Maxon TE-25 TE-25L Maintenance Manual

Maxon TE-25 TE-25L Maintenance Manual
M-11-20
REV. A
JUNE 2014
MAINTENANCE MANUAL
© 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-11-20, REVISION A ............................................................. 6
WARNINGS & SAFETY INSTRUCTIONS ............................................................................ 8
LIFTGATE TERMINOLOGY (PAINTED MODELS) ............................................... 10
LIFTGATE TERMINOLOGY (GALVANIZED MODELS) .........................................11
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PERIODIC MAINTENANCE................................................................................................ 12
PERIODIC MAINTENANCE CHECKS ................................................................................ 12
PERIODIC MAINTENANCE CHECKLIST ........................................................................... 13
CHECKING HYDRAULIC FLUID ........................................................................................ 14
CHANGING HYDRAULIC FLUID ........................................................................................ 16
PLATFORM ADJUSTMENT ................................................................................................ 18
REPLACING PLATFORM TORSION SPRING ................................................................... 20
SAFETY HOOK MAINTENANCE ....................................................................................... 23
PARTS BREAKDOWN ....................................................................................................... 24
TE-25 MAIN ASSEMBLY ..................................................................................................... 24
TE-25 MAIN ASSEMBLY (GALVANIZED) ........................................................................... 25
EXTENSION PLATE ASSEMBLY (PAINTED, WELD ON) .................................................. 26
EXTENSION PLATE ASSEMBLY (GALVANIZED, BOLT ON)............................................. 27
LIFT FRAME & PARALLEL ARMS ...................................................................................... 28
PLATFORM & FLIPOVER ASSEMBLY (RAMP) ................................................................. 30
SINGLE STEP ASSEMBLY (TE-25L GALVANIZED, BOLT ON) ......................................... 33
DUAL STEP ASSEMBLY (TE-25 GALVANIZED & PAINTED, BOLT ON) ........................... 34
PUMP COVER & MOUNTING PLATE ASSEMBLY ............................................................ 36
HYDRAULIC COMPONENTS (GRAVITY DOWN) .............................................................. 39
12 VDC POWER UNIT (GRAVITY DOWN) ......................................................................... 40
24 VDC POWER UNIT (GRAVITY DOWN) ......................................................................... 42
4
12 VDC POWER UNIT (POWER DOWN)........................................................................... 46
DECALS .............................................................................................................................. 48
ELECTRICAL COMPONENTS ............................................................................................ 51
CONTROL SWITCH & POWER CABLE ............................................................................. 51
OPTIONAL BATTERY BOX ELECTRICAL COMPONENTS ............................................... 52
OPTIONAL BATTERY BOX ASSEMBLY ............................................................................. 54
OPTIONAL BATTERY BOX ................................................................................................. 56
SYSTEM DIAGRAMS ......................................................................................................... 59
PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) ....................................... 59
HYDRAULIC SCHEMATIC (GRAVITY DOWN)................................................................... 60
ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 61
PUMP & MOTOR SOLENOID OPERATION (POWER DOWN).......................................... 63
HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 64
ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 65
TROUBLESHOOTING ........................................................................................................ 66
PLATFORM WILL NOT RAISE............................................................................................ 66
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 67
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 68
LIFTGATE WILL NOT LIFT RATED CAPACITY .................................................................. 69
PLATFORM RAISES SLOWLY ........................................................................................... 70
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY ................ 71
5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC COMPONENTS (POWER DOWN)................................................................ 45
SUMMARY OF CHANGES: M-11-20, REVISION A
PAGE
DESCRIPTION OF CHANGE
COVER
Updated REV and date of release.
6
Added SUMMARY OF CHANGES
23
Revised instructions on adjusting safety hook
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
40, 42, 46
39, 45, 70-71
48-50
Clarified torque specs for electrical connections on started solenoid
Updated flow regulator (control) valve P/N 906923-01, HP hose P/N 288241-01 and
description
Replaced Warning decal P/N 282479-01 with WARNING & CAUTION decal sheet
P/N 282522-01. Added FAMILY OWNED DECAL P/N 283445-01
6
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.
WARNINGS & SAFETY
INSTRUCTIONS
! WARNING
• 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.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• 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. 8-1). To minimize hazard remove galvanizing from weld area, provide
adequate ventilation, and wear suitable respirator.
FIG. 8-1
8
• 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.
• 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
9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
SAFETY INSTRUCTIONS
LIFTGATE TERMINOLOGY
(PAINTED MODELS)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL
SWITCH
LIFT
CYLINDER
EXTENSION
PLATE
CONTROL
HANDLE
PLATFORM
OPENER
LIFT FRAME
PARALLEL
ARM
PUMP COVER
PLATFORM
MAIN
FRAME
WEDGE FLIPOVER
FIG. 10-1
10
LIFTGATE TERMINOLOGY
CONTROL
SWITCH
EXTENSION
PLATE
DOCK BUMPER
LIFT
CYLINDER
PLATFORM
OPENER
LIFT FRAME
PARALLEL
ARM
PLATFORM
PUMP COVER
STEP
MAIN
FRAME
WEDGE FLIPOVER
FIG. 11-1
11
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
(GALVANIZED MODELS)
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHECKS
!
WARNING
Never operate the Liftgate with parts loose or missing.
NOTE: Make sure vehicle is parked on level ground while performing the maintenance checks.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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 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.
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.
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.
12
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.
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 tights 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.
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.
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.
13
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PERIODIC MAINTENANCE CHECKLIST
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.
1. Unbolt & remove pump cover
(FIG. 14-1).
POWER UNIT
(REF)
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
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)
PUMP COVER
UNBOLTING / BOLTING PUMP COVER
FIG. 14-1
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
PLATFORM POSITION
FLUID LEVEL
FILLER
CAP
“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
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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.
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
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
POWER UNIT
(REF)
5. Bolt on the pump cover as shown
in FIG. 17-1. Torque the bolts (cap
screws) to 10 - 14 lbs.- in.
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. 18-1). 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. 18-2). If
indications are correct in both cases (FIGS. 18-1 &
18-2), Liftgate is installed correctly and no adjustment is needed. If indications are incorrect, continue with instruction 2.
TIP OF
FLIPOVER
PLATFORM & SHACKLES
TOUCH GROUND
FIG. 18-1
TIP OF
FLIPOVER
LEVEL LINE
PLATFORM EDGE ABOVE
BED LEVEL
FIG. 18-2
NOTE: If tip of flipover touches first (FIG. 18-3),
do instruction 2. If the shackle touches first
(FIG. 19-1), skip instruction 2 and do 3.
2. Make sure platform is still at ground level. If the
shackle is not touching the ground, measure and
compare distance “A” (FIG. 18-3) with TABLE 18-1
to determine the correct shim. Make shims as needed (FIG. 18-5). Weld shim as shown in FIG. 18-4.
RAISE TIP OF
FLIPOVER
THIS DISTANCE “A”
“A”
(TABLE 18-1)
REQUIRED WELD SIZE
SHIM
“W”
THICKNESS
7/8”
1/16”
1/16”
2”
1/8”
1/8”
3”
3/16”
3/16”
3-15/16”
1/4”
1/4”
SHACKLES DO NOT TOUCH
GROUND
FIG. 18-3
CENTERED
(TOP EDGES FLUSH)
PLATFORM
TABLE 18-1
2-1/4”
SHIM
(TABLE 18-1)
1-1/2”
SHACKLE
(REF)
2 PLACES
“W”
(TABLE 18-1)
SHIM (1/16”, 1/8”, 3/16”, or 1/4”)
MADE FROM STEEL FLAT
FIG. 18-5
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 18-4
18
LOWER TIP OF
FLIPOVER
THIS DISTANCE “B”
GRIND METAL FROM
PLATFORM STOP
7/8”
1/16”
2”
1/8”
3”
3/16”
3-15/16”
1/4”
“B”
(TABLE 19-1)
TIP OF
FLIPOVER
PLATFORM DOES NOT
TOUCH GROUND
FIG. 19-1
TABLE 19-1
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. 18-1.
PLATFORM
STOP
PLATFORM
GRIND HERE
(TABLE 19-1)
SHACKLE
(REF)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 19-2
19
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. 19-1) with TABLE
19-1 to determine how much to grind
from the platform stops (FIG. 19-2).
Grind correct amount of metal (TABLE
19-1) from platform stop as shown in
FIG. 19-2.
PERIODIC MAINTENANCE
REPLACING PLATFORM TORSION SPRING
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.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
TORSION
SPRING
3. Raise Liftgate to a convenient work
height to gain access and release tension on the torsion spring.
!
ROLL PIN
(REMOVED)
CAUTION
To prevent injury and equipment
damage, make sure there is no tension on torsion spring before removing hinge pin.
BUSHING
PLATFORM
HINGE PIN
PIN
COLLAR SHACKLE
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 and
bushing (FIG. 20-1). Remove torsion
spring and bushing.
REMOVING HINGE PIN
(RH SIDE OF PLATFORM SHOWN)
FIG. 20-1
SHORT LEG
5. Install the torsion spring and bushing as shown in (FIG. 20-2). Make
sure the long leg of the spring is
inserted in the bracket located on
the shackle. Make sure the short
end of the spring is visible and resting against the block on the platform
hinge bracket (FIG. 20-2).
BLOCK
PLATFORM
HINGE
BRACKET
BUSHING
LONG
LEG
BRACKET
SHACKLE
INSTALLING HINGE PIN
(RH SIDE OF PLATFORM SHOWN)
FIG. 20-2
20
ROLL PIN
(INSTALLED)
PLATFORM HINGE
BRACKET
7. Operate the Liftgate according to
instructions in Operation Manual
to make sure it operates correctly.
PLATFORM
HINGE PIN
PIN COLLAR
FIG. 21-1
21
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 hinge bracket (FIG. 21-1).
Line up 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. 21-1).
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
22
PERIODIC MAINTENANCE
EXTENSION CORRECT
PLATE
POSITION
CHECK SAFETY HOOK FUNCTION
1. When raising platform to stowed position,
listen for sound of safety hook engaging
platform loop.
PLATFORM LOOP
(WRONG 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
LOOP ADJUSTMENT
FIG. 23-1
1. If the safety hook is not positioned correctly
(FIG. 23-1), lower platform to ground level (Operation Manual).
EXTENSION
PLATFORM LOOP
PLATE
(WRONG POSITION)
2. Adjust by bending the platform loop as shown
in FIG. 23-2.
BEND IN
THIS
DIRECTION
3. Stow the platform and check for correct
safety hook position. Repeat adjustment if
required.
SAFETY
HOOK
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.
CORRECT
POSITION
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
PARTS BREAKDOWN
TE-25 MAIN ASSEMBLY
REFER TO (WELD ON)
EXTENSION PLATE ASSEMBLY
2A
(2 PLACES)
2C
(2 PLACES)
1
5
4
3
2
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
2B, 2C
(2 PLACES)
2B
(2 PLACES)
REFER TO LIFT FRAME
& PARALLEL ARMS
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
REFER TO PUMP
COVER, HYDRAULIC
COMPONENTS, &
POWER UNITS
FIG. 24-1
ITEM QTY. PART NO.
DESCRIPTION
266424-01
MAIN FRAME, TE-25
267434-01
MAIN FRAME, TE-25L
1
280790-02
PLATFORM OPENER
2A
2
280082-01
ROLLER, OPENER, 3-1/2” DIA.
2B
4
900033-10
CAP SCREW, 1/2”-20 X 3-1/2” LG, GRADE 8
2C
4
901008
LOCK NUT, 1/2”-20
3
1
263018
CYLINDER PIN, 1” DIA X 4-1/8” LG.
4
1
221416
ROLL PIN, 3/8” X 2” LG.
5
1
260916-06
SELF LUBE BEARING, 1” DIA X 1” LG.
1
1
2
TABLE 24-1
24
REFER TO (BOLT ON)
EXTENSION PLATE ASSEMBLY
REFER TO
STEPS ASSEMBLY
REFER TO
STEPS ASSEMBLY
2C
2A
(2
PLACES)
(2 PLACES)
5
1
4
3
2
2B
2B & 2C
(2 PLACES)
(2 PLACES)
REFER TO LIFT FRAME
& PARALLEL ARMS
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
REFER TO PUMP
COVER, HYDRAULIC
COMPONENTS, &
POWER UNITS
FIG. 25-1
ITEM QTY. PART NO.
DESCRIPTION
266424-01G
MAIN FRAME, TE-25 (GALVANIZED)
267434-01G
MAIN FRAME, TE-25L (GALVANIZED)
1
280790-02G
PLATFORM OPENER (GALVANIZED)
2A
2
280082-01
ROLLER, OPENER, 3-1/2” DIA.
2B
4
900033-10
CAP SCREW, 1/2”-20 X 3-1/2” LG, GRADE 8
2C
4
901008
LOCK NUT, 1/2”-20
3
1
263018
CYLINDER PIN, 1” DIA X 4-1/8” LG.
4
1
221416
ROLL PIN, 3/8” X 2” LG.
5
1
260916-06
SELF LUBE BEARING, 1” DIA X 1” LG.
1
1
2
TABLE 25-1
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
TE-25 MAIN ASSEMBLY (GALVANIZED)
EXTENSION PLATE ASSEMBLY (PAINTED, WELD ON)
VIEWED FROM UNDER
EXTENSION PLATE
4
3C
3A
3B
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
6
3D
5
2
3
7
1
FIG. 26-1
ITEM QTY. PART NO.
DESCRIPTION
REF
1
267419-01
EXTENSION PLATE ASSY (PAINTED)
1
6
207644
RIVET, 3/16” DIA, .40” LG.
2
1
266705-01
MAXON PLATE
3
1
267418-01
EXTENSION PLATE WELDMENT
3A
1
262373
BRACKET
3B
1
215341
SAFETY HOOK WELDMENT
3C
1
262370-01
HANDLE (CURBSIDE)
3D
2
201561
FLAT, 1/4” X 1/2” X 1/2” LG.
4
1
215345
EXTENSION SPRING, 7/64” X 2-1/2” LG.
5
1
055011
HANDLE, RUBBER
6
1
203417
RENTAL LOCK BRACKET (OPTIONAL)
7
1
203570
INNER BRACKET, RENTAL LOCK (OPTIONAL)
TABLE 26-1
26
1
2, 2A
(13 PLACES)
2, 2B
(13 PLACES)
FIG. 27-1
ITEM QTY. PART NO.
284136-01G
EXTENSION PLATE WELDMENT, 96” LG. (GALVANIZED)
284136-02G
EXTENSION PLATE WELDMENT, 102” LG. (GALVANIZED)
283257-01
KIT, EXTENSION PLATE HARDWARE KIT, (96” VEH)
283257-02
KIT, EXTENSION PLATE HARDWARE KIT, (102” VEH)
13
283700-01
TEAR DROP (LOCK NUT), 1/2”-13 (96” WIDE VEH KIT)
15
283700-01
TEAR DROP (LOCK NUT), 1/2”-13 (102” WIDE VEH KIT)
13
901024-2
BOLT HEX, 1/2”-13 X 1.75” LG. (96” WIDE VEH KIT)
15
901024-2
BOLT HEX, 1/2”-13 X 1.75” LG. (102” WIDE VEH KIT)
1
1
2
REF
2A
2B
DESCRIPTION
TABLE 27-1
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
EXTENSION PLATE ASSEMBLY (GALVANIZED, BOLT ON)
LIFT FRAME & PARALLEL ARMS
3
6
5A
5
3
13
1A
3
6
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
13
3
1A
4
3
4
2
5A
1A
9
3
1A
1
3
10
8
3
14
7
12
5
11
14
10
3
FIG. 28-1
28
8
DESCRIPTION
263831
LIFT FRAME (TE-25)
263831-01G
LIFT FRAME (TE-25 GALVANIZED)
262383
LIFT FRAME, WIDE ARM (TE-25L)
262383-01G
LIFT FRAME, WIDE ARM (TE-25L GALVANIZED)
4
260916-03
SELF LUBE BEARING, 1” DIA X 1” LG.
2
1
263017
CYLINDER PIN
3
9
904717-06
ROLL PIN, 3/8” X 2” LG.
4
2
262342-02
PIN, 1” DIA X 4” LG.
5
2
263058
PARALLEL ARM
263058-01G
PARALLEL ARM (GALVANIZED)
4
260916-02
SELF LUBE BEARING, 1” DIA X 1-1/2” LG.
6
2
262342-03
PIN, 1” DIA X 3-1/2” LG.
7
1
281641-02
TORSION SPRING, LH (TE-25)
280795-01
TORSION SPRING, LH (TE-25L)
8
2
281483-01
PIN WELDMENT, 1” DIA X 4” LG.
267414-02
SHACKLE, LH (TE-25)
267414-02G
SHACKLE, LH (TE-25 GALVANIZED)
267435-01
SHACKLE, LH (TE-25L)
267435-01G
SHACKLE, LH (TE-25L GALVANIZED)
267416-01
PIN, 1” DIA X 13-1/4” LG.
267414-01
SHACKLE, RH (TE-25)
267414-01G
SHACKLE, RH (TE-25 GALVANIZED)
267435-02
SHACKLE, RH (TE-25L)
267435-02G
SHACKLE, RH (TE-25L GALVANIZED)
281641-01
TORSION SPRING, RH (TE-25)
280794-01
TORSION SPRING, RH (TE-25L)
1
1
1A
5A
9
10
11
1
2
1
12
1
13
2
908078-01
THRUST BEARING, 1” I.D.
14
2
091802-10
TUBE (BUSHING)
TABLE 29-1
29
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
PLATFORM & FLIPOVER ASSEMBLY
(RAMP)
3
1C
5
8
1A
2
FIG. 30-1
30
8
5
6
7
1B
8
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
6
1A
9
7
8
4
1
1
1
DESCRIPTION
267415-01
PLATFORM WELDMENT, 78-1/2” X 24”
267415-01G
PLATFORM WELDMENT, 78-1/2” X 24” (GALVANIZED)
1A
2
260916-03
SELF LUBE BEARING, 1” DIA X 2” LG.
1B
1
050162-16
CHAIN, # 2/0 X 3” LG.
1C
1
260458
“S” HOOK, 1-3/4” LG.
280819-01
FLIPOVER WELDMENT, 78-1/2” X 24” (TE-25L)
280819-01G
FLIPOVER WELDMENT, 78-1/2” X 24” (TE-25-L GALVANIZED)
280819-02
FLIPOVER WELDMENT, 78-1/2” X 24” (TE-25)
280819-02G
FLIPOVER WELDMENT, 78-1/2” X 24” (TE-25 GALVANIZED)
280751-01
TORSION BAR
280749-02
ANCHOR BOLT (TE-25)
280749-01
ANCHOR BOLT (TE-25L)
2
1
3
1
4
1
5
2
901008
LOCK NUT, 1/2”-20
6
2
280758-01
BUSHING, FLIPOVER
7
2
900033-4
CAP SCREW, 1/2”-20 X 1-3/4” LG, GRADE 8
8
6
902000-14
FLAT WASHER, 1/2”
9
1
901010
LOCK NUT, 1/2”-13
TABLE 31-1
31
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
32
7
8
(2 PLACES)
(2 PLACES)
6
2
7
(2 PLACES)
8
7
(2 PLACES) 6
9
8
(3 PLACES)
4
7
(2 PLACES)
7
8
(2 PLACES)
7
(3 PLACES)
11
10
(3 PLACES)
7
(2 PLACES)
5
8
(2 PLACES)
3
8
7
(2 PLACES)
8
7
8
(2 PLACES)
8
(2 PLACES)
7
(2 PLACES)
8
1
11
9
(2
PLACES)
7
(3 PLACES)
(3 PLACES)
10
(3 PLACES)
FIG. 33-1
ITEM QTY. PART NO.
DESCRIPTION
1
1
285898-04G
RH BOLT-ON SINGLE STEP (GALVANIZED)
2
1
285898-03G
LH BOLT-ON SINGLE STEP (GALVANIZED)
3
1
285899-01G
LH SUPPORT (GALVANIZED)
4
1
285899-02G
RH SUPPORT (GALVANIZED)
5
1
285897-02G
RH MOUNTING CHANNEL (GALVANIZED)
6
1
285897-01G
LH MOUNTING CHANNEL (GALVANIZED)
7
22
901023
FLANGED LOCK NUT 1/2”-13
8
16
901024-1
HEX BOLT, 1/2”-13 X 1-1/4” LG.
9
6
901024-8
HEX BOLT, 1/2”-13 X 2-1/2” LG.
10
6
092036-10
TUBE, 5/8” X 1-1/2” LG.
11
1
285896-01
RUBBER BUMPER, 2-1/2” X 3” X 18-3/4” LG.
TABLE 33-1
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
SINGLE STEP ASSEMBLY (TE-25L GALVANIZED, BOLT ON)
DUAL STEP ASSEMBLY (TE-25 GALVANIZED & PAINTED, BOLT ON)
10
(2 PLACES)
7
(2 PLACES)
10
(2 PLACES)
5
10
(2 PLACES)
7
10
7
6
8
(2 PLACES)
3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
10
2
10
(2 PLACES)
7
(2 PLACES)
5
7
10
(2 PLACES) (2 PLACES)
7
(2 PLACES)
10
(3 PLACES)
11
7
10
7
10
(2 PLACES)
10
(2 PLACES)
4
9
(3 PLACES)
10
6
7
(2 PLACES)
11
8
(2 PLACES)
7
(2 PLACES)
9
(3 PLACES)
1
10
(2 PLACES)
10
(3 PLACES)
FIG. 34-1
34
DESCRIPTION
285477-02
RH BOLT-ON DUAL STEP
285477-02G
RH BOLT-ON DUAL STEP (GALVANIZED)
285477-01
LH BOLT-ON DUAL STEP
285477-01G
LH BOLT-ON DUAL STEP (GALVANIZED)
1
283990-03
LH SUPPORT
4
1
283990-04
RH SUPPORT
5
2
283993-01
MOUNTING CHANNEL
283993-01G
MOUNTING CHANNEL (GALVANIZED)
6
2
283998-02
SPACER, JUMPER (IF EQUIPPED)
283998-02G
SPACER, JUMPER (GALVANIZED) (IF EQUIPPED)
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 BOLT, 1/2”-13 X 2-1/4” LG.
9
6
901024-8
HEX 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, 2-1/2” X 3” X 24” LG.
1
1
2
1
3
7
10
11
2
TABLE 35-1
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM QTY. PART NO.
PUMP COVER & MOUNTING PLATE ASSEMBLY
11
12
14
11
9
13
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
15
11
11
8
8
12
11
6
7
(5 PLACES)
10
(5 PLACES)
3
4
4
5
MAIN FRAME
(REF)
2
12 VDC POWER UNIT
OR
24 VDC POWER UNIT
(REF)
1A
FIG. 36-1
36
1
1B
1
DESCRIPTION
1
266419-01
COVER ASSEMBLY
1A
1
096045-10
FOAM STRIP, 60” LG.
1B
1
261740
LABEL, OIL LEVEL
266427-01
PLATE, PUMP MOUNT
266427-01G
PLATE, PUMP MOUNT (GALVANIZED)
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
1
908022-02
PLUG, FLEXIBLE
7
5
900009-3
CAP SCREW, 5/16”-18 X 3/4” LG, GR8
8
2
900014-4
CAP SCREW, 3/8”-16 X 1” LG, GR8
9
1
900014-5
CAP SCREW, 3/8”-16 X 1-1/4” LG, GR8
10
5
902000-7
FLAT WASHER, 5/16”
11
5
902013-11
FLAT WASHER, 3/8”
12
2
902011-4
LOCK WASHER, 3/8”
13
1
901002
LOCK NUT, 3/8”-16
14
1
282895-01
JUMPER, GROUND
15
1
208153
PLASTIC TIE, 4”
TABLE 37-1
37
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
38
SEE 12 VDC POWER UNIT
(GRAVITY DOWN)
8
1
6
1A
7
5
3
2
9
4
10
FIG. 39-1
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)
282999-01
HYDRAULIC LOCK VALVE ASSEMBLY, 12V (IF EQUIPPED)
10
1
282999-02
HYDRAULIC LOCK VALVE ASSEMBLY, 24V (IF EQUIPPED)
1
1A
1
TABLE 39-1
39
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.
FUSED POWER CABLE
(REF. CONTROL SWITCH
& POWER CABLE)
3
12
15
4
9
13
10
CONTROL SWITCH
WIRING HARNESS
(REF. CONTROL SWITCH
& POWER CABLE)
5
1A,1B
2
6
1
14
7
BARB FITTING
(REF. GRAVITY
DOWN HYDRAULIC
COMPONENTS)
11
8
FIG. 40-1
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
40
REF
DESCRIPTION
268070-01
12 VDC POWER UNIT (GRAVITY DOWN)
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
CARTRIDGE RELIEF VALVE
14
1
908016-01
GROMMET, 3/4” I.D.
15
1
268024-01
WIRE ASSY, 16GA WHITE, 3” LG.
1
TABLE 41-1
41
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 starter solenoid, 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.
11
FUSED POWER CABLE
(REF. CONTROL SWITCH
& POWER CABLE)
14
2
3
8
12
9
CONTROL SWITCH
WIRING HARNESS
(REF. CONTROL SWITCH
& POWER CABLE)
4
1A,1B
5
BARB FITTING
(REF. GRAVITY
DOWN HYDRAULIC
COMPONENTS)
1
6
13
10
7
FIG. 42-1
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
42
-
REF
DESCRIPTION
280610-24
24 VDC POWER UNIT (GRAVITY DOWN)
1
290002
3-PIECE GEAR PUMP
1A
1
226594
OIL SEAL KIT
1B
1
290020
O-RING
2
1
280404
CABLE ASSEMBLY
3
1
281571-01
SOLENOID SWITCH, 24 VDC
4
1
905152
90 DEG ELBOW
5
1
280806-01
FILLER CAP
6
1
267733-11
RESERVOIR, 3 QT, VERTICAL WITH VENT
7
1
908017-01
DRAIN PLUG
8
1
280416
WIRE ASSEMBLY
9
1
281571-01
VALVE ASSEMBLY, 24 VDC
10
1
908018-01
GROMMET, 5/16” I.D.
11
1
281573-01
MOTOR, 24 VDC, 2-TERMINAL
12
1
906740-01
CARTRIDGE RELIEF VALVE
13
1
908016-01
GROMMET, 19/32”
14
1
280566-01
WIRE ASSY, 16GA GREEN
1
TABLE 43-1
43
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
44
SEE 12 VDC POWER UNIT
(POWER DOWN)
1
7
2
3
9
4
5
8
6
FIG. 45-1
ITEM
1
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
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)
TABLE 45-1
45
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.
1
7
CONTROL SWITCH
WIRING HARNESS
(REF. CONTROL SWITCH
& POWER CABLE)
15
2
FUSED POWER CABLE
(REF. CONTROL SWITCH
& POWER CABLE)
17
13
16
14
4
5
3
6
15
9
17
8
10
12
11
FIG. 46-1
46
QTY
PART NO.
DESCRIPTION
REF
268181-01
12 VDC POWER UNIT (POWER DOWN)
1
1
268176-01
MOTOR, 12 VDC
2
1
268029-01
SWITCH, SOLENOID
3
1
290044
VALVE CARTRIDGE, DOUBLE SPADE
4
1
290045
COIL, DOUBLE SPADE, 2 WAY
5
1
290047
VALVE CARTRIDGE, 4 WAY
6
1
290048
COIL, DOUBLE SPADE, 4 WAY
7
1
280404
CABLE ASSEMBLY
8
1
267733-01
RESERVOIR, 3 QT, VERTICAL
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
280416
WIRE ASSEMBLY
16
1
268027-01
WIRE ASSEMBLY, 18 GA, #10 RING - 5/16” RING
17
2
905152
ELBOW, 90 DEG, O-RING
TABLE 47-1
47
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
RAISE/LOWER DECAL
P/N 264507
CAPACITY DECAL
P/N 220382
OR
CAPACITY DECAL
(SPECIAL LIFTGATES ONLY)
P/N 220387
WARNING DECAL
(2 PLACES, LH SIDE NOT SHOWN)
P/N 265736-01
MAXPRO DECAL
P/N 267338-01
FAMILY OWNED DECAL
P/N 283445-01
STOW WARNING DECAL
P/N 282847-02
WARNING & CAUTION
DECAL SHEET
P/N 282522-01
INSTRUCTION DECAL
P/N 251867-03
FIG. 48-1
48
RAISE/LOWER DECAL
P/N 264507
CAPACITY DECAL
(SPECIAL LIFTGATES ONLY)
P/N 220387
WARNING DECAL
(2 PLACES, LH SIDE NOT SHOWN)
P/N 265736-01
MAXPRO DECAL
P/N 267338-01
INSTRUCTION DECAL
P/N 251867-03
FAMILY OWNED DECAL
P/N 283445-01
STOW WARNING DECAL
P/N 282847-02
49
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAPACITY DECAL
P/N 220382
DECALS - Continued
FIG. 50-1
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECAL SHEET
P/N 282522-01
50
ELECTRICAL COMPONENTS
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.
BLACK
WHITE
(TO
POWER
UNIT)
BLACK
4
WHITE
2
1
(FOR REFERENCESEE DECALS)
GREEN
GREEN
RED
(POWER DOWN
VERSION ONLY)
3
FIG. 51-1
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)
TABLE 51-1
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
FIG. 51-2
51
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL SWITCH & POWER CABLE
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.
TABLE 53-1
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
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
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
58
SYSTEM DIAGRAMS
MOTOR
STARTER
SOLENOID
PRESSURE
(PORT A)
VENT
PORT
S2 VALVE
POWER UNIT
FIG. 59-1
POWER UNIT MOTOR & SOLENOID OPERATION
LIFTGATE
FUNCTION
SOLENOID OPERATION
( MEANS ENERGIZED)
PORT
STARTER SOL
& MOTOR
S2 VALVE
RAISE
A
LOWER
REFER TO VALVES SHOWN ON
HYDRAULIC SCHEMATIC
TABLE 59-1
59
LOCK VALVE
(ON RH CYLINDER)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN)
HYDRAULIC SCHEMATIC (GRAVITY DOWN)
HYDRAULIC CYLINDER
2 GPM FLOW
CONTROL VALVE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC
LOCK VALVE
(GALVANIZED
MODELS ONLY)
RETURN PORT
(PLUGGED)
PRESSURE PORT
VENT PORT
S2
VALVE
RELIEF VALVE
(SET AT 3250 PSI)
CHECK VALVE
AUX. HAND
PUMP PORT
(PLUGGED)
PUMP
M
MOTOR
(REFERENCE)
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 60-1
60
FILLER HOLE
(PLUGGED)
CONTROL SWITCH
UP
DOWN
WHITE
GREEN BLACK
WHITE
GREEN BLACK
CABLE
ASSEMBLY
S2
VALVE
THERMAL
SWITCH
(IN MOTOR
CASING)
HYDRAULIC
LOCK VALVE
(GALVANIZED
MODELS ONLY)
STARTER
SOLENOID
M
CABLE WITH
175 AMP FUSE
BATTERY
FIG. 61-1
61
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SCHEMATIC (GRAVITY DOWN)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
62
MOTOR
STARTER SOLENOID
PORT B
PORT A
S2
VALVE
S1 VALVE
POWER UNIT
FIG. 63-1
POWER UNIT MOTOR & SOLENOID OPERATION
LIFTGATE
FUNCTION
SOLENOID OPERATION
( MEANS ENERGIZED)
PORT
RAISE
A
LOWER
B
STARTER SOL
& MOTOR
S1 VALVE
S2 VALVE
REFER TO VALVES SHOWN ON
HYDRAULIC SCHEMATIC
TABLE 63-1
63
LOCK VALVE
(ON RH CYLINDER)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP & MOTOR SOLENOID OPERATION (POWER 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
HYDRAULIC LOCK VALVE
(GALVANIZED MODELS ONLY)
PORT B - LOWER
(POWER DOWN)
PORT A - RAISE
S2
VALVE
RELIEF VALVE 2
(SET AT 1100 PSI)
S1
VALVE
RELIEF VALVE 1
(SET AT 3200 PSI)
MOTOR
(REF)
PUMP
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 64-1
64
AUX. HAND
PUMP PORT
(PLUGGED)
RED
DOWN
UP
CONTROL SWITCH
GREEN
WHITE
BLACK
RED
GREEN
CABLE
ASSEMBLY
THERMAL
SWITCH
(IN MOTOR
CASING)
STARTER
SOLENOID
S2
VALVE
GREEN
CABLE WITH
175 AMP FUSE
HYDRAULIC
LOCK VALVE
(GALVANIZED
MODELS ONLY)
M
BATTERY
FIG. 65-1
65
S1
VALVE
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. Use voltmeter to verify power is being supplied to solenoid terminal “B”
(FIG. 66-1). Recharge the battery if there is less than 12.6 volts.
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. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
3. Touch a jumper wire to terminals “B” & “D” (FIG. 66-1). 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. 66-1).
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. 66-1
66
PLATFORM RAISES BUT LEAKS DOWN
COIL
FIG. 67-1
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. 67-2). With platform on
ground, unscrew the valve stem (Item 2, FIG.
67-2) 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. 673). 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.
2
1
1/8”
FIG. 67-2
VENT/DOWN PORT
RAISE PORT
FIG. 67-3
67
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Check if solenoid valves are constantly energized by touching a screwdriver to the top nut of the solenoid (FIG. 671). 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.
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.
1. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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. 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.
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.
68
VENT/DOWN PORT
PRESSURE
PORT
FIG. 68-1
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
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. 69-2). 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. 69-1
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.
69-1). 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
69
FIG. 69-2
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. Use voltmeter to verify power is being supplied to
solenoid terminal “B”. Recharge the battery if voltmeter indicates less than 12.6 volts (FIG. 70-1).
TERMINAL
“B”
BATTERY (+)
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.
FIG. 70-1
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. 70-3). 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. 70-3.
4. See the CHECKING HYDRAULIC FLUID procedure. If necessary, add hydraulic fluid.
5. Verify the pump motor is grounded to the vehicle frame.
PRESSURE
GAUGE
RELIEF
VALVE
ADJUST
SCREW
(REMOVE
PLUG)
6. Check for leaking hoses and fittings. Tighten or replace
as required.
7. Check for structural damage or poor lubrication. Replace
worn parts.
8. Check the filter in the pump reservoir. Replace if necessary.
9. 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 control switch in
the “raise” position. Adjust the relief valve on the side of
the pump until the gauge shows 3250 PSI (FIG. 70-2).
Remove gauge and reinstall pressure hose.
70
FIG. 70-2
VENT/DOWN
PORT
PRESSURE
PORT
FLOW
CONTROL
VALVE
FIG. 70-3
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.
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.
2
1
1/8”
FIG. 71-2
VENT/DOWN PORT
(REF)
RAISE PORT
(REF)
FLOW
CONTROL
VALVE
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).
FIG. 71-3
71
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement