Maxon TE-25/TE-30 TUK-A-WAY® Maintenance Manual

Maxon TE-25/TE-30 TUK-A-WAY® Maintenance Manual
M-16-35
REV B
NOVEMBER 2017
© 2017 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-16-35, REVISION B ............................................................. 6
WARNINGS ........................................................................................................................... 7
SAFETY INSTRUCTIONS .................................................................................................... 8
LIFTGATE TERMINOLOGY .................................................................................................. 9
PERIODIC MAINTENANCE................................................................................................ 10
PERIODIC MAINTENANCE CHECKS ................................................................................ 10
PERIODIC MAINTENANCE CHECKLIST ............................................................................11
CHECKING HYDRAULIC FLUID ........................................................................................ 13
CHANGING HYDRAULIC FLUID ........................................................................................ 15
PLATFORM ADJUSTMENT ................................................................................................ 18
REPLACING PLATFORM TORSION SPRING ................................................................... 21
SAFETY HOOK MAINTENANCE ........................................................................................ 23
DECALS & PLATES ........................................................................................................... 24
PUMP, MOTOR & SOLENOID OPERATION - GRAVITY DOWN ....................................... 26
PUMP, MOTOR & SOLENOID OPERATION - POWER DOWN ......................................... 27
HYDRAULIC SYSTEM DIAGRAMS ................................................................................... 28
HYDRAULIC SCHEMATIC (GRAVITY DOWN)................................................................... 28
HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 29
ELECTRICAL SYSTEM DIAGRAMS ................................................................................. 30
ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 30
ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 31
TE SERIES ELECTRICAL VALUES .................................................................................... 32
TROUBLESHOOTING ........................................................................................................ 33
PLATFORM WILL NOT RAISE............................................................................................ 33
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 34
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 35
LIFTGATE WILL NOT LIFT RATED CAPACITY .................................................................. 36
PLATFORM RAISES SLOWLY ........................................................................................... 37
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY ................ 38
SUMMARY OF CHANGES: M-16-35, REVISION B
PAGE
Cover
DESCRIPTION OF CHANGE
Includes TE-15 and TE-20 liftgates.
14
Combined EXXON & MOBIL oils on the same row with updated part numbers.
29
Updated power down hydraulic schematic shows solenoid valves S1 & S2.
30, 31
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32
Gravity down and power down electrical schematics are updated to same level of
details as installation manual.
Added TE Series electrical values.
6
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.
!
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.
• 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.
• Recommended practices for welding galvanized steel are contained in the current AWS (American Welding Society) D19.0 Welding Zinc-Coated Steel. Damage to Liftgate and/or vehicle,
and personal injury can result from welds that are done incorrectly.
7
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WARNINGS
SAFETY INSTRUCTIONS
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.
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• 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
LIFT
CYLINDER
CONTROL
SWITCH
DOCK
BUMPER
PLATFORM
OPENER
FLEX STEP
PARALLEL
ARM
PLATFORM
PUMP BOX
(COVER SHOWN)
MAIN
FRAME
WEDGE FLIPOVER
LIFT FRAME
TORSION SPRINGS
9
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LIFTGATE TERMINOLOGY
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHECKS
!
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)
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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 or galvanized finish where bare metal is showing. MAXON recommends
using the aluminum primer touchup paint or cold galvanize spray for galvanized finish.
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.
10
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 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
Lift-gate is dirty, clean it off. Touch up the paint or galvanized finish where bare metal is
showing. To maintain the protection provided by the original paint system or galvanized
finish, MAXON recommends using the aluminum primer touchup paint or cold galvanize
spray for galvanized finish.
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.
11
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PERIODIC MAINTENANCE CHECKLIST
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHECKLIST - Continued
NOTE: Lube fittings are shown for the cylinder, LH lift arm, and LH parallel
arm. There are also lube fittings at the same places on the RH
cylinder, lift arm, and parallel arm.
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Refer to lubrication diagram (FIG. 12-1) to find the lube
fittings on cylinders and arms. Pump EP chassis grease
in each lube fitting on the cylinders and arms until grease
starts oozing from ends of the bearings. Then, wipe off
excess grease with a clean lint-free cloth.
CYLINDER
LH LIFT ARM &
PARALLEL ARM
RH LIFT ARM &
PARALLEL ARM
LUBRICATION DIAGRAM
FIG. 12-1
12
CHECKING HYDRAULIC FLUID
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.
NOTE: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions.
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 14-1 & 14-2 for recommended brands of ISO 32 & ISO 15 oils.
NOTE: Hydraulic oil level must be minimum of 1-1/2” above the bottom
of reservoir to operate Liftgate.
1. With platform at bed height, check oil level
in the pump reservoir (FIG. 13-1). To add
oil, pull out filler cap (no threads) (FIG.
13-1). Add hydraulic oil in reservoir to the
level shown in FIG. 13-1.
RESERVOIR
1-7/8” - 2-3/8” (GD)
2-5/8” - 3-1/8” (PD)
FILLER CAP
2. Reinstall filler cap (FIG. 13-1).
PUMP RESERVOIR
(GRAVITY DOWN POWER UNIT SHOWN)
FIG. 13-1
PUMP MOUNT
PLATE
POWER UNIT
(REF)
3. Bolt on the pump cover as shown
in FIG. 13-2. Torque the bolts (cap
screws) to 10 - 14 lb-in.
CAP
SCREWS
(5 PLACES)
FLAT
WASHERS
(5 PLACES)
PUMP COVER
BOLTING ON PUMP COVER
FIG. 13-2
13
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CAUTION
PERIODIC MAINTENANCE
CHECKING HYDRAULIC FLUID - Continued
ISO 32 HYDRAULIC OIL
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RECOMMENDED
BRANDS
PART NUMBER
CHEVRON
HIPERSYN 32
KENDALL
GOLDEN MV
SHELL
TELLUS S2 VX 32
EXXONMOBIL
UNIVIS N-32, DTE-24
TABLE 14-1
ISO 15 OR MIL-H-5606 HYDRAULIC OIL
RECOMMENDED
BRANDS
PART NUMBER
CHEVRON
FLUID A, AW-MV-15
KENDALL
GLACIAL BLU
SHELL
TELLUS S2 VX 15
EXXONMOBIL
UNIVIS HVI-13
ROSEMEAD
THS FLUID 17111
TABLE 14-2
14
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: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions.
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 14-1 & 14-2 for recommended brands of ISO 32 & ISO 15 oils.
GRAVITY DOWN LIFTGATES
1. Remove the pump cover (FIG. 13-1). Place empty
5 gallon bucket under drain plug (FIG. 15-1).
2. Lower platform to ground. Pull out (no
threads) drain plug (FIG. 15-1). Drain hydraulic fluid from system. Reinstall drain plug.
3. Pull out (no threads) filler cap (FIG. 15-1)
and refill reservoir with hydraulic fluid to
level shown in FIG. 15-1. Reinstall filler
cap (FIG. 15-1).
RESERVOIR
1-7/8” - 2-3/8” (GD)
2-5/8” - 3-1/8” (PD)
4. Bolt on the pump cover as shown in FIG. 16-1
Torque the bolts (cap screws) to 10-14 lb-in.
DRAIN
PLUG
FILLER CAP
LIFTGATE SHOWN WITH GRAVITY
DOWN PUMP & MOTOR
FIG. 15-1
POWER DOWN LIFTGATES
1. Remove the pump cover (FIG. 13-1). Place empty
5 gallon bucket under drain plug (FIG. 15-1).
2. Open and raise platform to vehicle bed height.
Pull out (no threads) drain plug (FIG. 15-1). Drain
hydraulic fluid.
3. Disconnect the white wire (FIG. 15-2) from starter
solenoid. Lower the platform while draining the
remaining hydraulic fluid from system. Reinstall
drain plug. Reconnect the white wire to starter
solenoid.
4. Pull out (no threads) filler cap (FIG. 15-1) and
refill reservoir with hydraulic fluid to level shown
in FIG. 15-1. Reinstall filler cap (FIG. 15-1).
15
WHITE
WIRE
STARTER
SOLENOID
POWER DOWN PUMP
FIG. 15-2
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CHANGING HYDRAULIC FLUID
PERIODIC MAINTENANCE
CHANGING HYDRAULIC OIL - Continued
5. Bolt on the pump cover as shown
in FIG. 16-1. Torque the cap
screws to 10-14 lb-in.
PUMP MOUNT
PLATE
POWER UNIT
(REF)
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CAP
SCREWS
(5 PLACES)
FLAT
WASHERS
(5 PLACES)
PUMP COVER
BOLTING PUMP COVER
FIG. 16-1
16
17
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THIS PAGE INTENTIONALLY LEFT BLANK
PERIODIC MAINTENANCE
PLATFORM ADJUSTMENT
NOTE: Before doing the following procedure, make sure vehicle is parked on level
ground.
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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. Outboard edge on top 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
OUTBOARD
EDGE
NOTE: If tip of flipover touches first
(FIG. 18-3A), do instructions 2
and 3. If the shackle touches
first (see FIG. 20-1), skip 2 and
3 and do instructions 4 and 5.
LEVEL LINE
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 to determine the correct
shim. Next, mark position on shackle (FIG.
18-3B).
PLATFORM EDGE
ABOVE BED LEVEL
FIG. 18-2
PLATFORM STOP
SHACKLE
RAISE TIP OF
FLIPOVER
THIS DISTANCE “A”
9/16”
WELD
REQUIRED SHIM
THICKNESS
SIZE “W”
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”
1/4”
MARK HERE
MARKING SHIM
POSITION
FIG. 18-3B
SHIMS TO RAISE TIP OF FLIPOVER
TABLE 18-1
“A”
(TABLE 18-1)
SHACKLES DO NOT TOUCH GROUND
FIG. 18-3A
18
2-1/4”
1-1/2”
SHIM (1/16”, 1/8”, 3/16”, or 1/4”)
MADE FROM STEEL FLAT
FIG. 19-1
SHIM
(TABLE 18-1 )
CENTERED
SHACKLE
(REF)
“W”
(TABLE 18-1)
2 PLACES
WELDING SHIMS (RH SHACKLE SHOWN)
FIG. 19-2
19
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3. Make shims as needed (FIG. 19-1). Position bottom edge of shim to line up with
mark on shackle (FIG. 19-2). Then, weld
the shim to shackle as shown in FIG. 19-2.
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 to determine how
much to grind from the platform
stops (FIG. 20-2).
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LOWER TIP OF
FLIPOVER
THIS DISTANCE “B”
9/16”
“B”
(TABLE 20-1)
GRIND METAL FROM
PLATFORM STOP
TIP OF FLIPOVER DOES NOT
TOUCH GROUND
FIG. 20-1
1/16”
1-1/4”
1/8”
1-15/16”
3/16”
2-5/8”
1/4”
TIP OF
FLIPOVER
GRIND TO LOWER TIP
TABLE 20-1
PLATFORM
STOP
GRIND ENTIRE
SURFACE HERE
(TABLE 20-1)
PLATFORM
SHACKLE
(REF)
GRINDING PLATFORM STOPS
(RH SHACKLE SHOWN)
FIG. 20-2
5. Grind correct amount of metal (TABLE
20-1) 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
FIG. 20-3
20
REPLACING PLATFORM TORSION SPRING
2. Fold platform.
3. Raise Liftgate to a convenient work
height to gain access and release
tension on the torsion spring.
!
LOCK
NUT
CAUTION
FLAT
WASHER
PLATFORM
HINGE PIN
To prevent injury and equipment damage, make sure there is no tension on
torsion spring before removing hinge
pin.
4. Remove cap screw, flat washer and
locknut 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.
CAP
SCREW
TORSION
SPRING
PIN
COLLAR
SHACKLE
FIG. 21-1
5. Install the torsion spring as shown
in (FIG. 21-2). Make sure the long
leg of the spring is inserted through
the hole in the block on the shackle
(FIG. 21-2). Make sure the short
end of the spring is positioned as
shown in FIG. 21-2.
PLATFORM
HINGE
BRACKET
SHACKLE
SHORT LEG
BLOCK
FIG. 21-2
21
LONG
LEG
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1. Fold flipover onto platform.
PERIODIC MAINTENANCE
REPLACING PLATFORM TORSION SPRING - Continued
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6. Drive platform hinge pin inboard to
correct position through the platform
hinge bracket (FIG. 22-1). Line up
LOCK
the hole in the platform hinge pin with
NUT
the hole in the pin collar. Reinstall
cap screw through the pin collar and
secure with flat washer and locknut
PLATFORM
(FIG. 22-1).
HINGE PIN
FLAT
WASHER
CAP
SCREW
PLATFORM HINGE
BRACKET
FIG. 22-1
22
PIN
COLLAR
SAFETY HOOK MAINTENANCE
1. When raising platform to stowed position,
listen for sound of safety hook engaging
platform loop.
EXTENSION
PLATE
PLATFORM LOOP
(CORRECT POSITION)
2. When the Liftgate is stowed, see if platform loop is seated in the safety hook as
shown in FIG. 23-1.
SAFETY HOOK
PLATFORM LOOP SHOWN HOOKED
IN CORRECT POSITION
FIG. 23-1
LOOP ADJUSTMENT
1. If the safety hook is not positioned
correctly (FIG. 23-2), lower platform
enough to access the safety hook. (See
Operation Manual for instructions to
lower the platform.)
PLATFORM LOOP
(CORRECT POSITION)
PLATFORM LOOP
(INCORRECT POSITION)
2. Adjust by bending the platform loop so
it seats correctly in the hook as shown
in FIG. 23-2.
3. Stow the platform and check for correct
safety hook position (FIG. 23-2). Repeat adjustment if required.
PLATFORM LOOP SHOWN HOOKED
INCORRECTLY
FIG. 23-2
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CHECK SAFETY HOOK FUNCTION
DECALS & PLATES
NOTE: Ensure there is no residue, dirt or corrosion where decals are attached.
If necessary, clean surface before attaching decals.
NOTE: Preferred decal layout is shown, Decals on the Liftgate are attached at the
factory. If vehicle does not permit this layout, decals in the manual and
decal kit must be applied so that they are easily visible when approaching
vehicle to operate Liftgate. Use good common sense when locating
these decals on vehicle.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAPACITY DECAL
(REFER TO TABLE 25-1)
STOW WARNING DECAL
P/N 282847-02
INSTRUCTION DECAL
P/N 285800-01
DECAL “F”
DECAL “B”
DECAL “A”
DECAL “C”
WARNING DECAL
P/N 265736-03
FIG. 24-1
24
MODEL
DECAL P/N
CAPACITY
TE-15
220386
1500 POUNDS [680 KG]
TE-20
220387
2000 POUNDS [907 KG]
TE-25
220382
2500 POUNDS [1134 KG]
TE-30
220388
3000 POUNDS [1360 KG]
CAPACITY DECALS
TABLE 25-1
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECAL SHEET P/N 282522-01
FIG. 25-1
SYSTEM DIAGRAMS
PUMP, MOTOR & SOLENOID OPERATION - GRAVITY DOWN
MOTOR
JUNCTION
BLOCK
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PRESSURE
SOLENOID
SWITCH
VENT
SOLENOID
VALVE
GRAVITY DOWN PUMP MOTOR & SOLENOID SWITCH OPERATION
LIFTGATE
FUNCTION
RAISE
LOWER
SOLENOID SWITCH OPERATION
( MEANS ENERGIZED)
PORT
MOTOR
PRESSURE
VENT
SOLENOID VALVE
-
-
REFER TO VALVES SHOWN ON
HYDRAULIC SCHEMATIC
TABLE 26-1
26
MOTOR
POWER DOWN
MODULE
PORT A
“S2” VALVE
SOLENOID
SWITCH
“S1” VALVE
PORT B
POWER DOWN PUMP MOTOR & SOLENOID SWITCH OPERATION
LIFTGATE
FUNCTION
SOLENOID SWITCH OPERATION
( MEANS ENERGIZED)
PORT
MOTOR
RAISE
A
LOWER
B
VALVE
“S2”
VALVE
“S1”
-
-
REFER TO VALVES SHOWN ON
HYDRAULIC SCHEMATIC
TABLE 27-1
27
POWER DOWN
MODULE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP, MOTOR & SOLENOID OPERATION - POWER DOWN
HYDRAULIC SYSTEM DIAGRAMS
HYDRAULIC SCHEMATIC (GRAVITY DOWN)
HYDRAULIC CYLINDER
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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)
FIG. 28-1
28
FILLER HOLE
(PLUGGED)
HYDRAULIC CYLINDER
2 GPM FLOW
CONTROL
VALVE
PORT B - LOWER
(POWER DOWN)
PORT A - RAISE
S2
RELIEF VALVE 2
(SET AT 1100 PSI)
S1
RELIEF VALVE 1
(SET AT 3250 PSI)
MOTOR
(REF)
PUMP
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 29-1
29
AUX. HAND
PUMP PORT
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC (POWER DOWN)
ELECTRICAL SYSTEM DIAGRAMS
ELECTRICAL SCHEMATIC (GRAVITY DOWN)
CONTROL SWITCH
(UP)
(DOWN)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BLACK
GREEN
1
2
JUNCTION
BLOCK
WHITE
2
1
SOLENOID
VALVE
FUSE HOLDER
WITH 10 AMP
FUSE
STARTER
SOLENOID
CABLE WITH
175 A FUSE
MOTOR
BATTERY
FIG. 30-1
30
CYCLE
COUNTER
(IF
EQUIPPED)
WHITE
CONTROL SWITCH
(UP)
3
1
2
(DOWN)
POWER DOWN MODULE
BLACK
1
2
2
3
4
WHITE
(CABLE)
K1
RED
5
1
GREEN
BLACK
(CABLE)
RED
BLACK
FUSE HOLDER
WITH 10 AMP
FUSE
SOLENOID,
VALVE S2
SOLENOID,
VALVE S1
STARTER
SOLENOID
CABLE WITH
175 A FUSE
1
2
CYCLE COUNTER
(IF EQUIPPED)
MOTOR
BATTERY
FIG. 31-1
31
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ELECTRICAL SCHEMATIC (POWER DOWN)
SYSTEM DIAGRAMS
TE SERIES ELECTRICAL VALUES
12V
Solenoid Switch
24V
Coil Resistance:
5.4Ω @70ºF. ±15%
20.1Ω @70ºF. ±15%
Ampere:
2.2A
1.2A
Coil Resistance:
6.6Ω @ 70ºF. ±15%
26.7Ω @ 70ºF. ±15%
Ampere:
1.8A
0.9A
Coil Resistance:
8.0Ω @ 70ºF. ±15%
30Ω @ 70ºF. ±15%
Ampere:
1.5A
0.8A
Coil terminal torque: 10-15 lb-in max.
Contact terminal torque: 30-35 lb-in max.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Solenoid Valves (A, S1, & S2)
Coil terminal torque: 15-45 lb-in max.
Valve cartridge torque: 25-30 lb-ft max.
Coil nut torque: 15-45 lb-in
Solenoid Lock Valve
Coil terminal torque: 3-4.5 lb-ft max.
Valve cartridge torque: 18.5-22 lb-ft max.
Ground Cable
Cap Screw Torque: 24 lb-ft max.
TABLE 32-1
32
TROUBLESHOOTING
1. Use voltmeter to verify power is being supplied to solenoid terminal “B”
(FIG. 33-1). 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. 33-1). 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. 33-1).
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.
TERMINAL “B”
BATTERY (+)
TERMINAL “C”
GROUND (-)
7. Check for dirty pump motor relief
valve. Clean if necessary.
TERMINAL “D”
Replace any worn out relief valve
SWITCHED
BATTERY
(+)
parts.
STARTER
SOLENOID
TERMINAL “A”
MOTOR (+)
LOWERING
SOLENOID
FIG. 33-1
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT RAISE
TROUBLESHOOTING
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. 34-1). 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. 34-1
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. 34-2). With platform
on ground, unscrew the valve stem (Item 2,
FIG. 34-2) 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. 34-3).
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.
2
1
1/8”
FIG. 34-2
VENT/DOWN PORT
RAISE PORT
FIG. 34-3
34
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. 35-1).
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.
VENT/DOWN PORT
RAISE PORT
FIG. 35-1
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.
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES PARTIALLY AND STOPS
TROUBLESHOOTING
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. 36-2). Remove gauge and reinstall pressure
hose.
VENT/DOWN PORT
RAISE PORT
4. Check for dirty pump motor relief valve. Clean if
necessary. Replace any worn out relief valve
parts.
FIG. 36-1
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.
36-1). 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, and will not
lift load of rated capacity, the pump is worn and
needs to be replaced.
PRESSURE
GAUGE
FIG. 36-2
36
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. 37-1).
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. 37-1
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. 37-3). Raise the platform even
with the bed. Allow pump motor to run two seconds more while you watch for hydraulic
fluid at the 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. 37-3.
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.
FIG. 37-2
VENT/DOWN
PORT
9. With platform on the ground, remove the pressure
hose and fitting from the pump and replace it with a
PRESSURE
0-4000 PSI pressure gauge. Hold the control switch in
PORT
the “raise” position. Adjust the relief valve on the side of
the pump until the gauge shows 3250 PSI (FIG. 37-2).
Remove gauge and reinstall pressure hose.
37
FLOW
CONTROL
VALVE
FIG. 37-3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM RAISES SLOWLY
TROUBLESHOOTING
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. 38-1).
TERMINAL “B”
BATTERY (+)
2. Check for structural damage or poor lubrication.
Replace worn parts.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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. 38-2). A good solenoid will attract (magnetically)
the screwdriver to the nut and make it difficult to pull
the screwdriver away from the nut.
FIG. 38-1
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. 38-2). With platform supported,
unscrew the valve stem (Item 2, FIG. 38-2) 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. 38-2
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. 38-3) is
pointing to the direction of restricted fluid
flow (back toward pump). If required, remove
flow control valve and install it correctly (FIG.
38-3).
38
VENT/DOWN PORT
(REF)
RAISE PORT
(REF)
FLOW
CONTROL
VALVE
FIG. 38-3
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