first)
Visually check the platform hinge pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly or 1250 Cycles
maintenance checks.
11
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PERIODIC MAINTENANCE CHECKS
PERIODIC MAINTENANCE CHECKLIST
NOTE: Make sure vehicle is parked on level ground while performing the maintenance
checks.
Quarterly or 1250 Cycles (whichever occurs first)
Check the level and condition of the hydraulic fluid.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Visually check all hoses for chafing and fluid leaks. Tighten loose fittings or replace
parts as required.
Check electrical wiring for chafing and make sure wiring connections are tight and free
of corrosion. Use dielectric grease to protect electrical connections.
Check that all WARNING and instruction decals are in place. Also, make sure decals
are legible and decals are clean and undamaged.
Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.
Pump EP chassis grease in each lube fitting on the cylinders and arms until grease
starts oozing from ends of the bearings. Refer to lubrication diagram on the next
page. Wipe off excess grease with a clean lint-free cloth.
CAUTION
Damaged cylinder seals and contaminated hydraulic fluid can result from
painting the polished portion of the cylinder rod. To prevent damage, protect
the exposed polished portion of the cylinder rod while painting.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate or if the Liftgate is dirty, clean it off. Touch up the paint where bare metal is showing. To maintain
the protection provided by the original paint system, MAXON recommends aluminum
primer touchup paint kit, P/N 908134-01.
Semi-annually or 2500 Cycles (whichever occurs first)
Visually check the platform hinge pins for excessive wear and broken welds.
Do the Quarterly or 1250 Cycles Checks on this checklist.
12
PERIODIC MAINTENANCE
LH LIFT ARM &
PARALLEL ARM
CYLINDER
RH LIFT ARM &
PARALLEL ARM
LUBRICATION DIAGRAM
FIG. 13-1
13
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PERIODIC MAINTENANCE CHECKLIST - Continued
PERIODIC MAINTENANCE
CHECKING HYDRAULIC FLUID
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.
NOTE: Use correct grade of hydraulic fluid for your location.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 15-2 and 15-3 for recommended brands.
POWER UNIT
(REF)
1. Unbolt & remove pump cover
(FIG. 14-1).
NOTE: If the hydraulic fluid in the
reservoir is contaminated, do
the CHANGING HYDRAULIC
FLUID procedure in this section.
NOTE: If you have a power down
power unit, skip instructions
2 & 3.
CAP SCREWS
(5 PLACES)
2. For gravity down power unit, check the
hydraulic fluid level “H” in reservoir (FIG.
14-2 and TABLE 14-1). If needed,
add fluid to the reservoir as follows.
PLATFORM POSITION
PUMP COVER
UNBOLTING / BOLTING PUMP COVER
FIG. 14-1
FLUID LEVEL
“H”
STOWED
1-7/8” to 2-3/8”
VEHICLE BED HEIGHT
1-7/8” to 2-3/8”
ON THE GROUND
FLAT WASHERS
(5 PLACES)
3-1/2” to 4”
RESERVOIR
GRAVITY DOWN FLUID LEVEL
TABLE 14-1
3. Pull out (no threads) filler cap (FIG. 14-2).
Fill the reservoir with hydraulic fluid to level
“H” shown in FIG. 14-2 and TABLE 14-1.
Reinstall filler cap (FIG. 14-2).
“H”
FILLER CAP
GRAVITY DOWN POWER UNIT
FIG. 14-2
14
PERIODIC MAINTENANCE
4. For power down power unit, check the hydraulic
fluid level “H” in reservoir (FIG. 15-1 and TABLE
15-1). If needed, add fluid to the reservoir as follows.
PLATFORM POSITION
FILLER
CAP
FLUID LEVEL
“H”
STOWED
2-5/8” to 3-1/8”
VEHICLE BED HEIGHT
2-5/8” to 3-1/8”
ON THE GROUND
2-3/8” to 2-7/8”
“H”
RESERVOIR
POWER DOWN FLUID LEVEL
TABLE 15-1
POWER DOWN POWER UNIT
FIG. 15-1
5. Pull out (no threads) filler cap (FIG.
15-1). Fill the reservoir with hydraulic
fluid to level “H” shown in FIG. 15-1
and TABLE 15-1. Reinstall filler cap
(FIG. 15-1).
ISO 32 HYDRAULIC OIL
RECOMMENDED
BRANDS
6. Bolt on the pump cover (FIG. 14-1).
Torque the bolts (cap screws) to
10 - 14 lbs.- in.
PART NUMBER
AMSOIL
AWH-05
CHEVRON
HIPERSYN 32
KENDALL
GOLDEN MV
SHELL
TELLUS S2 V32
EXXON
UNIVIS N-32
MOBIL
DTE-13M, DTE-24,
HYDRAULIC OIL-13
TABLE 15-2
ISO 15 OR MIL-H-5606 HYDRAULIC OIL
RECOMMENDED
BRANDS
PART NUMBER
AMSOIL
AWF-05
CHEVRON
FLUID A, AW-MV-15
KENDALL
GLACIAL BLU
SHELL
TELLUS S2 V15
EXXON
UNIVIS HVI-13
MOBIL
DTE-11M
ROSEMEAD
THS FLUID 17111
TABLE 15-3
15
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CHECKING HYDRAULIC FLUID - Continued
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
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 15-2 and 15-3 for recommended brands.
GRAVITY DOWN LIFTGATES
1. Remove the pump cover (FIG. 17-1). Place empty
5 gallon bucket under drain plug (FIG. 16-1).
2. Lower platform to ground. Pull out (no threads)
drain plug (FIG. 16-1). Drain hydraulic fluid
from system. Reinstall drain plug.
3. Pull out (no threads) filler cap (FIG. 16-1) and
refill reservoir with hydraulic fluid to level shown in
FIG. 16-1. Reinstall filler cap (FIG. 16-1).
4. Bolt on the pump cover as shown in FIG. 17-1
Torque the bolts (cap screws) to 10 - 14 lbs.- in.
RESERVOIR
3-1/2” - 4”
DRAIN
PLUG
FILLER
CAP
LIFTGATE SHOWN WITH GRAVITY
DOWN PUMP & MOTOR
FIG. 16-1
1. Remove the pump cover (FIG. 17-1). Place empty
5 gallon bucket under drain plug (FIG. 16-1).
POWER DOWN LIFTGATES
2. Open and raise platform to vehicle bed height.
Pull out (no threads) drain plug (FIG. 16-1). Drain
hydraulic fluid.
3. Disconnect the motor power cable (FIG. 16-2)
from starter solenoid. Lower the platform while
draining the remaining hydraulic fluid from system.
Reinstall drain plug. Reconnect the motor power
cable to starter solenoid.
4. Pull out (no threads) filler cap (FIG. 16-1) and
refill reservoir with hydraulic fluid to level shown
in FIG. 16-1. Reinstall filler cap (FIG. 16-1).
16
STARTER
SOLENOID
MOTOR
POWER
CABLE
POWER DOWN PUMP
FIG. 16-2
CAP SCREWS
(5 PLACES)
FLAT WASHERS
(5 PLACES)
PUMP COVER
UNBOLTING / BOLTING PUMP COVER
FIG. 17-1
17
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POWER UNIT
(REF)
5. Bolt on the pump cover as shown in
FIG. 17-1. Torque the bolt (cap
screws) to 10 - 14 lbs.- in.
PERIODIC MAINTENANCE
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.
TIP OF
18-1). If the shackles and the tip of flipover
FLIPOVER
touch the ground at the same time, raise platform to bed height. Outboard edge on top of
flipover should be above bed level (FIG. 18-2).
PLATFORM & SHACKLES TOUCH
If indications are correct in both cases (FIGS.
GROUND (RAMP FLIPOVER SHOWN)
18-1 & 18-2), Liftgate is installed correctly and
FIG. 18-1
no adjustment is needed. If indications are
incorrect, continue with instruction 2.
NOTE: If tip of flipover touches first (FIG. 18-3A),
do instructions 2 and 3. If the shackle
touches first (FIG. 20-1), skip 2 and 3
and do instructions 4 and 5.
2. Make sure platform is still at ground level. If
the shackle is not touching the ground, measure and compare distance “A” (FIG. 18-3A)
with TABLE 18-1 or TABLE 18-2 to determine the correct shim. Next, mark position on
shackle (FIG. 18-3B).
RAISE TIP OF
RAMP FLIPOVER
THIS DISTANCE “A”
11/16”
SIZE “W”
1/16”
1/16”
1-3/8”
1/8”
1/8”
2-1/16”
3/16”
3/16”
2-3/4”
1/4”
1/4”
SHIMS TO RAISE RAMP FLIPOVER
TABLE 18-1
RAISE TIP OF
RAMP FLIPOVER
THIS DISTANCE “A”
WELD
REQUIRED SHIM
THICKNESS
SIZE “W”
9/16”
1/16”
1/16”
1-1/4”
1/8”
1/8”
1-15/16”
3/16”
3/16”
2-5/8”
1/4”
1/4”
LEVEL LINE
PLATFORM EDGE ABOVE BED
LEVEL (RAMP FLIPOVER SHOWN)
FIG. 18-2
PLATFORM STOP
WELD
REQUIRED SHIM
THICKNESS
OUTBOARD
EDGE
SHACKLE
MARK HERE
1/4”
MARKING SHIM
POSITION
FIG. 18-3B
“A”
(TABLES 18-1
OR 18-2)
SHACKLES DO NOT TOUCH GROUND
(RAMP FLIPOVER SHOWN)
FIG. 18-3A
SHIMS TO RAISE WEDGE FLIPOVER
TABLE 18-2
18
3. Make shims as needed (FIG. 19-1). Position bottom edge of shim to line up with
mark on shackle (FIG. 18-3A). Next, weld
the shim to shackle as shown in FIG. 19-2.
1-1/2”
SHIM (1/16”, 1/8”, 3/16”, or 1/4”)
MADE FROM STEEL FLAT
FIG. 19-1
SHIM
(TABLES 18-1
OR 18-2)
CENTERED
PLATFORM
SHACKLE
(REF)
2 PLACES
“W”
(TABLES 18-1 OR 18-2)
WELDING SHIMS (RH SHACKLE SHOWN)
FIG. 19-2
19
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2-1/4”
PERIODIC MAINTENANCE
PLATFORM ADJUSTMENT - Continued
4. Make sure platform is still at ground
level. If the tip of flipover is not touching
the ground, measure and compare distance “B” (FIG. 20-1) with TABLE 20-1
or TABLE 20-2 to determine how much
to grind from the platform stops (FIG.
20-2).
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LOWER TIP OF
RAMP FLIPOVER
THIS DISTANCE “B”
“B”
(TABLES 20-1
OR 20-2)
GRIND METAL FROM
PLATFORM STOP
11/16”
1/16”
1-3/8”
1/8”
2-1/16”
3/16”
2-3/4”
1/4”
TIP OF FLIPOVER DOES NOT TOUCH
GROUND (RAMP FLIPOVER SHOWN)
FIG. 20-1
GRIND TO LOWER TIP
(RAMP FLIPOVER)
TABLE 20-1
LOWER TIP OF
WEDGE FLIPOVER
THIS DISTANCE “B”
9/16”
TIP OF
FLIPOVER
PLATFORM
STOP
PLATFORM
GRIND METAL FROM
PLATFORM STOP
1/16”
1-1/4”
1/8”
1-15/16”
3/16”
2-5/8”
1/4”
GRIND TO LOWER TIP
(WEDGE FLIPOVER)
TABLE 20-2
GRIND ENTIRE
SURFACE HERE
(TABLES 20-1
OR 20-2)
SHACKLE
(REF)
GRINDING PLATFORM STOPS
(RH SHACKLE SHOWN)
FIG. 20-2
5. Grind correct amount of metal (TABLE
20-1 or 20-2) from platform stop as
shown in FIG. 20-2.
6. 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. 20-3.
TIP OF
FLIPOVER
SHACKLE
PLATFORM & SHACKLES TOUCH
GROUND (RAMP FLIPOVER SHOWN)
FIG. 20-3
20
1. Fold flipover onto platform.
2. Fold platform.
3. Raise Liftgate to a convenient work
height to gain access and release
tension on the torsion spring.
ROLL PIN
(REMOVED)
TORSION
SPRING
!
PLATFORM
HINGE PIN
CAUTION
To prevent injury and equipment damage,
make sure there is no tension on torsion
spring before removing hinge pin.
4. Drive out the roll pin from pin collar on the
platform hinge bracket. Drive the platform
hinge pin outboard from the shackle just
enough to free the torsion spring (FIG.
21-1). Remove torsion spring.
PIN
COLLAR
SHACKLE
FIG. 21-1
SHORT LEG
5. Install the torsion spring as shown
in (FIG. 21-2). Make sure the
long leg of the spring is resting
against the block on the shackle
(FIG. 21-2). Make sure the short
end of the spring is positioned as
shown in FIG. 21-2.
LONG
LEG
PLATFORM
HINGE
BRACKET
BLOCK
SHACKLE
FIG. 21-2
21
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
REPLACING PLATFORM TORSION SPRING
PERIODIC MAINTENANCE
REPLACING PLATFORM TORSION SPRING - Continued
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
6. Drive platform hinge pin inboard to
correct position through the platform PLATFORM
hinge bracket (FIG. 22-1). Line up
HINGE PIN
the hole in the platform hinge pin
with the hole in the pin collar. Install
the roll pin through the pin collar until
roll pin protrudes equally from both
sides of the collar (FIG. 22-1).
7. Operate the Liftgate according to
instructions in Operation Manual
to make sure it operates correctly.
ROLL PIN
(INSTALLED)
PIN COLLAR
PLATFORM HINGE
BRACKET
FIG. 22-1
22
CHECK SAFETY HOOK FUNCTION
EXTENSION
PLATE
1. When raising platform to stowed position, listen for sound of safety hook
engaging platform loop.
PLATFORM LOOP
(WRONG POSITION)
CORRECT
POSITION
2. When the Liftgate is stowed, see if
platform loop is positioned above the
safety hook as shown in FIG. 23-1.
SAFETY
HOOK
PLATFORM
FIG. 23-1
LOOP ADJUSTMENT
1. If the safety hook is not positioned correctly,
lower platform to ground level (Operation
Manual).
EXTENSION
PLATE
PLATFORM LOOP
(WRONG POSITION)
2. Adjust by bending the platform loop as shown
in FIG. 23-2.
3. Stow the platform and check for correct
safety hook position. Repeat adjustment if
required.
BEND IN
THIS
DIRECTION
SAFETY
HOOK
CORRECT
POSITION
FIG. 23-2
LUBRICATION (IF REQUIRED)
1. Make sure front surface of safety
hook (FIG. 23-3) is lubricated with
automotive grease. Apply grease
if required.
CONTROL HANDLE ROD
(TYPICAL LUBE POINT)
BRACKETS
2. Make sure control handle rod
(FIG. 23-3) is lubricated where it
has contact with brackets. Apply
automotive grease if required.
SAFETY HOOK FRONT SURFACE
FIG. 23-3
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
SAFETY HOOK MAINTENANCE (IF EQUIPPED)
PARTS BREAKDOWN
72-150 & TE-20 MAIN ASSEMBLY (PAINTED)
REFER TO EXTENSION
PLATE ASSEMBLY
(PAINTED ONLY)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
5B
4
2
5
3
7
5C
5A
3A
6
REFER TO LIFT FRAME &
PARALLEL ARMS
2
1
REFER TO PUMP
COVER, HYDRAULIC
COMPONENTS &
POWER UNITS
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
(RAMP FLIPOVER SHOWN)
24
DESCRIPTION
269646-01
MAIN FRAME, 72-150 & TE-20
269630-02G
MAIN FRAME, 72-150 & TE-20 (GALVANIZED)
1
904717-06
ROLL PIN, 3/8” X 2” LG.
1
261895-101
PIN ASSEMBLY, 1” DIA X 5-1/8” LG.
1
224342
GREASE FITTING, 1/4”
4
1
260916-06
SELF LUBE BEARING, 1” DIA X 1” LG.
5
1
269638-01
OPENER ASSEMBLY
269638-01G
OPENER ASSEMBLY (GALVANIZED)
1
1
2
3
3A
5A
2
280082-01
ROLLER
5B
4
900033-10
CAP SCREW, 1/2”-20 X 3-1/2” LG, GRADE 8
5C
4
901008
LOCK NUT, 1/2”-20
6
2
901024-9
HEX FRAME BOLT, 1/2”-13 X 2-3/4” LG.
7
2
901023
FLANGE LOCK NUT, 1/2”-13
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
PARTS BREAKDOWN
72-150 & TE-20 MAIN ASSEMBLY (GALVANIZED)
REFER TO BOLT-ON
EXTENSION PLATE
REFER TO
STEPS ASSEMBLY
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
6
REFER TO
STEPS ASSEMBLY
5
4
5C
2
3
5A
7
3A
5B
REFER TO LIFT FRAME &
PARALLEL ARMS
1
REFER TO PUMP
COVER, HYDRAULIC
COMPONENTS &
POWER UNITS
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
(RAMP FLIPOVER SHOWN)
26
DESCRIPTION
269646-01
MAIN FRAME, 72-150 & TE-20
269630-02G
MAIN FRAME, 72-150 & TE-20 (GALVANIZED)
1
904717-06
ROLL PIN, 3/8” X 2” LG.
1
261895-101
PIN ASSEMBLY, 1” DIA X 5-1/8” LG.
1
224342
GREASE FITTING, 1/4”
4
1
260916-06
SELF LUBE BEARING, 1” DIA X 1” LG.
5
1
269638-01
OPENER ASSEMBLY
269638-01G
OPENER ASSEMBLY (GALVANIZED)
1
1
2
3
3A
5A
1
280082-01
ROLLER
5B
1
905202-03
CLEVIS PIN, 1/2” DIA X 2-1/2” LG.
5C
1
030805
COTTER PIN, 1/2” DIA. X 1” LG.
6
2
901024-9
HEX FRAME BOLT, 1/2”-13 X 2-3/4” LG.
7
2
901023
FLANGE LOCK NUT, 1/2”-13
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
EXTENSION PLATE ASSEMBLY (PAINTED)
VIEWED FROM UNDER
EXTENSION PLATE
4
3B
3C
3A
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3D
5
6
8
3
2
7
1
ITEM QTY. PART NO.
DESCRIPTION
REF
1
204090
EXTENSION PLATE ASSEMBLY (PAINTED)
1
6
207644
RIVET, 3/16” DIA, .40” LG
2
1
266705-01
MAXON PLATE
3
1
263000
EXTENSION PLATE WELDMENT
3A
1
215342
SPRING LEVER, 2-1/2” LG
3B
1
215341
SAFETY HOOK WELDMENT
3C
1
201606
HOOK RELEASE HANDLE, 5/8” X 52-3/4” LG
3D
2
201561
FLAT, 1/2” X 1/4”
4
1
215345
EXTENSION SPRING, 7/64” X 2-1/2” LG
5
1
203417
RENTAL LOCK BRACKET (OPTIONAL)
6
1
055011
HANDLE
7
1
203570
INNER BRACKET, RENTAL LOCK (OPTIONAL)
8
1
267338-01
MAX PRO DECAL (PAINTED MODELS ONLY)
28
4 (15 PLACES)
5
(15 PLACES)
3
3
2
1
ITEM QTY. PART NO.
DESCRIPTION
REF
1
285814-01G
BOLT-ON EXTENSION PLATE, 11” X 96” LG, GALVANIZED
1
6
207644
RIVET, 3/16” DIA, .40” LG
2
1
266705-01
MAXON PLATE
3
1
267338-01
MAX PRO DECAL (PAINTED MODELS ONLY)
4
15
283700-01
TEAR DROP WELDMENT
5
15
901024-2
HEX FRAME BOLT .1/2”-13 X 1-3/4” LG.
29
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BOLT-ON EXTENSION PLATE ASSEMBLY (GALVANIZED)
LIFT FRAME & PARALLEL ARMS
5A
4A
3
3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
5
4A
6A
3
4A
4A
4
1A
4
1A
1
5A
2A
3
6
2
1A
6A
10
1A
8A
8
3
7A
4A
3
4
9
7
3
4
4A
30
11
DESCRIPTION
285816-01
LIFT FRAME
285816-01G
LIFT FRAME (GALVANIZED)
4
260916-03
SELF LUBE BEARING, 1” DIA. X 1” LG.
1
261895-101
PIN, 1” DIA. X 5-1/8” LG.
1
224342
GREASE FITTING, 1/4” SELF DRILLING
3
9
904717-06
ROLL PIN, 3/8” X 2” LG.
4
6
252686-101
PIN, 1” DIA. X 4” LG.
6
224342
GREASE FITTING, 1/4” SELF DRILLING
285825-01
PARALLEL ARM, LH
285825-01G
PARALLEL ARM, LH (GALVANIZED)
260916-03
SELF LUBE BEARING, 1” DIA X 1” LG.
285825-02
PARALLEL ARM, RH
285825-02G
PARALLEL ARM, RH (GALVANIZED)
2
260916-03
SELF LUBE BEARING, 1” DIA X 1” LG.
1
262981-101
PIN 1” DIA. X 14” LG.
1
224342
GREASE FITTING, 1/4” SELF DRILLING
1
260830-101
PIN 1” DIA. X 7-1/4” LG.
1
224342
GREASE FITTING, 1/4” SELF DRILLING
9
1
201640
TORSION SPRING
10
1
262979-01
SHACKLE ASSEMBLY, LH
262979-01G
SHACKLE ASSEMBLY, LH (GALVANIZED)
11
1
262979-02
SHACKLE ASSEMBLY, RH
262979-02G
SHACKLE ASSEMBLY, RH (GALVANIZED)
1
1
1A
2
2A
4A
5
1
5A
6
2
1
6A
7
7A
8
8A
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
PLATFORM & FLIPOVER ASSEMBLY (RAMP)
2
4
5
2A
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
3
3
4
1
4
5
ITEM QTY. PART NO.
DESCRIPTION
205012
RAMP FLIPOVER (72” WIDE, 10” + 4” DEEP RAMP)
205012G
RAMP FLIPOVER (72” WIDE, 10” + 4” DEEP RAMP)
(GALVANIZED)
205012-01
RAMP FLIPOVER (84” WIDE, 10” + 4” DEEP RAMP)
205012-01G
RAMP FLIPOVER (84” WIDE, 10” + 4” DEEP RAMP)
(GALVANIZED)
262975-01
PLATFORM (72” WIDE, 22” DEEP)
269647-01G
PLATFORM (72” WIDE, 22” DEEP) (GALVANIZED)
262975-02
PLATFORM (84” WIDE, 22” DEEP)
269647-02G
PLATFORM (84” WIDE, 22” DEEP) (GALVANIZED)
2
260916-03
BEARING, SELF LUBE
3
2
900033-4
CAP SCREW, 1/2”-20 x 1-3/4” LG. GR8
4
4
902000-14
FLAT WASHER, 1/2”
5
2
901008
LOCK NUT, 1/2”-20
1
1
2
1
2A
32
2
4
5
2A
4
3
3
4
1
4
5
ITEM QTY. PART NO.
DESCRIPTION
266966-01
WEDGE FLIPOVER (72” WIDE, 14” DEEP WEDGE)
266966-01G
WEDGE FLIPOVER (72” WIDE, 14” DEEP WEDGE)
(GALVANIZED)
266966-02
WEDGE FLIPOVER (84” WIDE, 14” DEEP WEDGE)
266966-02G
WEDGE FLIPOVER (84” WIDE, 14” DEEP WEDGE)
(GALVANIZED)
262975-01
PLATFORM (72” WIDE, 22” DEEP)
269647-01G
PLATFORM (72” WIDE, 22” DEEP) (GALVANIZED)
262975-02
PLATFORM (84” WIDE, 22” DEEP)
269647-02G
PLATFORM (84” WIDE, 22” DEEP) (GALVANIZED)
2
260916-03
BEARING, SELF LUBE
3
2
900033-4
CAP SCREW, 1/2”-20 x 1-3/4” LG. GR8
4
4
902000-14
FLAT WASHER, 1/2”
5
2
901008
LOCK NUT, 1/2”-20
1
1
2
1
2A
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM & FLIPOVER ASSEMBLY (WEDGE)
SINGLE STEP ASSEMBLY (GALVANIZED, BOLT-ON)
10
1
6
(2 PLACES)
7
(2 PLACES)
(2 PLACES)
7
7
1
6
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
6
6
(2
PLACES)
(2 PLACES)
7
6
(2 PLACES)
(2 PLACES)
6
7
2
6
2
7
(2 PLACES)
(2 PLACES)
7
7
2
8
9
(3 PLACES)
6
(2 PLACES)
7
(2 PLACES)
6
6
(2 PLACES)
(3 PLACES)
7
(3 PLACES)
8
7
2 (2 PLACES)
9
(3 PLACES)
34
DESCRIPTION
285897-01
MOUNTING CHANNEL, LH
285897-02
MOUNTING CHANNEL, RH
1
285898-01G
LH SINGLE STEP , BOLT ON, GALVANIZED
3
1
285898-02G
RH SINGLE STEP, BOLT ON, GALVANIZED
4
1
285899-01G
LH SUPPORT WELDMENT, GALVANIZED
5
1
285899-02G
RH SUPPORT WELDMENT, GALVANIZED
6
16
901023
FLANGE LOCK NUT
7
16
901024-1
HEX FRAME BOLT 1.25
8
1
285896-01
RUBBER BUMPER, 2-1/2” X 3” X 18-3/4” LG.
9
3
092036-10
TUBE, 5/8” X 1-1/2” LG.
10
6
901024-8
HEX BOLT, 1/2” - 13 X 2-1/2” LG.
1
1
2
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
DUAL STEP ASSEMBLY (GALVANIZED, BOLT ON)
5
8
(2 PLACES)
10
(2 PLACES)
7
(2 PLACES)
7
8
(2 PLACES)
10
6
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4
10
(2 PLACES)
7
(2 PLACES)
7
(2 PLACES)
12
10
(2 PLACES)
10
8
(2 PLACES) (2 PLACES)
5
10
(2 PLACES)
10
2
11
(3 PLACES)
(2 PLACES)
13
(3 PLACES)
7
(2 PLACES)
6
7
3
10
10
(2 PLACES)
7
(2 PLACES)
11
(2 PLACES)
10
13
(3 PLACES)
36
12
7
(2 PLACES)
(2 PLACES)
10
1
(3 PLACES)
DESCRIPTION
285819-01
LH BOLT-ON DUAL STEP
285819-01G
LH BOLT-ON DUAL STEP (GALVANIZED)
285819-02
RH BOLT-ON DUAL STEP
285819-02G
RH BOLT-ON DUAL STEP (GALVANIZED)
1
283990-04
RH SUPPORT
4
1
283990-03
LH SUPPORT
5
2
283993-01
MOUNTING CHANNEL
283993-01G
MOUNTING CHANNEL (GALVANIZED)
6
2
283998-01
SPACER JUMPER
283998-01G
SPACER JUMPER (GALVANIZED)
16
901024-1
HEX BOLT, 1/2”-13 X 1-1/4” LG.
20
901024-1
HEX BOLT, 1/2”-13 X 1-1/4” LG. (IF EQUIPPED WITH WALK
RAMP)
8
4
901024-3
HEX FRAME BOLT, 1/2”-13 X 2-1/4” LG
9
6
901024-8
HEX FRAME BOLT 1/2”-13 x 2-1/2” LG. (IF EQUIPPED WITH 24”
BUMPER)
24
901023
FLANGED LOCK NUT 1/2”-13 (IF EQUIPPED WITH 6” BUMPER)
26
901023
FLANGED LOCK NUT 1/2”-13 (IF EQUIPPED WITH 24” BUMPER)
285492-01
RUBBER BUMPER, 1-7/8” X 1 X 6” LG.
905344-01
RUBBER BUMPER, 21/2” X 3 X 24” LG.
1
1
2
1
3
7
10
11
2
12
6
092036-10
TUBE, 5/8” X 1-1/2” LG.
13
6
901024-8
HEX FRAME BOLT, 1/2”-13 X 21/2” LG.
37
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
PUMP COVER & MOUNTING PLATE ASSEMBLY (GRAVITY DOWN)
12
8
9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
14
11
(4 PLACES)
4
2
11
13
6
(5 PLACES)
3
7
10
(5 PLACES)
5
9
12 VDC POWER UNIT
OR
24 VDC POWER UNIT
(REF, GRAVITY DOWN)
1A
1
38
1B
QTY. PART NO.
DESCRIPTION
266406-01
PUMP ASSEMBLY, GRAVITY DOWN (12 VOLT)
266406-01G
PUMP ASSEMBLY, GRAVITY DOWN (12 VOLT, GALVANIZED)
266406-24
PUMP ASSEMBLY, GRAVITY DOWN (24 VOLT)
266406-24G
PUMP ASSEMBLY, GRAVITY DOWN (24 VOLT, GALVANIZED)
1
266419-01
COVER ASSEMBLY
1A
1
096045-10
ADHESIVE FOAM STRIP, 60” LG.
1B
1
261740
LABEL, OIL LEVEL
266427-01
PLATE, PUMP MOUNT
266427-01G
PLATE, PUMP MOUNT (GALVANIZED)
REF
1
1
2
1
3
1
266428-01
GROMMET, 3/16” HOLE
4
3
266428-02
GROMMET, 1/4”HOLE
5
1
266428-06
GROMMET, 9/16” HOLE
6
5
900009-3
SCREW, CAP 5/16”-18 X 3/4” LG, GR8
7
1
900014-4
SCREW, CAP 3/8”-16 X 1” LG, GR8
8
1
900014-5
SCREW, CAP 3/8”-16 X 1-1/4” LG, GR8
9
2
902011-4
LOCK WASHER, 3/8”
10
5
902000-7
FLAT WASHER, 5/16”
11
5
902013-11
FLAT WASHER, 3/8”
12
1
282895-01
GROUND JUMPER
13
1
908022-02
PLUG, FLEXIBLE
14
1
901002
LOCK NUT, 3/8’-16
39
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
PUMP COVER & MOUNTING PLATE ASSEMBLY (POWER DOWN)
12
8
9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
13
11
(4 PLACES)
2
4
11
3
6
(5 PLACES)
5
10
(5 PLACES)
5
7
9
12 VDC POWER UNIT
(REF, POWER DOWN)
1A
1
40
1B
DESCRIPTION
268180-01
PUMP ASSEMBLY, POWER DOWN
268180-01G
PUMP ASSEMBLY, POWER DOWN (GALVANIZED)
1
266419-01
COVER ASSEMBLY
1A
1
096045-10
ADHESIVE FOAM STRIP, 60” LG.
1B
1
261740
LABEL, OIL LEVEL
268179-01
PLATE, PUMP MOUNT
268179-01G
PLATE, PUMP MOUNT (GALVANIZED)
REF
1
1
2
1
3
1
908022-02
PLUG, FLEXIBLE
4
3
266428-02
GROMMET, 1/4”HOLE
5
2
266428-06
GROMMET, 9/16” HOLE
6
5
900009-3
SCREW, CAP 5/16”-18 X 3/4” LG, GR8
7
1
900014-4
SCREW, CAP 3/8”-16 X 1” LG, GR8
8
1
900014-5
SCREW, CAP 3/8”-16 X 1-1/4” LG, GR8
9
2
902011-4
LOCK WASHER, 3/8”
10
5
902000-7
FLAT WASHER, 5/16”
11
5
902013-11
FLAT WASHER, 3/8”
12
1
282895-01
GROUND JUMPER
13
1
901002
LOCK NUT, 3/8’-16
41
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
42
SEE 12 VDC POWER UNIT
(GRAVITY DOWN)
8
1
6
1A
7
9
5
3
2
4
10
ITEM QTY. PART NO.
DESCRIPTION
266408-01
CYLINDER ASSY, 3-1/2” DIA X 10” STROKE X
1-1/2” ROD DIA (TE-25)
266401-02
CYLINDER ASSY, 3-1/2” DIA X 10” STROKE X
1-1/4” ROD DIA (TE-25L)
1
260916-03
BEARING, SELF LUBE
2
1
906722-01
ELBOW, 90 DEG O-RING, #6 M-M
3
1
906923-01
FLOW REGULATOR VALVE, 2 GPM
4
1
288241-01
HOSE ASSY, 3/8” HP, 54” LG.
5
1
224370-07
HOSE, PLASTIC 60-1/2” LG.
6
1
228012
ADAPTER, STRAIGHT THREAD, 9/16”-18 M - 1/4” F
7
1
202406
ELBOW, BRASS 1/4” x 1/4”
8
1
906728-01
DUAL BARBED FITTING, 1/64” I.D.
9
1
906786-01
UNION, STRAIGHT, #6 M-M (IF EQUIPPED WITH HYDRAULIC LOCK)
10
1
282999-01
HYDRAULIC LOCK VALVE ASSEMBLY, 12V (IF EQUIPPED)
282999-02
HYDRAULIC LOCK VALVE ASSEMBLY, 24V (IF EQUIPPED)
1
1A
1
43
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC COMPONENTS (GRAVITY DOWN)
12 VDC POWER UNIT (GRAVITY DOWN)
CAUTION
To prevent damage to metal case starter solenoid, hold bottom terminal
nut securely with wrench when loosening and tightening top terminal nut.
Do not over-tighten the terminal nuts. For the 5/16” load terminals, torque
nuts to 35 lbs.-in. Torque the nuts on #10-32 control terminals to 15 lbs.-in.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
To prevent damage when installing 2-way valves, torque valve cartridge
nut to 30 lbs.-in. max.
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
3
12
15
9
4
COVER (REF)
13
10
CONTROL SWITCH
WIRING HARNESS
(REF. CONTROL SWITCH
& POWER CABLE)
5
1A,1B
2
6
1
14
7
11
8
44
BARB FITTING
(REF. GRAVITY
DOWN HYDRAULIC
COMPONENTS)
DESCRIPTION
REF
1
268070-01
12 VDC POWER UNIT (GRAVITY DOWN)
1
1
290002
3-PIECE GEAR PUMP
1A
1
226594
OIL SEAL KIT
1B
1
290020
O-RING
2
1
268027-01
WIRE ASSEMBLY, 18 GA, #10 RING - 5/16” RING
3
1
280404
CABLE ASSEMBLY
4
1
268029-01
SOLENOID SWITCH
5
1
905152
ELBOW, 90 DEG, O-RING
6
1
280806-01
FILLER CAP
7
1
267733-11
RESERVOIR, 3 QT, VERTICAL WITH VENT
8
1
908017-01
DRAIN PLUG
9
1
280416
WIRE ASSEMBLY
10
1
290043
VALVE ASSEMBLY, 2 WAY
11
1
908018-01
GROMMET, 5/16” I.D.
12
1
280374
MOTOR, 12 VOLT DC
13
1
906740-01
RELIEF VALVE (RED SPRING)
14
1
908016-01
GROMMET, 3/4” I.D.
15
1
268024-01
WIRE ASSY, 16GA WHITE, 3” LG
45
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
24 VDC POWER UNIT (GRAVITY DOWN)
CAUTION
To prevent damage to plastic case starter solenoid, hold bottom terminal
nut securely. Do not over-tighten the terminal nuts. For the 5/16” load terminals, torque nuts to 35 lbs.-in. Torque the nuts on #10-32 control terminals to 15 lbs.-in.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
12
3
2
CONTROL SWITCH
WIRING HARNESS
(REF)
4
9
COVER (REF)
13
10
5
6
11
14
1
7
8
46
15
DESCRIPTION
REF
1
280610-24
24 VDC POWER UNIT (GRAVITY DOWN)
1
1
290065
3-PIECE GEAR PUMP
2
1
280566-01
WIRE ASSEMBLY, 16 GA, GREEN
3
1
280404
CABLE ASSEMBLY
4
1
281571-01
MOTOR STARTER SOLENOID, 24 VOLT DC
5
1
905152
90 DEG ELBOW
6
1
280806-01
FILLER CAP
7
1
280589-01
RESERVOIR
8
1
908017-01
DRAIN PLUG
9
1
280416
WIRE ASSEMBLY
10
1
281572-01
24 VDC COIL
11
1
906719-01
VALVE
12
1
281573-01
MOTOR, 24 VOLT DC
13
1
906737-01
RELIEF VALVE
14
1
908016-01
GROMMET, 19/32”
15
1
908018-01
GROMMET, 5/16”
47
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
48
SEE 12 VDC POWER UNIT
(POWER DOWN)
1
7
2
3
9
4
ITEM
1
QTY.
8
5
PART
NO.
6
DESCRIPTION
266408-01
CYLINDER ASSY, 3-1/2” DIA X 10” STROKE X
1-1/2” ROD DIA (TE-25)
266401-02
CYLINDER ASSY, 3-1/2” DIA X 10” STROKE X
1-1/4” ROD DIA (TE-25L)
1
2
1
905152
ELBOW, 90 DEG SAE #6-JIC37 #6
3
1
260916-03
BEARING, SELF LUBE
4
1
906722-01
ELBOW, 90 DEG, O-RING, #6 M-M
5
1
906923-01
FLOW REGULATOR VALVE, 2 GPM
6
1
288241-01
HOSE ASSEMBLY, 3/8”HP, 54”LG.
7
1
280634-01
HOSE ASSEMBLY, 3/8”HP, 50”LG.
8
1
906786-01
UNION, STRAIGHT, #6 M-M (IF EQUIPPED WITH HYDRAULIC
LOCK)
9
1
282999-01
HYDRAULIC LOCK VALVE ASSEMBLY, 12V (IF EQUIPPED)
282999-02
HYDRAULIC LOCK VALVE ASSEMBLY, 24V (IF EQUIPPED)
49
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC COMPONENTS (POWER DOWN)
12 VDC POWER UNIT (POWER DOWN)
CAUTION
To prevent damage to metal case starter solenoid, hold bottom terminal
nut securely with wrench when loosening and tightening top terminal nut.
Do not over-tighten the terminal nuts. For the 5/16” load terminals, torque
nuts to 35 lbs.-in. Torque the nuts on #10-32 control terminals to 15 lbs.-in.
CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
To prevent damage when installing 2-way valves, torque valve cartridge
nut to 30 lbs.-in. max.
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
7
1
15
2
CONTROL SWITCH
WIRING HARNESS
(REF. CONTROL SWITCH
& POWER CABLE)
COVER (REF)
15
13
6
14
3
3B
4B
4
5
3A
4A
9
15
8
10
12
11
50
QTY
PART NO.
DESCRIPTION
REF
1
268181-01
12 VDC POWER UNIT (POWER DOWN)
1
1
268176-01
MOTOR, 12 VDC
2
1
268029-01
SWITCH, SOLENOID
3
1
906821-01
2P2W VALVE & COIL ASSEMBLY, 4 WAY, DOUBLE SPADE
3A
1
906822-01
2P2W VALVE
3B
1
290045
COIL, DOUBLE SPADE, 2 WAY
4
1
290046
VALVE ASSEMBLY, 4 WAY, DOUBLE SPADE
4A
1
290047
VALVE CARTRIDGE, 4 WAY
4B
1
290048
COIL, DOUBLE SPADE, 3 OR 4 WAY
5
2
280416
WIRE ASSEMBLY
6
1
268079-01
WIRE ASSEMBLY, 18 GA, #10 RING - 5/16” RING
7
1
280404
CABLE ASSEMBLY
8
1
267733-01
RESERVOIR, 3 QT, VERTICAL WITH VENT
9
1
280806-01
FILLER CAP
10
1
908016-01
GROMMET, 3/4” I.D.
11
1
908017-01
DRAIN PLUG
12
1
908018-01
GROMMET, 5/16” I.D.
13
1
906738-02
RELIEF VALVE, ADJUST, 3200PSI
14
1
268174-01
RELIEF VALVE, ADJUST, 1100PSI
15
2
905152
ELBOW, 90 DEG, O-RING
51
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
OPTIONAL BATTERY BOX ELECTRICAL COMPONENTS
NOTE: MAXON recommends using dielectric grease on all electrical connections.
12 VOLT BATTERY CONNECTIONS
FOR 12 VOLT POWER
3
(GROUND CABLE
TO PUMP BOX)
(-) BATTERY CABLE
TO COMMON
GROUND
4
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FUSED CABLE
TO TRUCK
OR TRACTOR
BATTERY
6
5
(FUSED CABLE
TO PUMP BOX)
(IN PARTS BOX)
1
2
FIG. 52-1
3
(GROUND CABLE
TO PUMP BOX)
5
(FUSED CABLE
TO PUMP BOX)
(IN PARTS BOX)
12 VOLT BATTERY CONNECTIONS
FOR 24 VOLT POWER
(-) BATTERY CABLE
TO COMMON
GROUND
FUSED CABLE
TO TRUCK
OR TRACTOR
BATTERY
6
1
2
FIG. 52-2
52
QTY
PART NO.
DESCRIPTION
1
1
221736
CIRCUIT BREAKER 150 AMP
2
1
269308-18
CABLE ASSEMBLY, 2 GA (RED),18” LG.
3
1
268226-06
CABLE ASSEMBLY, 2 GA, 74” LG.
4
1
251871-14
CABLE ASSEMBLY, 2 GA, 10” LG
5
1
285487-02
CABLE ASSEMBLY, 2 GA, 200 AMP, 42” LG.
6
1
269308-10
CABLE ASSEMBLY, 2 GA (RED),10” LG.
53
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
OPTIONAL BATTERY BOX ASSEMBLY
!
WARNING
Explosive hydrogen gas from charging batteries can accumulate in battery box if
not vented from the box. To prevent hydrogen gas from accumulating, ensure the
3 ventilation holes in battery box are not plugged or covered.
VENTILATION HOLES
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
REFER TO
BATTERY BOX
11, 12, 13
(2 PLACES)
9
(3 PLACES)
10 (3 PLACES)
6
8 (3 PLACES)
6 (3 PLACES)
4 (4 PLACES)
ROD ANCHOR
POINT (REF)
(3 PLACES)
7
1
3
(4 PLACES)
2
(4 PLACES)
5
(4 PLACES)
54
QTY
PART NO.
DESCRIPTION
1
1
269535-01G
BATTERY MOUNT PLATE WELDMENT, GALVANIZED
2
4
902013-14
FLAT WASHER, 9/16”
3
4
902011-7
LOCK WASHER, 9/16”
4
4
900033-6
CAP SCREW, 1/2”-20 X 2-1/4” LG., GR8
5
4
901011-10
HEX NUT, 1/2”-20
6
3
227722-01
ROD, L-SHAPE BATTERY HOLD DOWN
7
1
250479
BRACKET (BATTERY HOLD DOWN)
8
3
902013-10
FLAT WASHER, 5/16”
9
3
901005
HEX NUT, 5/16”-18, GR8
10
3
902011-3
LOCK WASHER, #10
11
2
902013-09
FLAT WASHER, 1/4”
12
2
900002-4
PAN HEAD SCREW, 1/4”-20 X 1 LG.
13
2
901000
LOCK NUT, 1/4”-20
55
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
OPTIONAL BATTERY BOX
4
2
(4 PLACES)
4
(4 PLACES)
1
5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
6
8
5
12
3
8
7
13
(2 PLACES)
14
(2 PLACES)
11
(2 PLACES)
9
11
(4 PLACES)
10
(4 PLACES)
56
QTY
PART NO.
DESCRIPTION
REF
1
269561-01
BATTERY BOX
1
1
269526-01
BOX
2
4
908022-03
PLUG, 5/16”
3
1
908022-08
PLUG, 1-1/16”
4
6
908022-07
PLUG, 1/4”
5
4
266428-02
GROMMET, 1”
6
1
269558-01
COVER
7
2
908193-01
RUBBER LATCH
8
2
908194-01
FASTENING KNOB
9
2
285884-01
BATTERY BOX HINGE STAINLESS STEEL
10
8
903715-03
BLIND RIVET, 1/4” X 1/4”-3/8”
11
10
903438-01
WASHER, 1/4”
12
2
908022-05
PLUG, 9/16”
13
2
900719-07
BUTTON HEAD SCREW, 1/4”-20 X 1” LG.
14
2
903137-01
LOCK NUT, 1/4”-20, NYLON
57
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
DECALS
NOTE: Ensure there is no residue, dirt or corrosion where decals are attached.
If necessary, clean surface before attaching decals.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STOW WARNING DECAL
P/N 282847-02
CAPACITY DECAL
(72-150 ONLY)
P/N 220386
RAISE/LOWER DECAL
P/N 264507
CAPACITY DECAL
(TE-20 ONLY)
P/N 220387
WARNING DECAL
(2 PLACES, LH SIDE NOT SHOWN)
P/N 265736-03
WARNING & CAUTION
DECAL SHEET
P/N 282522-01
FIG. 58-1
58
INSTRUCTION DECAL
P/N 251867-06
FIG. 59-1
59
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECAL SHEET
P/N 282522-01
CONTROL SWITCH AND POWER CABLE
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.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BLACK
(TO
POWER
UNIT)
WHITE
BLACK
(FOR REFERENCESEE DECALS)
WHITE
2
1
4
GREEN
GREEN
RED
(POWER DOWN
VERSION ONLY)
3
ITEM QTY. PART NO.
1
1
DESCRIPTION
268025-01
CABLE ASSEMBLY, 85” LG (12 VDC GRAVITY DOWN)
280637-01
CABLE ASSEMBLY, 84” LG (24 VDC GRAVITY DOWN)
268170-01
CABLE ASSEMBLY, 85” LG (POWER DOWN)
267959-01
MOLDED SWITCH ASSEMBLY (GRAVITY DOWN)
264951-04
MOLDED SWITCH ASSEMBLY (POWER DOWN)
2
1
3
2
900057-5
SCREW, SELF-TAPPING #10-24 X 1” LG.
4
1
905206
SWITCH BOOT SEAL
5
1
264422
CABLE ASSEMBLY, 175 AMPS, 38’ LG
6
1
264687
KIT, MEGAFUSE (175 AMP FUSE & HEATSHRINK TUBING)
SHORT END TO
VEHICLE BATTERY
6
5
! WARNING
Do not attach cable to battery until
Liftgate repairs are completed.
LONG END TO PUMP
MOTOR SOLENOID
60
HYDRAULIC SYSTEM DIAGRAMS
HYDRAULIC CYLINDER
2 GPM FLOW
CONTROL VALVE
RETURN PORT
(PLUGGED)
VENT PORT
PRESSURE PORT
VALVE A
RELIEF VALVE
(SET AT 3250 PSI)
CHECK VALVE
AUX. HAND
PUMP PORT
(PLUGGED)
PUMP
M
MOTOR
(REFERENCE)
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
61
FILLER HOLE
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC (GRAVITY DOWN)
HYDRAULIC SCHEMATIC (POWER DOWN)
HYDRAULIC CYLINDER
2 GPM FLOW
CONTROL
VALVE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PORT B - LOWER
(POWER DOWN)
PORT A - RAISE
VALVE A
RELIEF VALVE 2
(SET AT 1100 PSI)
VALVE E
RELIEF VALVE 1
(SET AT 3200 PSI)
MOTOR
(REF)
PUMP
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
62
AUX. HAND
PUMP PORT
(PLUGGED)
ELECTRICAL SYSTEM DIAGRAMS
CONTROL SWITCH
WHITE
GREEN BLACK
WHITE
GREEN BLACK
CABLE
ASSEMBLY
THERMAL
SWITCH
(IN MOTOR
CASING)
SOLENOID,
VALVE A
STARTER
SOLENOID
CABLE WITH
175 AMP FUSE
MOTOR
BATTERY
63
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SCHEMATIC (GRAVITY DOWN)
ELECTRICAL SCHEMATIC (POWER DOWN)
RED
BLACK
(DOWN)
(UP)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WHITE
CONTROL SWITCH
BLACK
WHITE
GREEN
RED
GREEN
CABLE
ASSEMBLY
THERMAL
SWITCH
(IN MOTOR
CASING)
STARTER
SOLENOID
SOLENOID,
VALVE A
GREEN
CABLE WITH
175 AMP FUSE
BATTERY
64
SOLENOID,
VALVE E
TROUBLESHOOTING
1. Use voltmeter to verify power is being supplied to solenoid terminal “B”
(FIG. 65-1). Recharge the battery if there is less than 12.6 volts.
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. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
3. Touch a jumper wire to terminals “B” & “D” (FIG. 65-1). 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. 65-1).
a. If motor runs, replace the motor solenoid.
b. If motor does not run, repair or replace the pump motor.
NOTE: In most cases, you can avoid having to manually bleed hydraulic system by
correctly positioning Liftgate platform before disconnecting any lifting cylinder high pressure hydraulic lines. The following procedure can save time and
prevent accidental fluid spills and hazards.
5. Check for structural damage and
replace worn parts.
6. Check filter in the pump reservoir.
Replace filter if necessary.
7. Check for dirty pump motor relief
valve. Clean if necessary.
Replace any worn out relief valve
parts.
STARTER
SOLENOID
TERMINAL “A”
MOTOR (+)
TERMINAL “C”
GROUND (-)
TERMINAL “D”
SWITCHED
BATTERY (+)
TERMINAL “B”
BATTERY (+)
LOWERING
SOLENOID
FIG. 65-1
65
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT RAISE
PLATFORM RAISES BUT LEAKS DOWN
1. Check if solenoid valves are constantly energized by
touching a screwdriver to the top nut of the solenoid
(FIG. 66-1). Try pulling the screwdriver away from the
solenoid. If the solenoid nut attracts the screwdriver
(magnetically) without pushing the toggle switch, the control circuit is operating incorrectly. Check if toggle switch,
wiring or coil are faulty.
COIL
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FIG. 66-1
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to manually bleed hydraulic system by
correctly positioning Liftgate platform before disconnecting any lifting cylinder high pressure hydraulic lines. The following procedure can save time and
prevent accidental fluid spills and hazards.
2. Check the valve stem by removing the coil
assembly (Item 1, FIG. 66-2). With platform
on ground, unscrew the valve stem (Item 2,
FIG. 66-2) from the pump. Push on the plunger
that is located inside the valve stem by inserting a small screwdriver blade in the end. If the
plunger does not move freely, (approximately
1/8”) replace the valve stem. When reinstalling valve stem, torque hex nut to 30 in-lbs.
3. Check the hydraulic cylinder. With the platform
on the ground, remove the hydraulic line from
the vent/down port of the cylinder (FIG. 663). Raise the platform even with the bed. Allow
pump motor to run two seconds more while
you watch for hydraulic fluid at the vent/down
port. A few drops of hydraulic fluid escaping
the vent/down port is normal; however, if it
streams from the vent/down port, piston seals
are worn. Replace seals.
66
2
1
1/8”
FIG. 66-2
VENT/DOWN PORT
RAISE PORT
FIG. 66-3
TROUBLESHOOTING
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
1. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
2. Use voltmeter to verify the battery shows 12.6 volts or more.
3. Check for structural damage and poor lubrication. Replace worn parts.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate platform before opening hydraulic lines. Refer to following
procedure. Save time on the job and prevent accidental fluid spills and hazards.
4. Check the hydraulic cylinder. With the platform
on the ground, remove the breather plug or
vent line from the vent/down port of the cylinder (FIG. 67-1). Raise the platform even with
the bed. Allow pump motor to run two seconds
more while you watch for hydraulic fluid at the
vent/down port. A few drops of hydraulic fluid
escaping the vent/down port is normal; however, if it streams from the vent/down port, piston
seals are worn. Replace seals.
5. Check filter in the pump reservoir. Replace
filter if necessary.
6. Check for dirty pump motor relief valve. Clean
if necessary. Replace any worn out relief valve
parts.
67
VENT/DOWN PORT
PRESSURE
PORT
FIG. 67-1
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 the battery shows 12.6 volts or more under load from pump motor.
2. Check for structural damage and lack of lubrication. Replace worn parts.
CAUTION
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 0-4000 PSI pressure gauge. Hold the switch in
the “UP” position. Adjust the relief valve on the
side of the pump until the gauge shows 3250 PSI
(FIG. 68-2). Remove gauge and reinstall pressure
hose.
VENT/DOWN PORT
PRESSURE
PORT
4. Check for dirty pump motor relief valve. Clean if
necessary. Replace any worn out relief valve
parts.
FIG. 68-1
5. Check the hydraulic cylinder. With the platform
on the ground, remove the breather plug or vent
line from the vent/down port of the cylinder (FIG.
68-1). Raise the platform even with the bed.
Allow pump motor to run two seconds more while
you watch for hydraulic fluid at the vent/down port.
A few drops of hydraulic fluid escaping the vent/
down port is normal; however, if it streams from
the vent/down port, piston seals are worn. Replace seals.
RELIEF
VALVE
ADJUST
SCREW
(REMOVE
PLUG)
6. If pump cannot produce 3250 PSI can’t lift load
capacity with a minimum of 12.6 volts available,
the pump is worn and needs to be replaced.
PRESSURE
GAUGE
68
FIG. 68-2
TROUBLESHOOTING
1. Use voltmeter to verify power is being supplied to
solenoid terminal “B”. Recharge the battery if voltmeter indicates less than 12.6 volts (FIG. 69-1).
TERMINAL
“B”
BATTERY (+)
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.
FIG. 69-1
2. Check the hydraulic cylinder. With the platform on the ground, remove the breather plug
or vent line from the vent/down port of the cylinder (FIG. 69-3). Raise the platform even
with the bed. Allow pump motor to run two seconds more while you watch for hydraulic
fluid at the vent/down port. A few drops of hydraulic fluid escaping the vent/down port is
normal; however, if it streams from the vent/down port, piston seals are worn. Replace
seals.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate platform before opening hydraulic lines. Refer to following
procedure. Save time on the job and prevent accidental fluid spills and hazards.
3. Check and clean flow control valve in high pressure hydraulic line attached to cylinder.
When installing flow control valve, make sure arrow on valve is oriented as shown
in FIG. 69-3.
4. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
5. Verify the pump motor is grounded to the vehicle frame.
6. Check for leaking hoses and fittings. Tighten or replace
as required.
PRESSURE
GAUGE
RELIEF
VALVE
ADJUST
SCREW
(REMOVE
PLUG)
7. Check for structural damage or poor lubrication. Replace
worn parts.
8. Check the filter in the pump reservoir. Replace if necessary.
9. With platform on the ground, remove the pressure
FIG. 69-2
VENT/DOWN
PORT
hose and fitting from the pump and replace it with a
0-4000 PSI pressure gauge. Hold the control switch in PRESSURE
the “raise” position. Adjust the relief valve on the side of
PORT
the pump until the gauge shows 3250 PSI (FIG. 69-2).
Remove gauge and reinstall pressure hose.
FLOW
CONTROL
VALVE
FIG. 69-3
69
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES SLOWLY
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
70
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY
1. Use voltmeter to verify power is being supplied to
solenoid terminal “B”. Recharge the battery if voltmeter displays less than 12.6 volts (FIG. 71-1).
TERMINAL
“B”
BATTERY (+)
2. Check for structural damage or poor lubrication.
Replace worn parts.
3. Check if solenoid valve is getting power by holding a
screwdriver against the top nut of the solenoid. Push
control switch to “lower” position to energize solenoid
(FIG. 71-2). A good solenoid will attract (magnetically)
the screwdriver to the nut and make it difficult to pull
the screwdriver away from the nut.
FIG. 71-1
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate platform before opening hydraulic lines. Refer to following
procedure. Save time on the job and prevent accidental fluid spills and hazards.
4. Check the valve stem by removing the coil assembly (Item 1, FIG. 71-2). With platform supported,
unscrew the valve stem (Item 2, FIG. 71-2) from
the pump. Push on the plunger located inside the
valve stem by inserting a small screwdriver blade in
the end. If the plunger does not move freely (approximately 1/8”), replace the valve stem.
2
1
1/8”
FIG. 71-2
5. Check if filtering screen on solenoid valve is
plugged. Clean carefully if required.
6. Check and clean flow control valve in high
pressure hydraulic line attached to cylinder.
7. Check if flow control valve (FIG. 71-3) is
pointing to the direction of restricted fluid
flow (back toward pump). If required, remove
flow control valve and install it correctly (FIG.
71-3).
VENT/DOWN PORT
(REF)
RAISE PORT
(REF)
FLOW
CONTROL
VALVE
FIG. 71-3
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