Maxon GPTLR TUK-A-WAY® Maintenance Manual

Maxon GPTLR TUK-A-WAY® Maintenance Manual
M-16-26
OCTOBER 2018
© MAXON Lift Corp. 2018
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-16-26.................................................................................... 6
WARNINGS ........................................................................................................................... 8
SAFETY INSTRUCTIONS .................................................................................................... 9
LIFTGATE TERMINOLOGY ................................................................................................ 10
PERIODIC MAINTENANCE................................................................................................ 11
PERIODIC MAINTENANCE CHECKS .................................................................................11
PERIODIC MAINTENANCE CHECKLIST ........................................................................... 14
CHECKING HYDRAULIC FLUID ........................................................................................ 16
CHANGING HYDRAULIC FLUID ........................................................................................ 18
PLATFORM TORSION SPRING ADJUSTMENT ................................................................ 22
PERIODIC MAINTENANCE................................................................................................ 28
REPLACING PLATFORM TORSION SPRING ................................................................... 28
DECALS .............................................................................................................................. 30
NONSKID & SAFETY STRIPING ....................................................................................... 32
SYSTEM DIAGRAMS ......................................................................................................... 34
PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) ........................................ 34
PUMP & MOTOR SOLENOID OPERATION (POWER DOWN).......................................... 35
HYDRAULIC SCHEMATIC (GRAVITY DOWN)................................................................... 36
HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 37
ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 38
ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 39
GPTLR ELECTRICAL VALUES........................................................................................... 40
RECOMMENDED BOLT TORQUES .................................................................................. 41
TROUBLESHOOTING ........................................................................................................ 42
PLATFORM WILL NOT RAISE & MOTOR WILL NOT RUN ............................................... 42
PLATFORM WILL NOT RAISE, BUT MOTOR RUNS ......................................................... 43
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 44
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 46
LIFTGATE WILL NOT LIFT RATED CAPACITY .................................................................. 48
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY ............... 50
SUMMARY OF CHANGES: M-16-26
PAGE
Cover
DESCRIPTION OF CHANGE
Updated date of release.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
8
Removed galvanized warning decal. Added notes for recommended practices for welding galvanized steel to refer to AWS (American Welding Society) D19.0 Welding
Zinc-Coated Steel. Added California Proposition 65 WARNING.
10
Main assembly shows new bolt-on mounting plates and horizontal power unit.
17
Combined EXXON & MOBIL oils on the same row with updated part numbers.
30
Updated illustration shows location for control switch decal.
31
Added QR code parts decal and serial plate.
34, 35
Updated illustration of pump and motor solenoid operation has no thermal switch on the
pump motor, and shows direction of controlled flow on flow control valve. Fused control
switch power connection shows new 10 AMP fuse holder assembly.
38
Updated gravity down electrical schematic, shows cycle counter (if equipped).
39
Updated power down electrical schematic, shows cycle counter (if equipped).
40
Added GPTLR electrical values.
6
7
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THIS PAGE INTENTIONALLY LEFT BLANK
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.
!
WARNING
Installing and maintaining a liftgate can expose you to chemicals, including lead, which are
knowto the State of California to cause cancer and birth defects or other reproductive harm. To
minimize exposure, install and maintain liftgate in a well-ventilated area and wear proper Personal protective equipment (PPE). For more information go to www.P65Warnings.ca.gov.
WARNINGS
!
WARNING
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• 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.
8
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
• 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
• Read and understand the instructions in this Maintenance Manual before performing maintenance on the Liftgate.
LIFTGATE TERMINOLOGY
EXTENSION
PLATE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL
SWITCH
PUMP
BOX
LIFT
CYLINDER
PARALLEL
ARM
PLATFORM
SPRING ASSIST
TORSION BAR
BOLT ON MOUNTING
PLATE
TORSION SPRING
HYDRAULIC
LOCK
MAIN
FRAME
PLATFORM
OPENER
FLIPOVER WITH
FIXED RAMP
10
PLATFORM
SUPPORT
LIFT
ARM
PERIODIC MAINTENANCE
! WARNING
Never operate the Liftgate if parts are loose or missing.
NOTE: Make sure vehicle is parked on level ground while performing the
maintenance checks.
Quarterly or 1250 Cycles (whichever occurs first)
Check the hydraulic fluid level in the pump reservoir. Refer to the CHECKING HYDRAULIC FLUID procedure in the PERIODIC MAINTENANCE section. If hydraulic fluid appears
contaminated, refer to the CHANGING HYDRAULIC FLUID procedure in the PERIODIC
MAINTENANCE section. Keep track of the grade of hydraulic fluid in the pump reservoir.
Never mix two different grades of fluid.
Check all hoses and fittings for chafing and fluid leaks. Make sure hydraulic lock is in place
and undamaged. Replace if necessary.
Check electrical wiring for chafing and make sure wiring connections are tight and free of
corrosion.
Check that all WARNING and instruction decals, nonskid stickers, and safety striping
are in place. Also, make sure decals are legible and decals, nonskid, and safety striping are
clean and undamaged.
Check that all roll pins are in place and protrude evenly from both sides of hinge pin collar.
Replace roll pins if necessary.
Check both platform torsion springs to make sure there is grease between the coils. If
grease is not visible in the valley between each coil, apply spray-on white lithium grease.
Unfold & fold platform. If platform feels heavy while starting to fold, do PLATFORM TORSION SPRING ADJUSTMENT in the PERIODIC MAINTENANCE section of this manual.
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. If
bare metal is exposed on galvanized portions of the Liftgate, touch up the galvanized finish.
To maintain original galvanized finish, MAXON recommends cold galvanize spray.
Semi-annually or 2500 Cycles (whichever occurs first)
Visually check the platform hinge pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly or 1250 Cycles
maintenance checks.
11
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PERIODIC MAINTENANCE CHECKS
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHECKS - Continued
Annually or 5000 Cycles (whichever occurs first)
Visually check the entire Liftgate for excessively worn
parts and broken welds, especially hinge pins. See
PARTS BREAKDOWN section for replacement parts.
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Check the platform and flipover as follows. Unfold
the platform and flipover. Raise the platform to
vehicle bed height and then lower it to the ground.
Check if the shackles and tip of flipover touch the
ground at the same time (FIG. 12-1). With the
shackles touching, tip of a ramp-style flipover may
be no more than 1/4” above the ground. A flipover
equipped with retention ramp may have a maximum
2” of ground clearance at the tip of the flipover.
If the shackles are 1” or more above the ground
when the tip of the flipover is touching the ground
(FIG. 12-2), perform the ADJUST PLATFORM
procedure in the Installation Manual (M-16-24).
If the adjustment does not correct the problem,
check pins and bearings at the pivot points on both
sides of the Liftgate (see FIG. 12-3). See PARTS
BREAKDOWN section for replacement parts.
Also, for aluminum flipovers
equipped with single retention ramp and for steel
flipovers, ensure latch is
in place, undamaged, and
working correctly. See
PARTS BREAKDOWN section for replacement parts.
1/4” (MAX.)
(SEE NOTE)
TIP OF
STANDARD
FLIPOVER
SHACKLE
PLATFORM & SHACKLES
TOUCHING THE GROUND
FIG. 12-1
TIP OF
FLIPOVER
1”
(OR MORE)
SHACKLE
SHACKLES NOT TOUCHING
THE GROUND
FIG. 12-2
LIFT
CYLINDER
LIFT ARM
PARALLEL
ARM
PLATFORM
PIVOT POINTS
(PINS & BEARINGS)
PIVOT POINTS TO CHECK
FIG. 12-3
12
Also, do the Semi-annual or
2500 Cycles and Quarterly
or 1250 Cycles checks.
THRUST BEARINGS
PARALLEL
ARM
SHACKLE
0.050”
(MIN.)
0.050”
(MIN.)
CHECKING SHACKLE
CLEARANCES (RH SIDE SHOWN)
FIG. 13-1A
1”- 2”
PLATFORM ABOVE GROUND LEVEL
FIG. 13-1
13
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To prevent unnecessary wear
on parallel arms, check for worn
thrust bearings as follows. Position the platform 1”-2” above
ground (FIG. 13-1). Push against
the shackle (Item 1, FIG. 13-1A)
and measure clearance (Item 1,
FIG. 13-1A). Then, push against
other side of shackle (Item 2,
FIG. 13-1A) and measure clearance (Item 2, FIG. 13-1A). Repeat for LH side shackle. If clearance is less than 0.050”, replace
thrust bearing. See PARTS
BREAKDOWN section for replacement parts.
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHECKLIST
NOTE: Make sure vehicle is parked on level ground while performing maintenance checks.
Quarterly or 1250 Cycles (whichever occurs first)
Check the level and condition of the hydraulic fluid.
Visually check all hoses and fittings for chafing and fluid leaks, and check hydraulic lock.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Check electrical wiring for chafing and make sure wiring connections are tight and free
of corrosion.
Check that all WARNING and instruction decals, nonskid stickers, and safety striping are in place. Also, make sure decals are legible and decals, nonskid, and safety
striping are clean and undamaged.
Check that all roll pins are in place and protrude evenly from both sides of hinge pin collar. Replace roll pins if necessary.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate or if the Liftgate is dirty, clean it off. Touch up the galvanized finish where bare metal is showing.
Check both platform torsion springs to make sure there is grease in the valley between
each coil. If grease is not visible, apply spray-on white lithium grease to the valley between each coil. Unfold & fold platform. If platform feels heavy while starting to fold, do
PLATFORM TORSION SPRING ADJUSTMENT in the PERIODIC MAINTENANCE
section of this manual.
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.
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.
Annually or 5000 Cycles (whichever occurs first)
Visually check the entire Liftgate for excessively worn parts and broken welds, especially hinge pins.
Visually check platform & flipover. (See the PERIODIC MAINTENANCE CHECKS topic
for more information.)
Visually check the thrust bearings on the shackles.
Do the Semi-annual or 2500 Cycles Checks on this checklist.
Do the Quarterly or 1250 Cycles Checks on this checklist.
For more details pertaining to this checklist, see the PERIODIC MAINTENANCE CHECKS
section in this Maintenance Manual.
14
LH CYLINDER,
LIFT ARM &
PARALLEL ARM
RH CYLINDER,
LIFT ARM &
PARALLEL ARM
GPTLR LUBRICATION DIAGRAM
FIG. 15-1
15
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NOTE: Lube fittings are shown for the RH cylinder, lift arm, and parallel arm.
There are also lube fittings at the same places on the LH cylinder, lift arm,
and parallel arm. Refer to the PERIODIC MAINTENANCE CHECKS and
PERIODIC MAINTENANCE CHECKLIST for the recommended grease
and maintenance interval.
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: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions.
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 17-1 & 17-2 for recommended brands of ISO 32 & ISO 15 oils.
1. Unbolt and remove pump cover
(FIG. 16-1).
2. Check the hydraulic fluid level in
reservoir as follows. With Liftgate
stowed, or platform at vehicle bed
height, level should be as shown in
FIG. 16-2.
CAP SCREW,
5/16”-18
(2 PLACES)
HOLDER FLAT
(2 PLACES)
NOTE: If the hydraulic fluid in the
reservoir is contaminated, do
the CHANGING HYDRAULIC
FLUID procedure in this section.
POWER UNIT
(REF)
PUMP COVER
3. If needed, add fluid to the reservoir as
follows. Pull out (no threads) filler cap
(FIG. 16-2). Fill the reservoir with hydraulic fluid to level shown in FIG. 162. Reinstall filler cap (FIG. 16-2).
UNBOLTING PUMP COVER
FIG. 16-1
CAUTION
Pump cover must be correctly secured to prevent it from becoming
a hazard. To secure pump cover,
the long side of the holder flats
must butt against pump cover as
shown in the illustration.
FLAT WASHER,
5/16”
(2 PLACES)
NYLON NUT,
5/16”-18
(2 PLACES)
RESERVOIR
FILLER
CAP
3”(PD)
1-1/2”(GD)
4. Bolt on the pump cover as shown
in FIG. 16-1. Torque the bolts (cap
screws) to 10-14 lb-in.
POWER UNIT FLUID LEVEL
FIG. 16-2
16
RECOMMENDED
BRANDS
PART NUMBER
CHEVRON
HIPERSYN 32
KENDALL
GOLDEN MV
SHELL
TELLUS S2 VX 32
EXXONMOBIL
UNIVIS N-32, DTE-24
TABLE 17-1
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 17-2
17
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ISO 32 HYDRAULIC OIL
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: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions.
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 17-1 & 17-2 for recommended brands of ISO 32 & ISO 15 OILS.
GRAVITY DOWN & POWER DOWN LIFTGATES
1. Unbolt and remove pump cover
(FIG. 18-1). Place empty 5 gallon bucket under drain plug
(FIG. 18-2).
CAP SCREW,
5/16”-18
(2 PLACES)
FLAT WASHER,
5/16”
(2 PLACES)
NYLON NUT,
5/16”-18
(2 PLACES)
HOLDER FLAT
(2 PLACES)
POWER UNIT
(REF)
PUMP COVER
UNBOLTING PUMP COVER
FIG. 18-1
RESERVOIR
DRAIN PLUG
FIG. 18-2
18
GRAVITY DOWN LIFTGATES
2. Pull out (no threads) filler cap (FIG. 19-1)
and refill reservoir with hydraulic fluid to
level shown in FIG. 19-1. Reinstall filler
cap (FIG. 19-1).
RESERVOIR
FILLER CAP
3”(PD)
1-1/2”(GD)
DRAIN PLUG
3. Stow the Lift and do the CHECKING HYDRAULIC FLUID procedure in this section of the
manual.
GRAVITY DOWN PUMP & MOTOR
FIG. 19-1
POWER DOWN LIFTGATES
1. Open and raise platform to vehicle bed height.
Pull out (no threads) drain plug (FIG. 19-1).
Drain hydraulic fluid.
STARTER
SOLENOID
HEX NUT
WHITE WIRE
2. Disconnect the white wire (FIG. 19-2) from
starter solenoid. Lower the platform while
draining the remaining hydraulic fluid from system. Reinstall drain plug. Reconnect the white
wire to starter solenoid.
3. Pull out (no threads) filler cap (FIG. 19-1) and refill
reservoir with hydraulic fluid to level shown in FIG.
19-1. Reinstall filler cap (FIG. 19-1).
4. Stow the Lift and do the CHECKING HYDRAULIC
FLUID procedure in this section of the manual.
19
POWER DOWN PUMP
FIG. 19-2
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1. Lower platform to ground. Pull out (no
threads) drain plug (FIG. 19-1). Drain
hydraulic fluid from system. Reinstall
drain plug.
PERIODIC MAINTENANCE
GRAVITY DOWN & POWER DOWN LIFTGATES
CAUTION
Pump cover must be correctly secured to prevent it from becoming a
hazard. To secure pump cover, the long side of the holder flats must butt
against pump cover as shown in the illustration.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Bolt on the pump cover as shown
in FIG. 20-1. Torque the bolts (cap
screws) to 10-14 lb-in.
CAP SCREW,
5/16”-18
(2 PLACES)
FLAT WASHER,
5/16”
(2 PLACES)
NYLON NUT,
5/16”-18
(2 PLACES)
HOLDER FLAT
(2 PLACES)
POWER UNIT
(REF)
PUMP COVER
BOLTING PUMP COVER
FIG. 20-1
20
21
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THIS PAGE INTENTIONALLY LEFT BLANK
PERIODIC MAINTENANCE
PLATFORM TORSION SPRING ADJUSTMENT
NOTE: Perform the following adjustment if platform feels heavy as you start to
fold it for stowing. If adjusted as follows, the torsion springs will reduce the
amount of effort you need to start folding the platform.
1. Make sure vehicle is parked on level
ground. LOWER the Liftgate to the ground
and unfold platform only (FIG. 22-1).
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
NOTE: A properly adjusted platform
will stay on ground or horizontal
position when open flipover is
being folded. Acceptable force to
fold the platform is 40 lb max.
UNFOLDING PLATFORM
FIG. 22-1
NOTE: Bottom of unfolded platform
should be 4” or less above the
ground. If distance is more than
4”, and platform can be folded
and unfolded with ease, the
greater distance is allowed and
no adjustment is necessary.
2. Measure the distance between the
bottom block of the platform and the
ground (FIG. 22-2).
4” MAX
PLATFORM 0-4” ABOVE GROUND
FIG. 22-2
22
To prevent possible injury and damage to Liftgate, have another qualified
person hold platform in position to keep it from falling open.
3. Position platform and flipover to 90 degrees, +2 / -0 degrees (FIG. 23-1A). Get
a second person to hold the platform in
place while you take measurements.
4. On RH side of platform, position the
torsion spring so it rests on pin (FIGS.
23-1A & 23-1B). Make sure free leg of
torsion spring is parallel to chamfered
surface on support block (FIG. 23-1B).
Measure gap “H” between leg of the
torsion spring and support block (FIG.
23-1B). Get enough 1/16” shim washers
(Kit items), to equal measured gap.
PIN LOCATION
FIG. 23-1A
SUPPORT
BLOCK
“H”
PIN
TORSION
SPRING
FREE
LEG
CORRECTLY POSITIONED
PLATFORM & FLIPOVER
FIG. 23-1B
23
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! WARNING
PLATFORM TORSION SPRING ADJUSTMENT - Continued
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
5. If necessary, adjust the torsion
SHACKLE BRACKET
springs to lower the platform to 4” or
PIN BRACKET
less above the ground. Unbolt pin
bracket (FIG. 24-1). Then, rotate the
BOLT
pin bracket away from the shackle
bracket until the free leg of the torsion
spring makes contact with the new
block welded to the platform support.
Then, using shim washers that equal
PIN
LOCK NUT
the gap “H” measured in step 14,
insert the shim washers between pin
bracket and shackle bracket (FIGS.
FLAT WASHER SHACKLE
24-1 and 24-2.). Bolt shim washers
ADJUST PLATFORM
in place between pin bracket and
FIG. 24-1
shackle bracket (FIG. 24-2). Tighten
bolt and lock nut.
6. Repeat steps 2, 3, and 4 for the LH
torsion spring.
7. Repeat step 1 to check clearance of
bottom of platform above the ground.
PIN BRACKET
LOCK NUT
BOLT
FLAT WASHER
SHACKLE BRACKET
SHIM WASHERS
SHIMMING TORSION SPRING
FIG. 24-2
24
8. If shimming is not possible, grind the
contact surface on the support blocks
(FIGS. 25-1 and 25-2) in small 1/16”
increments to lower the platform to 4”
or less, between bottom block and the
ground (FIG. 25-3).
CONTACT SURFACE
LH BLOCK
SPRING
GRINDING LH BLOCK
FIG. 25-1
RH BLOCK
CONTACT SURFACE
SPRING
GRINDING RH BLOCK
FIG. 25-2
4” MAX
PLATFORM 0-4” ABOVE GROUND
FIG. 25-3
25
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NOTE: If shimming is not possible, the spring contact surface on the new stops
may be ground in small 1/16” increments to lower the platform closer to the
ground.
PLATFORM TORSION SPRING ADJUSTMENT - Continued
! CAUTION
Stow Liftgate under hydraulic pressure.
9. Fold platform as shown in FIG. 26-1.
Then, stow Liftgate as shown in FIG.
26-2.
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FOLDING PLATFORM
FIG. 26-1
LIFTGATE STOWED
FIG. 26-2
26
27
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THIS PAGE INTENTIONALLY LEFT BLANK
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.
PLATFORM
SUPPORT
1. Fold flipover onto platform.
LOCK NUT
BOLT
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2. Fold platform.
BUSHING
3. Raise Liftgate to a convenient
work height to gain access and
release tension on the torsion
spring.
SPRING
BRACKET
SHACKLE
WASHER
OUTER
SHIM
LOCK NUT
FIG. 28-1
! CAUTION
To prevent injury and equipment damage,
make sure there is no tension on torsion
spring before removing hinge pin.
4. Unbolt hinge pin from shackle and spring
bracket (FIG. 28-1). Remove bolts, washers, and lock nuts. Drive the hinge pin out
board toward the shackle just enough to
free the torsion spring and bushing (FIG.
28-2). Remove the torsion spring.
HINGE
PIN
BUSHING
TORSION
SPRING
SHACKLE
FIG. 28-2
28
6. Drive the hinge pin into correct
position through the platform
support as shown in FIG. 29-1.
Line up the bolt hole in the
hinge pin with the hole in the
shackle and spring bracket.
Bolt the hinge pin to platform
support and spring bracket
with bolts, washers, lock nuts
(FIG. 29-1). Torque the 3/8”16 spring pin bolt and 3/8”-16
spring bracket bolt 35 to 52
lb-ft.
CHAMFERED
LEG
LOCK NUT
PLATFORM
SUPPORT
BOLT
BUSHING
NON-CHAMFERED
LEG
HINGE
PIN
SPRING
BRACKET
WASHER
OUTER
SHIM BOLT
LOCK NUT
SHACKLE
FIG. 29-1
7. Do the PLATFORM TORSION
SPRING ADJUSTMENT in this
manual.
8. Operate the Liftgate according to
instructions in Operation Manual
to make sure it operates correctly.
29
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5. Install the new torsion spring
and bushing as shown in FIG.
29-1. Make sure non-chamfered leg of the spring is inserted in the spring bracket (FIG.
29-1). Make sure chamfered
leg of the spring is visible and
resting against the platform
support (FIG. 29-1).
DECALS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL SWITCH
DECAL
P/N 264507
INSTRUCTION DECAL
P/N 251867-09
DECAL SHEET
(SMALL, WARNING & CAUTION)
P/N 282522-01
CAPACITY DECAL
(SEE TABLE 30-1)
STOW WARNING DECAL
P/N 282847-02
CAPACITY DECALS
CAPACITY
PART NO.
2500 LB
220382
3300 LB
220388-02
4400 LB
253155
5500 LB
253161
TABLE 30-1
FIG. 30-1
30
PARTS QR CODE
DECAL
P/N 299348-07
SERIAL PLATE (REF)
CAUTION DECAL
(FLIPOVER EQUIPPED WITH LATCH ONLY)
P/N 267694-01
WARNING DECAL
P/N 265736-02
FIG. 31-1
31
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WARNING DECAL
P/N 265736-03
NONSKID & SAFETY STRIPING
NONSKID (LH)
P/N 281204-01
NONSKID (RH)
P/N 281204-02
SAFETY STRIPE TAPE
(2 PLACES)
P/N 096018-10
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FIG. 32-1
32
33
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THIS PAGE INTENTIONALLY LEFT BLANK
SYSTEM DIAGRAMS
PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN)
STARTER
SOLENOID
“A” VALVE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
MOTOR
DIRECTION OF
CONTROLLED
FLOW
GRAVITY DOWN POWER UNIT
FIG. 34-1
POWER UNIT MOTOR & SOLENOID OPERATION
LIFTGATE
FUNCTION
RAISE
LOWER
SOLENOID OPERATION
( MEANS ENERGIZED)
PORT
MOTOR
VALVE
“A”
LOCK
VALVE
-
-
A
VENT
-
REFER TO VALVES SHOWN ON
HYDRAULIC SCHEMATIC
TABLE 34-1
34
STARTER
SOLENOID
MOTOR
“S2” VALVE
“S1” VALVE
DIRECTION OF
CONTROLLED
FLOW
POWER DOWN POWER UNIT
FIG. 35-1
POWER UNIT MOTOR & SOLENOID OPERATION
LIFTGATE
FUNCTION
SOLENOID OPERATION
(
MEANS ENERGIZED)
PORT
MOTOR
RAISE
A
LOWER
B
VALVE
“S2”
VALVE
“S1”
-
-
-
REFER TO VALVES SHOWN ON
HYDRAULIC SCHEMATIC
TABLE 35-1
35
LOCK
VALVE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP & MOTOR SOLENOID OPERATION (POWER DOWN)
HYDRAULIC SCHEMATIC (GRAVITY DOWN)
HYDRAULIC CYLINDERS
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HYDRAULIC
LOCK VALVE
4.5 GPM FLOW
CONTROL VALVE
PORT B - RETURN
(PLUGGED)
PORT A - RAISE
VENT
PORT
FILL HOLE
(PLUGGED)
VALVE A
RELIEF VALVE
(SET AT 3250 PSI)
CHECK VALVE
AUX. HAND
PUMP PORT
(PLUGGED)
PUMP
M
MOTOR
(REF)
FILTER
RESERVOIR
DRAIN HOLE (PLUGGED)
FIG. 36-1
36
HYDRAULIC SCHEMATIC (POWER DOWN)
HYDRAULIC
LOCK VALVE
4.5 GPM FLOW
CONTROL VALVE
PORT B POWER DOWN
PORT A - RAISE
VALVE “S2”
FILTER
RELIEF VALVE 2
(SET AT 1100 PSI)
VALVE “S1”
RELIEF VALVE 1
(SET AT 3250 PSI)
MOTOR
(REF)
PUMP
FILTER
RESERVOIR
DRAIN HOLE (PLUGGED)
FIG. 37-1
37
AUX. HAND
PUMP PORT
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC CYLINDERS
ELECTRICAL SCHEMATIC (GRAVITY DOWN)
CONTROL SWITCH
(UP)
(DOWN)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
GREEN
BLACK
1
2
JUNCTION
BLOCK
WHITE
RED
SOLENOID
VALVE “A”
2
CYCLE
COUNTER
LOCK
VALVE
1
FUSE HOLDER
WITH 10 AMP
FUSE
CABLE WITH
175 AMP FUSE
STARTER
SOLENOID
MOTOR
BATTERY
BLACK
FIG. 38-1
38
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SCHEMATIC (POWER DOWN)
NOTE: One cycle is counted when
the down switch is activated
for 5-7 continuous seconds.
FIG. 39-1
39
GPTLR ELECTRICAL VALUES
12V
Solenoid Switch
24V
Coil Resistance:
5.4Ω @70ºF. ±15%
20.1Ω @70ºF. ±15%
Ampere:
2.2A
1.2A
S1 Coil Resistance:
6.6Ω @ 70ºF. ±15%
26.7Ω @ 70ºF. ±15%
S1 Ampere:
1.8A
0.9A
S2 Coil Resistance:
7.5Ω @ 70ºF. ±15%
30.8Ω @ 70ºF. ±15%
S2 Ampere:
1.6A
0.78A
Coil Resistance:
8.0Ω @ 70ºF. ±15%
30Ω @ 70ºF. ±15%
Ampere:
1.5A
0.8A
Coil terminal torque: 10-15 lb-in max.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Contact terminal torque: 30-35 lb-in max.
Solenoid Valves (A, S1, & S2)
Coil nut 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 nut 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 40-1
40
RECOMMENDED BOLT TORQUES
The torque values in the following table are provided for torquing grade 8
bolts on Liftgate mechanical parts. To prevent damage, never use the information in this table for torquing electrical or hydraulic hose connections on
the pump assembly.
TABLE 41-1
41
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CAUTION
TROUBLESHOOTING
PLATFORM WILL NOT RAISE & MOTOR WILL NOT RUN
1. Connect voltmeter between motor
STARTER
solenoid terminal “B” and ground
SOLENOID
wires connection on pump (FIG. 42-1).
Verify that full battery voltage is at
TERMINAL “D”
“B”. Recharge the battery if
SWITCHED BATTERY
voltmeter indicates less than
(+)
12.6 volts dc.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
VALVE “A”
LOWERING
SOLENOID VALVE
TERMINAL “A”
LOAD
TERMINAL “B”
BATTERY (+)
TERMINAL “C”
GROUND (-)
GRAVITY DOWN POWER UNIT
FIG. 42-1
2. Touch a jumper wire to terminals “B” & “D” (FIG. 42-1).
If motor runs, check control switch, the switch connections,
and white wire. Check and correct wiring connections or
replace the control switch.
3. Touch heavy jumper cables to terminals “A” & “B”
(FIG. 42-1).
a. If motor runs, replace the motor solenoid.
b. If motor does not run, repair or replace the pump motor.
42
1. Do the CHECKING HYDRAULIC FLUID
procedure in this manual. If necessary,
add hydraulic fluid.
RESERVOIR
2. Check for structural damage and 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.
3. Check pump oil filter in the reservoir
(FIGS. 43-1 and 43-2). Clean or
replace filter, if necessary.
RELIEF
VALVE
ADJUSTMENT
COVER
CHECKING THE RAISING RELIEF VALVE
(GRAVITY DOWN POWER UNIT)
FIG. 43-1
RESERVOIR
4. Check for dirty raising relief valve (FIGS.
43-1 and 43-2). Clean or replace
relief valve if necessary.
RELIEF
VALVE
ADJUSTMENT
COVER
CHECKING THE RAISING RELIEF VALVE
(POWER DOWN POWER UNIT)
FIG. 43-2
43
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PLATFORM WILL NOT RAISE, BUT MOTOR RUNS
TROUBLESHOOTING
PLATFORM RAISES BUT LEAKS DOWN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Check if the “A” (lowering)
solenoid valve is constantly
energized. Connect voltmeter
negative (-) lead to ground (-)
wires connection on pump and
positive (+) lead to (+) terminal
on the “A” (lowering) solenoid
valve (FIG. 44-1). If voltmeter
reads battery voltage, check
for faulty wiring or toggle
switch.
STARTER
SOLENOID
TERMINAL “D”
SWITCHED BATTERY
(+)
VALVE “A”
LOWERING
SOLENOID VALVE
TERMINAL “A”
LOAD
TERMINAL “B”
BATTERY (+)
TERMINAL “C”
GROUND (-)
GRAVITY DOWN POWER UNIT
FIG. 44-1
44
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. Make sure platform is on the ground. Remove
lowering solenoid valve (FIGS. 45-1 and
45-2). Push on the plunger in the valve by
inserting small screwdriver in the open end
(FIG. 45-3). If the plunger does not move with
a smooth, spring-loaded action (approximately
1/8”), replace the valve cartridge. Reinstall
lowering solenoid valve. Torque valve cartridge to 25 - 30 lb-in and hex nut to 15 - 45
lb-in.
COIL
NUT
REMOVING SOLENOID VALVE
(GRAVITY DOWN POWER UNIT)
FIG. 45-1
COIL
NUT
VALVE
CARTRIDGE
REMOVING SOLENOID VALVE
(POWER DOWN POWER UNIT)
FIG. 45-2
VALVE CARTRIDGE
1/8”
3. Check the hydraulic cylinder. With the platform at vehicle floor level, remove the hydraulic line from the LOWER port on the cylinder (FIG. 45-4). Hold the control switch in
the “RAISE” position for two seconds while
you watch for hydraulic fluid at the LOWER
port. A few drops of hydraulic fluid escaping
the port is normal. However, if fluid streams
out, piston seals are worn. Replace seals.
CHECKING SOLENOID VALVE
FIG. 45-3
LOWER PORT
RAISE PORT
FIG. 45-4
45
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VALVE
CARTRIDGE
CAUTION
TROUBLESHOOTING
PLATFORM RAISES PARTIALLY AND STOPS
1. Lower the opened platform to the ground. Do the
CHECKING HYDRAULIC FLUID procedure in
this manual. If necessary, add hydraulic fluid.
RESERVOIR
2. Use voltmeter to verify the battery voltage is
12.6 volts or more under load from pump motor.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3. Check for structural damage and poor
lubrication. Replace worn parts.
RELIEF
VALVE
ADJUSTMENT
COVER
CHECKING THE RAISING RELIEF VALVE
(GRAVITY DOWN POWER UNIT)
FIG. 46-1
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.
RESERVOIR
4. Check for dirty raising relief valve (FIGS.
46-1 and 46-2). Clean or replace
relief valve, if necessary.
RELIEF
VALVE
ADJUSTMENT
COVER
CHECKING THE RAISING RELIEF VALVE
(POWER DOWN POWER UNIT)
FIG. 46-2
46
6. Check pump oil filter in the reservoir
(FIGS. 46-1 and 46-2). Clean or replace
filter, if necessary.
47
LOWER PORT
RAISE PORT
FIG. 47-1
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5. Check the hydraulic cylinder. With the platform at vehicle floor level, remove the hydraulic line from the LOWER port on the cylinder (FIG. 47-1). Hold the control switch in
the “RAISE” position for two seconds while
you watch for hydraulic fluid at the LOWER
port. A few drops of hydraulic fluid escaping
the port is normal. However, if fluid streams
out, piston seals are worn. Replace seals.
TROUBLESHOOTING
LIFTGATE WILL NOT LIFT RATED CAPACITY
1. Use voltmeter to verify the battery voltage is 12.6
volts or more under load from pump motor.
2. Check for structural damage or lack of lubrication. Replace worn parts.
RELIEF VALVE
ADJUST SCREW
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.
3. Check the 3250 PSI relief valve as
follows. With platform on the ground,
remove plug from hand pump port
(FIGS. 48-1 and 48-2). Install 0-4000
PSI pressure gauge in the hand pump
port (FIGS. 48-1 and 48-2). Remove
cover for access to relief valve. Hold the
control switch in the “RAISE” position.
Adjust the relief valve until the gauge
reads 3250 PSI (FIGS. 48-1 and 48-2).
Remove gauge and reinstall plug in the
port. Then, reinstall relief valve cover.
HAND PUMP
PORT
ADJUSTMENT
COVER
PRESSURE
GAUGE
ADJUSTING RAISING RELIEF VALVE
(GRAVITY DOWN POWER UNIT)
FIG. 48-1
RELIEF VALVE
ADJUST SCREW
4. Check if pump relief valve is dirty. Clean or
replace relief valve, if necessary.
HAND PUMP
PORT
ADJUSTMENT
COVER
PRESSURE
GAUGE
ADJUSTING RAISING RELIEF VALVE
(POWER DOWN POWER UNIT)
FIG. 48-2
48
6. If pump cannot produce 3250 PSI or
lift the load capacity with a minimum of
12.6 volts available, the pump is worn
and needs to be replaced.
LOWER PORT
RAISE PORT
FIG. 49-1
49
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
5. Check the hydraulic cylinder. With the platform at
vehicle floor level, remove the hydraulic line from
the LOWER port on the cylinder (FIG. 49-1).
Hold the control switch in the “RAISE” position for
two seconds while you watch for hydraulic fluid at
the LOWER port. A few drops of hydraulic fluid escaping the port is normal. However, if fluid streams
out, piston seals are worn. Replace seals.
TROUBLESHOOTING
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Connect voltmeter (+) lead to
motor solenoid terminal “B” and
the (-) lead to the ground wires
connection on pump (FIG. 501). Verify that full battery voltage
is at “B”. Recharge the battery
if voltmeter indicates less than
12.6 volts dc.
STARTER
SOLENOID
TERMINAL “D”
SWITCHED BATTERY
(+)
TERMINAL “A”
LOAD
TERMINAL “B”
BATTERY (+)
TERMINAL “C”
GROUND (-)
VALVE “A”
LOWERING
SOLENOID VALVE
2. Check for structural damage or poor
lubrication. Replace worn parts.
GRAVITY DOWN POWER UNIT
FIG. 50-1
3. Check if the “D” terminal and
“S2” (lowering) solenoid valve
are getting battery voltage (FIG.
50-2). Connect voltmeter negative (-) lead to ground (-) wires
connection on pump and positive (+) lead to the “D” terminal
(FIG. 50-2). Hold control switch
in the “LOWER” position. Then,
connect voltmeter (+) lead to
(+) terminal on the “S2” (lowering) solenoid valve (FIG. 50-2).
If voltmeter shows a much lower
reading than +12.6 volts dc or a
reading of 0 volts, check for faulty
control switch and wiring, battery
cable, ground wire connections
in pump assembly, and pump
motor.
STARTER
SOLENOID
TERMINAL “D”
SWITCHED BATTERY
(+)
TERMINAL “A”
LOAD
TERMINAL “B”
BATTERY (+)
TERMINAL “C”
GROUND (-)
VALVE “S2”
LOWERING
SOLENOID VALVE
POWER DOWN POWER UNIT
FIG. 50-2
50
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.
CAUTION
To prevent damage to flow control
valve, do not disassemble the valve.
FLOW CONTROL VALVE ON BACK OF
GRAVITY DOWN PUMP ASSEMBLY
FIG. 51-1
4. Make sure platform is on the ground. Check
the flow control valve as follows. Remove
flow control valve (FIG. 51-1). Ensure the
flow control valve operates with a smooth
spring-loaded action. Check for debris inside
the valve. Clean or replace the flow control
valve, if necessary. Reinstall flow control
valve (if good) or a replacement.
5. Check the lowering solenoid valve as follows.
Check if filtering screen is plugged. Clean
carefully if required. Push on the plunger in the
valve by inserting small screwdriver in the open
end (FIG. 51-3). If the plunger does not move
with a smooth, spring-loaded action (approximately 1/8”), replace the valve cartridge. Reinstall lowering solenoid valve (if good) or a
replacement. Torque valve cartridge to 25-30
lb-ft and hex nut to 30 lb-in.
51
FLOW
CONTROL
VALVE
FLOW CONTROL VALVE ON BACK OF
POWER DOWN PUMP ASSEMBLY
FIG. 51-2
VALVE CARTRIDGE
1/8”
CHECKING SOLENOID VALVE
FIG. 51-3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FLOW
CONTROL
VALVE
CAUTION
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