80 SERIES (2002 Release, Aluminum Platform)

80 SERIES (2002 Release, Aluminum Platform)
M-97-28
REV. D
JANUARY 2003
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 Manuals (and replacements), download
Manuals from Maxon’s website at www.maxonlift.com.
WARRANTY/ RMA POLICY & PROCEDURE
LIFTGATE WARRANTY
Term of Warranty: 2 Years from Date of In-Service (In service date cannot exceed 3 months from ship date.)
Type of Warranty: Full Parts and Labor
This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s specifications as set forth
in MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments,
damage or malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this
warranty does not cover equipment that has had unauthorized modifications or alterations made to the product.
MAXON agrees to replace any components which are found to be defective during the first 2 years of service, and will reimburse for labor based
on MAXON’s Liftgate Warranty Flat Rate Schedule. (Copy of the Flat Rate is available at www.maxonlift.com.)
All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and
labor, MAXON’s Technical Service Department must be notified and an “Authorization Number” obtained.
All claims for warranty must be received within 30 Days of the repair date, and include the following information:
1. Liftgate Model Number and Serial Number
2. The End User must be referenced on the claim
3. Detailed Description of Problem
4. Corrective Action Taken, and Date of Repair
5. Parts used for Repair, Including MAXON Part Number(s)
6. MAXON R.M.A. # and/or Authorization # if applicable (see below)
7. Person contacted at MAXON if applicable
8. Claim must show detailed information I.e. Labor rate and hours of work performed
Warranty claims can also be placed on-line at www.maxonlift.com. On-line claims will be given priority processing.
All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s
Warranty Department within 30 days of repair date.
All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior
written approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with
original invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized
returns will be refused and will become the responsibility of the returnee.
Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in
plain view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned
parts are subject to no credit and returned back to the customer.
Defective Parts requested for return must be returned within 30 days of the claim date for consideration to:
MAXON Lift Corp.
16205 Distribution Way, Cerritos, CA 90703
Attn: RMA#__
MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income
due to downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.
MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.
All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not
returned in new condition will be subject to an additional reworking charge which will be based upon the labor and material cost required to return
the Liftgate or component to new condition.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase.
Type of Warranty: Part replacement only
MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts and original invoice.
All warranty replacements parts will be sent out via ground freight. If a Rush Shipment is requested all
freight charges will be billed to the requesting party.
TABLE OF CONTENTS
WARNINGS ...................................................................................................... 6
LIFTGATE TERMINOLOGY ................................................................................................... 7
SERVICE TIME CHART ........................................................................................................ 8
PERIODIC MAINTENANCE CHECKLIST ........................................................................... 10
CHANGING HYDRAULIC FLUID ......................................................................................... 11
ADJUSTMENTS ........................................................................................... 13
PLATFORM ADJUSTMENT ................................................................................................ 14
SADDLE ADJUSTMENT .................................................................................................... 16
REPLACING PLATFORM TORSION SPRING .................................................................... 17
PARTS BREAKDOWN .................................................................................. 18
80 SERIES FINAL ASSEMBLY ........................................................................................... 19
80 SERIES MAIN FRAME & LIFTING FRAME .................................................................... 20
PLATFORM & FLIPOVER ASSY (NO CART STOP) ........................................................... 22
PLATFORM & FLIPOVER ASSY (SINGLE CART STOP) ................................................... 23
FLIPOVER (SINGLE CART STOP) ..................................................................................... 24
PLATFORM & FLIPOVER ASSY (DUAL CART STOP) ....................................................... 25
FLIPOVER (DUAL CART STOP) ........................................................................................ 26
HYDRAULIC COMPONENTS - GRAVITY DOWN................................................................ 28
PUMP BOX ASSEMBLY - GRAVITY DOWN ....................................................................... 29
HYDRAULIC COMPONENTS - POWER DOWN ................................................................. 30
PUMP BOX ASSEMBLY - POWER DOWN ........................................................................ 31
CONTROL SWITCH AND POWER CABLE ........................................................................ 32
DECALS ............................................................................................................................ 33
TABLE OF CONTENTS - Continued
SCHEMATICS ............................................................................................... 36
HYDRAULIC SCHEMATIC - GRAVITY DOWN .................................................................... 37
ELECTRICAL SCHEMATIC - GRAVITY DOWN .................................................................. 38
HYDRAULIC SCHEMATIC - POWER DOWN ..................................................................... 39
ELECTRICAL SCHEMATIC - POWER DOWN .................................................................... 40
TROUBLESHOOTING .................................................................................. 41
PLATFORM WILL NOT RAISE ............................................................................................ 42
PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 43
PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 44
LIFTGATE WILL NOT LIFT RATED CAPACITY ................................................................... 45
PLATFORM RAISES SLOWLY ........................................................................................... 46
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS TOO QUICKLY .. 47
Comply with the following WARNINGS while maintaining Liftgates. See Operation Manual
M-00-37 for operating safety requirements.
!
WARNINGS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• Read and understand the instructions in this Maintenance Manual before performing maintenance on the Liftgate.
• Before operating the Liftgate, read and understand the operating instructions in Operation Manual
M-97-37.
• Comply with all WARNING and instruction decals attached to the Liftgate.
• Keep decals clean and legible. If decals are defaced or missing, replace them. Free replacement
decals are available from Maxon Parts Department.
• Consider the safety and location of bystanders and location of nearby objects when operating the
Liftgate. Stand to one side of the platform while operating the Liftgate
• Do not allow untrained persons to operate the Liftgate.
• Do not stand under, or allow obstructions under the platform when lowering the Liftgate. Be sure
your feet are clear of the Liftgate.
• Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.
• Wear apppropriate safety equipment such as protective eyeglasses, faceshield and clothing while
performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.
• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no flames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek first aid. If acid gets on your
skin, immediately wash it off with soap and water.
• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the control
Toggle Switch and the Liftgate will stop.
• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the pump unit while the platform is raised. Listen for scraping, grating
and binding noises and correct the problem before continuing to operate Liftgate.
• If it is necessary to stand on the platform while maintaining the Liftgate, keep your feet and any
objects clear of the inboard edge of the platform. Your feet or objects on the platform could be
trapped between the platform and the Liftgate extension plate.
• Never perform unauthorized modifications on the Liftgate. Modifications may result in early failure of
the Liftgate and may create hazards for Liftgate operators and maintainers.
• Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial
number information with your parts order. Order replacement parts from:
MAXON LIFT CORP. Customer Service
11921 Slauson Ave., Santa Fe Springs, CA 90670
Phone: (800) 227-4116
• To order parts by e-mail, submit orders to [email protected]
6
CONTROL
SWITCH
EXTENTION
PLATE
PUMP BOX
PLATFORM
OPENER
SADDLE
MAIN FRAME
PLATFORM
LIFT CYLINDERS
FLIPOVER
PARALLEL
ARM
LIFT
ARM
CART STOP
(SINGLE SHOWN)
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATE TERMINOLOGY
(80 SERIES)
SERVICE TIME CHART
STRUCTURAL SERVICE TO BE PERFORMED
CHANGE PLATFORM PINS (EACH)
TIME REQ'D.
(HOURS)
.50
CHANGE ALL PINS
3.00
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CHANGE GREASELESS BUSHINGS (EACH)
.25
CHANGE PLATFORM TORSION SPRING
1.00
CHANGE EXTENSION PLATE
1.50
CHANGE LIFTFRAME ASSEMBLY
1.00
CHANGE PARALLEL ARM (EACH)
.50
CHANGE SHACKLES (EACH)
.50
CHANGE PLATFORM OPENER
.50
CHANGE PLATFORM LOCKING LATCH
.50
CHANGE ENTIRE PLATFORM
2.00
CHANGE PLATFORM MAIN SECTION
1.50
CHANGE PLATFORM FOLDING SECTION (ALUMINUM)
1.00
REPLACE FOLDING SECTION HINGE PIN (ALUMINUM)
2.00
ADJUST PLATFORM SLOPE
.50
ELECTRICAL SERVICE TO BE PERFORMED
TIME REQ'D.
(HOURS)
CHANGE MOTOR
1.00
CHANGE MOTOR SOLENOID
.50
CHANGE SOLENOID VALVE COIL (EACH)
.50
CHANGE POWER PACK, COMPLETE
1.00
CHANGE OUTSIDE SWITCH ASSEMBLY
.50
CHANGE CIRCUIT BREAKER
.50
CHANGE TOGGLE SWITCH (EACH)
.50
CHANGE WIRING HARNESS OUTSIDE
1.00
8
TIME REQ'D.
(HOURS)
CHANGE PUMP ASSEMBLY
1.00
CHANGE PUMP RESERVOIR
1.00
CHANGE AUXILIARY HAND PUMP
1.00
RESET PUMP AND RELIEF VALVE PRESSURE
.50
ADJUST LOWERING SPEED
.25
CHANGE EXTERNAL FLOW CONTROL VALVE
.50
CHANGE/CLEAN CARTRIDGE VALVE
1.00
CHANGE LIFT CYLINDER (EACH)
1.00
CHANGE EXTERNAL HYDRAULIC HOSES (EACH)
.25
CHANGE RETURN LINE (EACH)
.50
9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SERVICE TO BE PERFORMED
PERIODIC MAINTENANCE CHECKLIST
!
WARNING
Never operate the Liftgate with
parts loose or missing.
Annually
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Visually check the entire Liftgate for excessively worn parts and broken welds, especially the
Hinge Pins. See PARTS BREAKDOWN section for replacement parts. Also, do the Semiannual and Quarterly Maintenance checks.
Semi-annually
Visually check the Platform Hinge Pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly Maintenance checks.
Quarterly
Check the Hydraulic Fluid level in the Pump Reservoir. If hydraulic fluid must be added, select
the correct grade of fluid to use at your location.
+20 to +150 Degrees F
Below + 20 Degrees F
- Grade ISO 32
- Grade ISO 15
If Hydraulic Fluid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure on following page.
Keep track of the grade of Hydraulic Fluid in the Pump Reservoir and never mix two different
grades of fluid.
Check all Hoses and Fittings for chaffing and fluid leaks. Replace if necessary.
Check electrical wiring for chaffing and make sure wiring connections are tight and free of
corrosion.
Check that all WARNING and instruction decals are in place and legible.
Check that all roll pins are in place and protrude evenly from both sides of Hinge Pin collar.
Replace roll pins if necessary.
10
CHANGING 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: To prevent spills, drain used hydraulic fluid through a funnel into waste fluid container.
GRAVITY DOWN LIFTGATES
PUMP BOX
1. Place empty 5 Gallon Bucket under Drain Plug.
2. Open and lower Platform to ground. Remove
the Drain Plug (FIG. 1A). Drain hydraulic fluid
from system. Re-install Drain Plug.
DRAIN
PLUG
3. Remove Filler Cap (FIG. 1B), Refill reservoir
with hydraulic fluid to the top of FILL LEVEL
bar shown on decal (FIG.1B). Use correct
grade of hydraulic fluid for your location.
+20 to +150 Degrees F - Grade ISO 32
Below + 20 Degrees F - Grade ISO 15
4. Re-install Filler Cap (FIG. 1A).
POWER DOWN LIFTGATES
1. Place empty 5 Gallon Bucket under Drain Plug.
GRAVITY DOWN PUMP BOX
FIG. 1A
2. Open and raise Platform to vehicle bed height. Remove the Drain Plug (FIG. 1A). Drain
hydraulic fluid.
3. Disconnect the White Wire (FIG. 1B) from Motor Solenoid. Lower the Platform while
draining the remaining hydraulic fluid from system. Re-install Drain Plug. Reconnect the
White Wire to Motor Solenoid.
FILLER CAP
WHITE WIRE
4. Remove Filler Cap (FIG. 1B). Refill
reservoir with hydraulic fluid to the top of
FILL LEVEL bar shown on decal
(FIG.1B). Use correct grade of hydraulic
fluid for your location.
+20 to +150 Degrees F - Grade ISO 32
Below + 20 Degrees F - Grade ISO 15
5. Raise Platform to vehicle bed height. Check
hydraulic fluid again. If needed, add more
hydraulic fluid until level is at the top of the
FILL LEVEL bar shown on decal (FIG. 1B).
6. Re-install Filler Cap (FIG. 1B).
11
MOTOR SOLENOID
DECAL
POWER DOWN PUMP & MOTOR
FIG. 1B
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
12
13
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ADJUSTMENTS
PLATFORM ADJUSTMENT
NOTE: Before doing the following procedure,
make sure vehicle is parked on level ground.
LEVEL LINE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Make sure Platform is at ground level. Unfold
PLATFORM EDGE ABOVE BED LEVEL
the Platform and Flipover. The Shackles and
FIG. 4
the outboard edge of Platform must touch the
ground at the same time as shown in FIG. 5.
If the Shackles and the outboard edge of Platform are touching the ground, RAISE Platform
to bed height. Outboard edge of Platform
should be above bed level (FIG. 4). If indications are correct (FIGS. 4 & 5), Liftgate is
installed correctly and no adjustment is needed.
If indications are incorrect, continue with instrucPLATFORM & SHACKLES
YES
tion 2.
TOUCH GROUND
FIG. 5
2. If the platform is level at bed level (FIG. 6), if
Shackles do not touch the ground (FIG. 7), or
if edge of Platform does not touch the ground
LEVEL LINE
(FIG. 8), inspect each of the Hinge Pins for
visible wear before adjusting the Platform.
Replace Hinge Pins that are visibly worn.
PLATFORM EDGE AT BED LEVEL
Refer to Parts Breakdown section of this
FIG. 6
manual for repair parts.
3. Check Liftgate for structural damage that may
cause incorrect platform positioning. Repair
structural damage.
“A”
(TABLE 1)
NOTE: If the Platform is like FIG. 7 and there
is no structural damage or damaged hinge
pins, do instruction 4. If the Shackle touches
and the Platform edge does not (FIG. 8), skip
4 and do 5.
4. Make sure Platform is still at ground level. If the
Shackle is not touching the ground, measure
and compare distance “A” (FIG. 7) with
TABLE 1 to determine the correct shim. Make
shims as needed (FIG. 9). Weld shim as
shown in FIG. 10.
SHACKLES DO NOT TOUCH GROUND
FIG. 7
“B”
(TABLE 2)
PLATFORM DOES NOT
TOUCH GROUND
FIG. 8
14
5. Make sure Platform is still at ground
level. If edge of the Platform is not
touching the round, measure and
compare distance “B” (FIG. 8)
with TABLE 2 to determine how much
to grind from the Platform Stops
(FIG. 11). Grind correct amount of
metal (TABLE 2) from Platform Stop
as shown in FIG.. 11.
REQUIRED SHIM
THICKNESS
1"
1/16"
1/16"
2"
1/8"
1/8"
3"
3/16"
3/16"
4"
1/4"
1/4"
WELD SIZE
1”
SHIM (1/16”, 1/8”, or 1/4”) MADE
FROM STEEL FLAT
FIG. 9
NEW SHIM
(TABLE 1)
"W"
2 PLACES
“W”
(TABLE 1)
TABLE 1
SHACKLE
LOWER PLATFORM
EDGE (OUTBOARD)
THIS DISTANCE("B")
GRIND METAL FROM
PLATFORM STOP
1"
1/16"
2"
1/8"
3"
3/16"
4"
1/4"
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 10
GRIND THIS FACE
(SEE TABLE 2)
PLATFORM
TABLE 2
6. RAISE the Platform, then LOWER it
to the ground. Platform and Shackle
should touch the ground at the same
time as shown in FIG. 5.
SHACKLE
(REF)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 11
15
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RAISE PLATFORM
EDGE (OUTBOARD)
THIS DISTANCE ("A")
2-1/2”
SADDLE ADJUSTMENT
1. Lower Platform to ground level.
2. Remove bolts, lock nuts, and Saddle
(FIG. 2B) from Right Hand side (RH)
Mounting Plate. Repeat step for Left
Hand (LH) side.
MOUNTING
PLATE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BOLTS &
LOCK NUTS
SADDLE
PLATFORM
(REF)
BOLTING SADDLE
FIG. 2B
LIFT GATE - SIDE VIEW (RH SIDE SHOWN)
FIG. 2A
3. Stow the Platform as shown in FIG. 3A. Use floor jack positioned at center of Platform (near
hinge) to raise Platform 1/8” above Roller (FIG. 3B). Reinstall Saddle, Bolts and Locknuts on
RH side Mounting Plate (FIG. 3A). Repeat for Saddle on LH side. Butt each Saddle against
Platform, and tighten lock nuts.
ROLLER
LIFTING FRAME
BRACKET
PLATFORM
MOUNTING
PLATE
HINGE
SADDLE
BOLTS &
LOCK NUTS
STOWED LIFTGATE - SIDE VIEW
(RH SIDE SHOWN)
FIG. 3A
1/8”
GAP
GAP BETWEEN PLATFORM & ROLLER
FIG. 3B
16
REPLACING PLATFORM TORSION SPRING
2. Raise Platform to a convenient work height to gain access and release tension on the
Torsion Spring.
HINGE
BRACKET
HINGE PIN
PLATFORM
(REFERENCE)
! CAUTION
TORSION
SPRING
To prevent injury and equipment damage,
make sure there is no tension on torsion
spring before removing hinge pin.
LOCK NUT
3. Unbolt Hinge Pin from Hinge Bracket
(FIG. 4). Remove bolt and lock nut. Drive
the Hinge Pin inboard toward the Shackle
with a hammer and pin punch, just enough
to free the torsion spring (FIG. 4). Remove
spring from Shackle.
BOLT
SHACKLE
4. Install the Torsion Spring as shown in FIG. 5.
Make sure the long leg of the spring is inserted in the bracket located on Shackle
(FIG. 5). Make sure the short end of the
spring is visible and resting against the edge
of the Hinge Bracket (FIG. 5).
FIG. 4
PIN WELDMENT
SHORT LEG
PLATFORM
(REFERENCE)
5. Drive the Hinge Pin into correct
position through the Hinge
Bracket with a hammer and pin
punch as shown in FIG. 5. Line
up the bolt hole in the Hinge Pin
BOLT &
with the hole in the Hinge
LOCK NUT
Bracket. Bolt the Hinge Pin to
Hinge Bracket with bolt and
lock nut (FIG. 5).
HINGE
BRACKET
SHACKLE
LONG LEG
BRACKET
6. Operate the Liftgate to make
sure it operates correctly.
.
FIG. 5
17
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Manually fold Flipover onto Platform.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PARTS BREAKDOWN
18
80 SERIES FINAL ASSEMBLY
REFER TO HYDRAULIC
COMPONENTS & PUMP
BOX ASSEMBLY
2
4
8A
8B
6
8B
REFER TO
MAIN FRAME &
LIFTING FRAME
7
8
REFER TO PLATFORM
& FLIPOVER ASSEMBLY
1
3
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
226938
EYE,DROP FORGED PAD 3/4" X 1-1/2"
2
1
227700
HOOK ASSEMBLY
3
4
900014-4
BOLT, HEX HEAD 3/8-16 X 1"
4
2
901011-5
NUT, HEX HEAD 3/8-16 UNC-2B
5
1
226355
6
2
902001-2
WASHER, FLAT 3/8" X 1/16"
7
4
902011-4
WASHER, LOCK 3/8" X 15/16"
8
1
265994-01
OPENER ASSEMBLY
8A
1
030805
COTTER PIN 1/8" X 1"
8B
1
280082-01
ROLLER
8C
1
905202-03
PIN
EXTENSION PLATE
19
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
5
80 SERIES MAIN FRAME & LIFTING FRAME
24
8
29
27
26
2
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
15
16A
30
25
7
16
5
20
3
1
11
10
7
24
28
2
12 19
15
27
3
17A
22
1
12
31
20
32
7
17B
21
13
18
15
2
17
14
5
9
16
17B
4
29
8
14
17B
15
33
14
16A
14
2
18 15
23
30
7
17B
17A
6
20
11
1
15
80 SERIES MAIN FRAME & LIFTING FRAME
QUANTITY
PART NO.
1
4
030034
BOLT, 3/8"-24 X 1" LG. GR8
2
4
030035
BOLT 3/8"-24 X 1-1/4" LG. GR8
3
2
030038
BOLT, 3/8"-24X1-1/2" LG. GR8
4
1
050175
PLATE, MAXON HORIZONTAL
5
4
905112-06
6
6
207644
POP RIVET, 3/16" X 25/64" LG.
7
4
221416
ROLL PIN, 3/8" X 2" LG.
8
2
226358
PIN WELDMENT
9
1
226363-01
TORSION SPRING, 1/2" X 5-3/4" LG. RH
10
1
226363-02
SPRING, TORSION, 1/2" X 5-3/4" LG. LH
11
2
226365
PIN WELDMENT, SHACKLE
12
2
907026
ROLL PIN, 3/16 X 2-1/4" LG.
13
2
226372
ROUND TUBE, 1/4" (2" X 5/16"W)
14
4
226375
ROLLER, 1"
15
8
226941
NYLON LOCK NUT, 3/8"-24 THIN
16
2
261785-01
PARALLEL ARM WELDMENT (WITH BEARINGS)
8
905112-07
BEARING, SELF-LUBE, 1-3/8" X 1-3/4" LG.
1
261800-01
LIFT FRAME WELDMENT
17A
4
915112-01
BEARING, SELF-LUBE, 1-3/8" X 3/4" LG.
17B
4
915112-02
BEARING, SELF-LUBE, 1-3/8" X 1" LG.
18
2
262435
PIN WELDMENT, CYLINDER 1-3/8" DIA
19
2
262437
BUSHING WELDMENT-CYL HOSE CLAMP
20
2
262462
PIN WELDMENT, CYL. 1-3/8" DIA
21
2
265807-01
PIN WELDMENT, PLATFORM 1-3/8" X 13-1/8" LG.
22
1
265811-01
SHACKLE ASSY, LEFT HAND (WITH BEARINGS)
23
1
265811-02
SHACKLE ASSY, RIGHT HAND (WITH BEARINGS)
24
2
265849-01
SADDLE, LOW PROFILE HINGE
25
1
265866-01
MAIN FRAME WELDMENT
26
14
205780
27
2
266033-01
28
4
901023
29
4
901024-3
BOLT, HEX HEAD, 1/2"-13 X 2-1/4" LG.
30
2
902001-2
FLAT WASHER, 3/8"
31
2
902013-21
FLAT WASHER, 1-3/8"
32
2
905128-07
ROLL PIN 1/8" X 2-1/4" LG
33
2
040103-5
LOOM, SPLIT 1/2" X 5" LG
16A
17
DESCRIPTION
BEARING, SELF LUBE, 1-3/8" X 3/8" LG.
PLASTIC TIE, 7" LG
PIN WELDMENT, UNDERRIDE
FLANGE LOCK NUT
21
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
PLATFORM & FLIPOVER ASSY
(NO CART STOP)
P/N 265204-01
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1
5
3
6
4
1
4
4
5
2
6
2A
ITEM
QTY.
PART NO.
1
2
263456-04
HINGE ROD 1/2" DIA X 80-13/16" LG
2
1
263665-01
FLIPOVER WELDMENT, ALUMINUM, 30"
1
265819-01
HANDLE WELDMENT
3
1
265203-01
PLATFORM WELDMENT, ALUMINUM, 30"
4
16
280109
HINGE ASSEMBLY
5
2
280110
HINGE ASSEMBLY
6
4
905015-1
2A
DESCRIPTION
ROLL PIN, 3/16" X 3/4"
22
4
1
2
5
3
1
3
3
4
5
REFER TO FLIPOVER
(SINGLE CART STOP)
ITEM
QTY.
PART NO.
DESCRIPTION
1
2
263456-04
HINGE ROD 1/2" DIA X 80-13/16" LG
2
1
265203-01
PLATFORM WELDMENT, ALUMINUM, 30"
3
16
280109
HINGE ASSEMBLY
4
2
280110
HINGE ASSEMBLY
5
4
905015-1
ROLL PIN, 3/16" X 3/4"
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM & FLIPOVER ASSY
(SINGLE CART STOP)
P/N 265462-01
FLIPOVER (SINGLE CART STOP)
P/N 265457-01
4
13 5
3
14
6
12
3
13
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
8
11
9
4
12
2
10
1
1A
ITEM
QTY.
PART NO.
1
1
263670-01
FLIPOVER WELDMENT, ALUMINUM
1
265819-01
HANDLE WELDMENT
2
1
030406
ROLL PIN, 1/8" X 1"
3
2
030805
COTTER PIN 1/8" X 1"
4
6
253542
BEARING, SELF LUBE 1/2" X 1/2"
5
1
262481-02
ARM, OPENING AND CLOSING, RH
6
1
262508-01
RAMP WELDMENT, SINGLE CART STOP
7
1
262513-01
PIN, 1/2" DIA X 80-39/64" LG
8
1
262514
GAS SPRING
9
2
262515
METAL EYELET END FITING
10
1
262536
SPRING, TORSION, 1/8"
11
1
900047
SCREW,SHOULDER, 1/2" X 3/4" LG
12
2
902022
FLAT WASHER, 1/2"
13
2
905122-02
14
2
905135
1A
DESCRIPTION
BEARING, SELF LUBE 1/2" X 5/16"
PIN, CLEVIS 5/16" X 7/8"
24
4
1
2
5
3
1
4
3
4
5
REFER TO FLIPOVER
(DUAL CART STOP)
ITEM
QTY.
PART NO.
DESCRIPTION
1
2
263456-04
HINGE ROD, 1/2" DIA X 80-13/16" LG
2
1
265203-01
PLATFORM WELDMENT, ALUMINUM, 30"
3
16
280109
HINGE ASSEMBLY
4
2
280110
HINGE ASSEMBLY
5
4
905015-1
ROLL PIN, 3/16" X 3/4"
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM & FLIPOVER ASSY
(DUAL CART STOP)
P/N 265463-01
FLIPOVER (DUAL CART STOP)
P/N 265459-01
7
4
13
8
14
3
15
9
6
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
10
11
4
13
2
14 5
12
11
10
1
14
3
15
1A
ITEM
QTY.
PART NO.
1
1
263670-02
FLIPOVER ASSEMBLY, ALUMINUM
1
265819-01
HANDLE WELDMENT
2
1
030406
ROLL PIN, 1/8" X 1"
3
4
030805
COTTER PIN 1/8" X 1"
4
6
253542
BEARING, SELF LUBE 1/2" X 1/2"
5
1
262481-01
ARM, OPENING AND CLOSING LH
6
1
262481-02
ARM, OPENING AND CLOSING RH
7
1
262509-03
RAMP WELDMENT, DUAL CART STOP, LH
8
1
262509-04
RAMP WELDMENT, DUAL CART STOP, RH
9
1
262513-01
PIN, 1/2" DIA X 80 39/64" LG
10
2
262514
GAS SPRING
11
4
262515
METAL EYELET END FITING
12
2
900047
SCREW, SHOULDER, 1/2" X 3/4" LG
13
2
902022
FLAT WASHER, 1/2"
14
4
905122-02
15
4
905135
1A
DESCRIPTION
BEARING, SELF LUBE 1/2" X 5/16"
PIN, CLEVIS 5/16" X 7/8"
26
14
12
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
HYDRAULIC COMPONENTS - GRAVITY DOWN
CYLINDER (REF)
CYLINDER (REF)
17
17
16 13
13
16
15
14
16
8
3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
REFER TO PUMP
BOX ASSEMBLY
-GRAVITY DOWN
11
1
1
6
12
5
2
16
16
RH
ITEM
1
10
4
16
QTY.
PART NO.
2
266038-01
LH
7
9
10
DESCRIPTION
CYLINDER, 80-3
2
266039-01
CYLINDER, 80-4
2
1
265846-01
HOSE ASSY 3/8"HP SAE#8F,#6M 21" LG.
3
1
22437-17
PLASTIC HOSE, 14" X 30" LG
4
1
265888-01
HOSE ASSY, 3/8"HP, SAE#8 F-F 57" LG.
5
1
224370-13
PLASTIC HOSE, 14" X 75" LG.
6
1
224370-12
PLASTIC HOSE, 14" X 55" LG.
7
1
265888-02
HOSE ASSY, 3/8"HP, SAE#6 F-F, 77" LG.
8
1
215406
ELBOW, BRASS, 1/4" X 3/8"
9
1
905150
TEE, UNION 3/8" F.S. MALE,6-JLO
10
2
906704-01
ELBOW, STRAIGHT THREAD #8 F/S O-R M-M
11
2
906705-01
CONNECTOR, LONG, NPSC, SAE #6
12
1
906711-01
TEE, UNION AIRBRAKE, 1/4"
13
2
906707-01
ELBOW, STRAIGHT THREAD F/S O-R #6 M-M
14
1
906708-01
ELBOW, STRAIGHT THREAD F/S O-R #6 M-F SW
15
1
906709-01
VALVE,FLOW REGULATOR #6 SAE, 4GPM
16
8
906712-02
O-RING , #6 (3/8" FACE SEAL TUBE-END)
17
2
228012
ADAPTER, STRAIGHT THD. 9/16" TO 1/4" PIPE
28
2A
(LATCH)
2A
(LATCH)
2
7
5
5G
5C
5B
1
2A
(CATCH)
3
2A
(CATCH)
4
5E
5A
5F
5H
5D
6
ITEM
QTY.
PART NO.
1
1
266016-01
2
1
229383
PUMP BOX COVER
2
215139
CATCH & FASTENER
3
1
266032-01
CABLE ASSEMBLY, 16GA/3-WIRE
4
1
280566-01
GREEN WIRE ASSEMBLY, 16GA
5
1
266014-01
PUMP ASSEMBLY, GRAVITY DOWN
5A
1
280374
MOTOR, 12 VOLTS DC
5B
1
280372
SOLENOID VALVE, 12 VOLTS DC
5C
1
906721-01
5D
1
280394
MOTOR STARTER SOLENOID, 12 VOLTS DC
5E
1
280416
WIRE ASSEMBLY (16GA)
5F
1
280404
CABLE ASSEMBLY (2GA)
5G
1
229193
FILLER, BREATHER
5H
1
266030-01
6
1
REF
7
1
205780
2A
DESCRIPTION
PUMP BOX WELDMENT
RESERVOIR
DRAIN PLUG
DECAL (SEE DECAL SECTION)
PLASTIC TIE
29
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP BOX ASSEMBLY - GRAVITY DOWN
HYDRAULIC COMPONENTS - POWER DOWN
15
3
REFER TO PUMP
BOX ASSEMBLY
-POWER DOWN
14
8
1
1
11
13
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
13
15
15
16
2
4
16
16
10
10
RH
ITEM
6
15 9
15
12
7
LH
5
QTY.
PART NO.
2
266038-01
CYLINDER, 80-3
2
266039-01
CYLINDER, 80-4
2
1
265846-01
HOSE ASSY, 3/8"HP SAE#8F,#6M, 21" LG.
3
1
265847-01
HOSE ASSY, 3/8"HP SAE#6 F-F, 28" LG.
4
1
265888-01
HOSE ASSY, 3/8"HP SAE#8 F-F, 57" LG.
5
1
265888-02
HOSE ASSY, 3/8"HP SAE#8 F-F, 83" LG.
6
1
265889-01
HOSE ASSY, 3/8"HP SAE#6 F-F, 55" LG.
7
1
265889-02
HOSE ASSY, 3/8"HP SAE#6 F-F, 77" LG.
8
1
906709-01
VALVE,FLOW REGULATOR #6 SAE, 4GPM
9
1
905150
10
2
906704-01
ELBOW, STRAIGHT THR. #8F/S O-RING M-M
11
2
906705-01
CONNECTOR, LONG STR, THD SAE #6
12
1
906706-01
TEE, UNION SAE#8 F/S M-M
13
2
906707-01
ELBOW, STRAIGHT THD. #6F/S O-RING M-M
14
1
906708-01
ELBOW, STRAIGHT THD F/S O-RING #6M-F SW
15
6
906712-02
O-RING #6 (3/8" FACE SEAL TUBE-END)
16
5
906712-03
O-RING #8 (1/2" FACE SEAL TUBE-END)
1
DESCRIPTION
TEE, UNION, 3/8" F/S MALE,6-JLO
30
2A
(LATCH)
2A
(LATCH)
2
4
5F 5C
5H
5E
5D
1
2A
(CATCH)
3
2A
(CATCH)
5F
5G
5A
5B
5
5I
6
ITEM
QTY.
PART NO.
1
1
266016-01
2
1
229383
PUMP BOX COVER
2
215139
CATCH & FASTENER
3
1
266032-01
4
1
205780
5
1
266030-01
5A
1
280381
MOTOR, 12 VOLTS DC
5B
2
280394
MOTOR STARTER SOLENOID, 12 VOLTS DC
5C
2
906719-01
VALVE
5D
2
906720-01
10 VDC COIL
5E
1
906721-01
RESERVOIR
5F
2
280402
CABLE ASSEMBLY (2 GA)
5G
1
280543
CABLE ASSEMBLY (2 GA)
5H
1
229193
FILLER-BREATHER
5I
1
REF
DRAIN PLUG, 3/8"-18 NPTF
1
REF
DECAL (SEE DECAL SECTION)
2A
6
DESCRIPTION
PUMP BOX WELDMENT
CABLE ASSEMBLY, 16 GA/3-WIRE
PLASTIC TIE
PUMP ASSEMBLY, POWER DOWN
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP BOX ASSEMBLY - POWER DOWN
CONTROL SWITCH AND POWER CABLE
SWITCH BOOT SEAL
P/N 905206
SWITCH & CABLE
ASSEMBLY
P/N 264346
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
(SEE DECALS PAGES)
SCREWS, SELF-TAPPING #10 x 5/8”
P/N 030453
(2 PLACES)
NOTE: Use Switch to RAISE and LOWER Liftgate to make sure Switch
operates as shown on the decal.
SHORT END TO
VEHICLE BATTERY
FUSED BATTERY CABLE ASSEMBLY
(38’ STD.)
P/N 264422
!
WARNING
Do not attach cable to battery until
liftgate repairs are completed.
LONG END TO
PUMP MOTOR
SOLENOID
32
INSTRUCTION DECAL
P/N 251838
(REFERENCE)
CAPACITY DECAL
P/N 264081
(REFERENCE)
CAUTION DECAL
P/N 263998
!
WARNING
READ CAREFULLY
!
• Improper operation of this Lift can result in serious personal injury.
Do not operate unless you have been properly instructed and have
read, and are familiar with the operating instructions. If you do not
have a copy of the instructions, please obtain them from your
employer, distributor, or lessor, before you attempt to operate Lift.
• Be certain that the vehicle is properly and securely braked before
using the Lift.
• Always inspect this Lift for maintenance or damage before using it.
If there are signs of improper maintenance, damage to vital parts, or
slippery Platform surface, do not use the Lift until these problems
have been corrected.
• Do not overload the Lift. The load limit is based on evenly distributed cargo over the entire Platform surface. If you are using a pallet
jack, be sure it can be maneuvered safely. Do not operate a forklift on
the Platform or travel with the platform in an open position at any time.
• Load should be placed in a stable position close to the edge of the
Platform nearest the truck. The heaviest portion of the load should
never be placed beyond the center of the Platform away from the
truck.
• Never allow yourself, a helper, or bystander to stand in a position
where a falling load could land on either of you. Also do not allow
any part of yours or your helper’s body to be placed under, within, or
around any portion of the moving liftgate, or it’s mechanisms, or in a
position that would trap them between the platform and the ground or
truck when the liftgate is operated.
• If a helper is riding the Platform with you, make sure you are both
doing so safely and that you are not in danger of coming in contact
with any moving or potentially moving obstacles. USE GOOD
COMMON SENSE. If load appears to be unsafe, do not lift or lower it.
MAXON LIFT CORP.
PART NO. 264081
WARNING DECAL
P/N 264081
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECALS
DECALS - CONTINUED
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
UP/DOWN DECAL
P/N 264507
WARNING DECAL
P/N 264081
(REFERENCE)
CAUTION DECAL
P/N 263998
(REFERENCE)
CAPACITY DECAL (SEE TABLE 1)
P/N 264081
LIFT CAPACITY DECALS
CAPACITY
PART NO.
2500 LBS.
220382
3000 LBS.
220388
4000 LBS.
220389
5000 LBS.
220390
INSTRUCTION DECAL
P/N 251838
TABLE 1
34
FLUID LEVEL DECAL
P/N 265330-03
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
SCHEMATICS
36
HYDRAULIC CYLINDERS
4 GPM FLOW
CONTROL VALVE
PRESSURE PORT
RETURN PORT
VALVE A
RELIEF VALVE
(SET AT 3250 PSI)
PUMP
CHECK VALVE
M
MOTOR
(REFERENCE)
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
37
FILL HOLE
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC - GRAVITY DOWN
ELECTRICAL SCHEMATIC - GRAVITY DOWN
CONTROL SWITCH
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WHITE
WHITE
RED
YELLOW
GREEN
BLACK
CABLE
ASSEMBLY
SOLENOID,
VALVE A
THERMAL
SWITCH
STARTER
SOLENOID
CABLE WITH
200 AMP FUSE
MOTOR
BATTERY
38
HYDRAULIC CYLINDERS
4 GPM FLOW
CONTROL VALVE
PORT B - LOWER
(POWER DOWN)
PORT A - RAISE
VALVE
A
CHECK VALVE
VALVE
B
MOTOR
(REFERENCE)
CHECK VALVE
M
RELIEF VALVE
(SET AT
3250 PSI)
PUMP
CHECK VALVES
RELIEF VALVE
(SET AT
1000 PSI)
FILTERS
RESERVOIR
DRAIN HOLE
(PLUGGED)
39
FILL HOLE
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC - POWER DOWN
ELECTRICAL SCHEMATIC - POWER DOWN
CONTROL SWITCH
CABLE
ASSEMBLY
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
YELLOW
RED
WHITE
GREEN
WHITE
BLACK
THERMAL
SWITCH
SOLENOID,
VALVE B
STARTER
SOLENOID
(LOWER)
STARTER
SOLENOID
(RAISE)
MOTOR
CABLE WITH
200 AMP FUSE
BATTERY
40
SOLENOID,
VALVE A
41
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
TROUBLESHOOTING
PLATFORM WILL NOT RAISE
1. Connect voltmeter between Motor Solenoid Terminal “A” and Bracket (FIG. 1) to verify that
battery power is getting to “A”. Recharge the battery if voltmeter indicates less than 12.6
Volts DC.
CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
2. Fill Reservoir to within 1/2” below the top with the hydraulic fluid recommended in the
Periodic Maintenance Checklist.
3. Touch a jumper wire to terminals “A” & “C” (FIG. 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. 1).
a. If motor runs, replace the motor solenoid.
b. If motor does not run, repair or replace the pump motor.
NOTE: In most cases, you can avoid having to manually bleed Hydraulic System by
correctly positioning Liftgate Platform before disconnecting any Lifting Cylinder high pressure Hydraulic Lines. The following procedure can save t ime and prevent accidental fluid
spills and hazards.
5. Check for structural damage and
replace worn parts.
TERMINAL “A”
(VOLTMETER
+ LEAD )
MOTOR SOLENOID
BRACKET
(VOLTMETER
- LEAD )
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.
TERMINAL “C”
TERMINAL “B”
MOTOR
SOLENOID
FIG. 1
42
PLATFORM RAISES BUT LEAKS DOWN
TERMINAL “C”
(VOLTMETER + LEAD)
MOTOR SOLENOID
BRACKET
(VOLTMETER - LEAD )
FIG. 2
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to manually bleed Hydraulic System by
correctly positioning Liftgate Platform before disconnecting any Lifting Cylinder high pressure Hydraulic Lines. The following procedure can save t ime and prevent accidental fluid
spills and hazards.
2. Check the Valve Stem by removing the Coil
Assembly (FIG. 3, Item 1). With platform supported, unscrew the Valve Stem (FIG. 3, Item 2)
from the Pump. Push on the plunger located
inside the Valve Stem with a small screwdriver.
If the Plunger does not move freely (approximately 1/8”) replace the Valve Stem.
2
1
1/8”
FIG. 3
3. Check the Hydraulic Cylinder. With the Platform on
the ground, remove the Breather Plug or Line from
the Down Port of the Cylinder (FIG. 4). Raise the
Platform even with the bed. Allow pump motor to
run two seconds more while you watch for hydraulic fluid at the Down Port. A few drops of hydraulic
fluid escaping the Down Port is normal; however, if
it streams from the Down Port, Piston Seals are
worn. Replace Seals.
DOWN
PORT
PRESSURE
PORT
FIG. 4
43
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LOWERING
1. Check if Lowering Solenoid Valve is
SOLENOID VALVE
constantly energized. Connect voltmeter negative (-) lead to Motor
MOTOR
Solenoid bracket and positive (+)
lead to Motor Solenoid terminal “C”
(FIG. 2). If voltmeter reads battery
voltage (+12.6 Volts DC minimum)
without pushing the toggle switch, the
control circuit is operating incorrectly.
Check if toggle switch, wiring or coil
are faulty.
MOTOR SOLENOID
PLATFORM RAISES PARTIALLY AND STOPS
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Lower the opened Platform to the ground. Fill the Pump Reservoir on Gravity-Down
Liftgates to within 1/2” below the top with hydraulic fluid recommended in Periodic
Maintenance Checklist.
2. Use voltmeter to verify that the Battery shows 12.6 volts or more.
3. Check for Structural damage, or poor lubrication. Replace worn parts.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
4. Check the Hydraulic Cylinder. With the Platform on the ground, remove the Breather Plug or
Line from the Down Port of the Cylinder (FIG. 5). Raise the Platform even with the bed. Allow
pump motor to run two seconds more while you watch for hydraulic fluid at the Down Port. A
few drops of hydraulic fluid escaping the Down Port is normal; however, if it streams from
the Down Port, Piston Seals are worn. Replace Seals.
5. Check Filter in the Pump Reservoir. Replace filter if necessary.
6. Check for dirty pump motor relief valve. Clean if necessary. Replace any worn out relief
valve parts.
44
1. Use voltmeter to verify that the Battery shows 12.6 volts or more under load from pump
motor.
2. Check for Structural damage or lack of lubrication.Replace worn parts.
! CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
3. With Platform on the ground, remove the pressure
hose and fitting from the Pump and replace it with a 03000 PSI Pressure Gauge. Hold the switch in the “UP”
position. Adjust the Relief Valve on the side of the
Pump until the gauge shows 2800 to 3000 PSI (FIG. 6).
Remove guage and re-install pressure hose.
DOWN PORT
PRESSURE
PORT
4. Check for dirty pump motor relief valve. Clean if
necessary. Replace any worn out relief valve parts.
5. Check the Hydraulic Cylinder. With the Platform on the
ground, remove the Breather Plug or Line from the
Down Port of the Cylinder (FIG. 5). Raise the Platform
even with the bed. Allow pump motor to run two seconds more while you watch for hydraulic fluid at the
Down Port. A few drops of hydraulic fluid escaping the
Down Port is normal; however, if it streams from the
Down Port, Piston Seals are worn. Replace Seals.
FIG. 5
PRESSURE
GAUGE
6. If Pump cannot produce 2800-3000 PSI with a minimum of 12.6 Volts available, the Pump is worn and
needs to be replaced.
FIG. 6
45
RELIEF VALVE
ADJUST SCREW
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATE WILL NOT LIFT RATED CAPACITY
PLATFORM RAISES SLOWLY
MOTOR SOLENOID
BRACKET
(VOLTMETER
- LEAD )
1. Connect voltmeter between Motor Solenoid Terminal
“A” and Bracket (FIG. 7) to verify that battery power
is getting to “A”. Recharge the battery if voltmeter
indicates less than 12.6 Volts DC.
CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic
lines, clean up contaminants that can get in the
openings. Also, protect the openings from accidental
contamination during maintenance.
TERMINAL “A”
(VOLTMETER
+ LEAD )
FIG. 7
2. Check the Hydraulic Cylinder. With the Platform on the ground, remove the Breather Plug
or Line from the Down Port of the Cylinder (FIG. 9). Raise the Platform even with the bed.
Allow pump motor to run two seconds more while you watch for hydraulic fluid at the Down
Port. A few drops of hydraulic fluid escaping the Down Port is normal; however, if it streams
from the Down Port, Piston Seals are worn. Replace Seals.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
3. Check and clean Flow Control Valve (FIG. 8) in high pressure hydraulic line attached to
Cylinder. When installing Flow Control Valve make sure arrow on valve is oriented as
shown in FIG. 8.
DOWN PORT
4. Lower the opened Platform to the ground. Fill the Pump
Reservoir on Gravity-Down Liftgates to within 1/2” below the
top with hydraulic fluid recommended in Periodic Mainte- PRESSURE
PORT
nance Checklist.
5. Verify the Pump Motor is grounded to the vehicle
frame.
6. Check for leaking hoses and fittings. Tighten or
replace as required.
7. Check for structural damage or poor lubrication. Replace
worn parts.
FLOW
CONTROL
VALVE
FIG. 8
PRESSURE
GAUGE
8. Check the Filter in the Pump Reservoir. Replace if
necessary.
9. With Platform on the ground, remove the pressure hose
and fitting from the Pump and replace it with a 0-3000
PSI Pressure Gauge. Hold the Control switch in the
“RAISE” position. Adjust the Relief Valve on the side of
the Pump until the gauge shows 2800 to 3000 PSI
(FIG. 9). Remove guage and re-install pressure hose.
46
RELIEF VALVE
ADJUST SCREW
FIG. 9
1. Connect voltmeter between Motor Solenoid Terminal “A”
and Bracket (FIG. 10) to verify that battery power is
getting to “A”. Recharge the battery if voltmeter indicates
less than 12.6 Volts DC.
LOWERING
SOLENOID VALVE
TERMINAL “A”
(VOLTMETER
+ LEAD )
2. Check for structural damage or poor
lubrication. Replace worn parts.
3. Check if Lowering Solenoid Valve is getting
power . Connect voltmeter between Motor
Solenoid Bracket and Motor Solenoid
terminal “C” (FIG. 10). Push Control Switch
MOTOR
to “LOWER” position to energize Lowering
MOTOR SOLENOID
Solenoid. If voltmeter reads battery voltage
MOTOR SOLENOID
BRACKET
(+12.6 Volts DC minimum), control circuit is
TERMINAL “C”
(VOLTMETER - LEAD )
operating correctly (replace Lowering
(VOLTMETER + LEAD )
Solenoid). If voltmeter reads 0 Volts, check
FIG. 10
if toggle switch and wiring are faulty.
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system. Before
opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up
contaminants that can get in the openings. Also, protect the openings from accidental
contamination during maintenance.
NOTE: In most cases, you can avoid having to bleed the hydraulic system by correctly
positioning Liftgate Platform before opening hydraulic lines. Refer to following procedure.
Save time on the job and prevent accidental fluid spills and hazards.
4. Check the Valve Stem by removing the Coil Assembly
(FIG. 11, Item 1). With platform supported, unscrew the
Valve Stem (FIG. 11, Item 2) from the Pump. Push on the
plunger located inside the Valve Stem with a small
screwdriver. If the Plunger does not move freely (approximately 1/8”) replace the Valve Stem.
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. 12) is pointing to the
direction of restricted fluid flow (back toward pump). If
required, remove Flow Control Valve and install it
correctly (FIG. 12).
47
2
1
FIG. 11
1/8”
DOWN PORT
PRESSURE
PORT
FLOW
CONTROL
VALVE
FIG. 12
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY,
OR LOWERS TOO QUICKLY
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