M-00-26 REV. G JULY 2009 Maintenance Manual Contains: • Warranty Information • Warnings • Service Time Chart • Periodic Maintenance Checklist • Service and Maintenance Instructions • Decals • Hydraulic & Electrical System Diagrams • Troubleshooting © MAXON Lift Corp.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 LIFT CORP. CUSTOMER SERVICE: TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116 FAX: (888) 771-7713 NOTE: For latest version of all Manuals (and replacements), download the Manuals from Maxon’s website at www.maxonlift.com.
TABLE OF CONTENTS WARNINGS ........................................................................................................................... 6 SAFETY INSTRUCTIONS .................................................................................................... 6 PERIODIC MAINTENANCE.................................................................................................. 8 DECAL - WELDING CAUTION ...........................................................................................
ELECTRICAL SYSTEM DIAGRAMS ................................................................................. 47 WIRING SCHEMATIC, GRAVITY DOWN ........................................................................... 47 SINGLE PUMP BOX, GRAVITY DOWN.............................................................................. 48 DUAL PUMP BOX, GRAVITY DOWN ................................................................................. 49 WIRING SCHEMATIC, POWER DOWN .....................................
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining Liftgates. See Operation Manual for operating safety requirements. WARNINGS ! WARNING • Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your feet are clear of the Liftgate. • Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform edges) when operating the Liftgate. • Correctly stow platform when not in use.
• 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.
PERIODIC MAINTENANCE DECAL - WELDING CAUTION CAUTION Comply with welding CAUTION decals on Liftgate runners. NOTE: See following pages to find the other decals on Liftgate. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 ! CAUTION ! When performing any electrical welding operations to the structure of this Lift, be careful to connect the ground lead to the Liftgate component being welded (e.g.
11921 Slauson Ave. Santa Fe Springs, CA.
PERIODIC MAINTENANCE DECALS 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 CAUTION DECAL (2 PLACES) P/N 266508-01 DECAL “C” DECAL “D” DECAL “H” DECAL “B” SERIAL PLATE DECAL “G” PAINT DECAL (2 PLACES) P/N 267338-02 DECAL “A” DECAL “F” (2 PLACES) DECAL “E” PAINT DECAL (BMR-A, 2 PLACES) P/N 267338-01 KEEP HANDS CLEAR (2 PLACES) P/N 260009 FIG.
921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 (REFER TO TABLE 11-1) DECAL SHEET FIG. 11-1 Model DECAL SHEET P/N DECAL “C” BMRA-35 268309-01 3500 POUNDS BMRA-44 268309-02 4400 POUNDS BMRA-55 268309-03 5500 POUNDS BMRA-66 268309-04 6600 POUNDS DECAL SHEET PART NUMBERS TABLE 11-1 FIG.
PERIODIC MAINTENANCE MAXON BMR-A LIFTGATE PREVENTATIVE MAINTENANCE CHECKLIST PM Interval: 3 Months Equipment: Mechanic: Date: / / W/O # Location: Serial # Model # 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 Check Appropriate Box.
! WARNING Never operate the Liftgate with parts loose or missing. NOTE: Photocopy the PM CHECKLIST on the preceding page to help keep track of peri odic maintenance on the Liftgate. Keep completed form with maintenance records. Annually Change spin-on oil filter. Visually check the entire Liftgate for excessively worn parts and broken welds, especially the hinge pins. See Parts Manual for replacement parts. Also, do the Semi-annual and Quarterly Maintenance checks.
PERIODIC MAINTENANCE CHECKING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination. NOTE: Use correct grade of hydraulic fluid for your location. 11921 Slauson Ave. Santa Fe Springs, CA.
RECOMMENDED BRANDS PART NUMBER AMSOIL AWH-05 CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS T-32 EXXON UNIVIS N-32 MOBIL DTE-13M, DTE-24, HYDRAULIC OIL-13 TABLE 15-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER AMSOIL AWF-05 CHEVRON FLUID A, AW-MV-15 KENDALL GLACIAL BLU SHELL TELLUS T-15 EXXON UNIVIS HVI-13 MOBIL DTE-11M ROSEMEAD THS FLUID 17111 TABLE 15-2 15 11921 Slauson Ave. Santa Fe Springs, CA.
PERIODIC MAINTENANCE CHANGING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination. NOTE: Use correct grade of hydraulic fluid for your location. 11921 Slauson Ave. Santa Fe Springs, CA.
NOTE: Perform this procedure at a place where Liftgate platform can be lowered to lowest point of travel. Get a helper to operate Liftgate control switch. 1. Use UP/DOWN toggle switch to lower the opened platform to the ground. 2. Loosen, but do not disconnect, the cylinder line fitting from the pressure compensated flow control valve (FIG. 17-1) on top of both cylinders. PRESSURE COMPENSATED FLOW CONTROL VALVE CYLINDER LINE FITTING 3.
PERIODIC MAINTENANCE PLATFORM FOLDING AND UNFOLDING SPEED ADJUSTMENT 1. The speed settings for the closing cylinder are regulated by the pressure relief needle valves located on the pump manifold (FIGS. 18-1, 18-2, and 18-3). One valve is marked “O” (open platform) and the other is marked “C” (close platform). PUMP MANIFOLD OPENER VALVE ADJUSTMENT 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 CLOSER VALVE ADJUSTMENT POWER DOWN PUMP FIG. 18-1 2.
ADJUSTMENT ! WARNING Personal injury and damaged equipment could result if chains separate from platform under load. Never adjust the platform chains to compensate for excessive wear. Refer to chain inspection on the TIP OF PERIODIC MAINTENANCE CHECKLIST. PLATFORM Adjustment should only be necessary when new chains are installed. 1. Lower the platform to ground level. Check if tip of the flipover and bottom of the runners touch the ground at the same time (FIG. 19-1).
PLATFORM CHAIN ADJUSTMENT - Continued ! WARNING Personal injury and damaged equipment could result if chains separate from platform under load. Ensure each leg of u-bolts extends minimum of 1/8” from lock nut. When adjustment is complete, ensure jam nuts are tightened securely. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 4. To adjust with the u-bolt, do the following. If necessary, raise platform enough to gain access to the adjusting nuts on both u-bolts.
5. To remove links from each platform chain, do the following. Raise platform to a comfortable work height (FIG. 21-1A). Support the bottom of platform to remove tension from LH and RH chains. Next, unfasten both ubolts from platform (FIG. 21-1B). Remove a 1 or 2 links (as required) from both chains. Then, fasten u-bolts to platform as shown in (FIG. 21-1C). Tighten jam nuts securely. JAM NUT & FLATWASHER (2 PLACES) LOCK NUT & FLAT WASHER (2 PLACES) RH CHAIN SUPPORT PLATFORM RAISED & SUPPORTED FIG.
PLATFORM CHAIN ADJUSTMENT - Continued 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 6. Raise platform enough to remove supports. Then, lower platform to the ground (FIG. 22-1). Tip of flipover and runners should touch the ground at the same time as shown in FIG. 22-1. If necessary, repeat instructions 3 through 5 until tip of platform and runners touch ground at the same time. TIP OF FLIPOVER GROUND BOTTOM OF RUNNER TIP AND RUNNER TOUCHING GROUND FIG.
REPLACING PARTS 1. UNFOLD the platform. Lower the platform (DOWN) to comfortable height for work. Upper pin must be lower than the bottom of the column (see FIG. 23-1). 2. Disconnect the hydraulic hose from lower end of cylinder (FIG. 23-2). Plug hose to prevent spills. COLUMN 3. Remove the lower roll pin from inside coupling (FIG. 23-2) and then remove lower pin. UPPER PIN (CLOSING CYLINDER) 4. Remove the upper roll pin (FIG. 232) from the runner and then remove the upper pin. FIG. 23-1 5.
REPLACING PARTS LIFTING CYLINDER REPLACEMENT ! WARNING Use floor jack and jack stands to support platform while performing this procedure. 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.
VISE GRIP PLIERS COLUMN RUNNER 5. Remove upper roll pin & upper pin from cylinder (FIG. 25-2). Lift cylinder about 4” above top of column. LOWER ROLL PIN LOWER PIN SECURING CYLINDER FIG. 25-1 6. Remove cylinder from column as follows. Attach a chain hoist or equivalent lifting device to support the upper end of cylinder (FIG. 25-2). Remove vise grip pliers from cylinder. Hoist the cylinder until it clears the top of column. Then lower cylinder to the ground.
REPLACING PARTS LIFTING CYLINDER REPLACEMENT - Continued LIFTING LINE 9. To help remove air from rod end of housing, position cylinder on its side with the lifting line on top (FIG. 26-1). Then slowly return cylinder to vertical position (FIG. 22-3). CYLINDER POSITIONED ON SIDE FIG. 26-1 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 10. Remove extension hose and plug the lifting line (FIG. 26-1). CYLINDER WITH HOSE REMOVED FIG.
NOTE: Refer to Operation Manual for instructions to operate Liftgate. 1. Use control box to lower the platform (DOWN) to approximately 12” above the ground. Support platform with 2 jack stands (FIG. 27-1). Make sure ramp edge is 4” higher than inboard edge of platform. PLATFORM INBOARD EDGE RAMP EDGE RAMP 4” JACK STAND (AND JACKSTAND NOT SHOWN) FIG. 27-1 2. Unbolt pin collar from RH runner to remove chain arm (FIG 27-2). Then, unbolt and remove cover from runner. Repeat for LH chain arm and LH runner.
REPLACING PARTS RUNNER REPLACEMENT - Continued 3. Raise the platform (UP) slightly and place 2 more jack stands near the inboard edge (FIG. 28-1). 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 PLATFORM JACK STANDS (3RD & 4TH JACKSTANDS NOT SHOWN) FIG. 28-1 4. Unbolt platform and connector bar from pin at the RH runner (FIG. 28-2). Then, remove pin. Repeat for LH runner. BOLT LOCK NUT PIN HEX NUT BOLTS FLAT WASHER (2 PLACES) LOCK WASHER FIG.
FIG. 29-1 6. Use the control box to lower runners (DOWN) to the ground. SPRING GUARD NOTE: If replacing LH runner, skip steps 7, 8, and 9. 7. Do the opening/closing cylinder removal steps in the OPENING/CLOSING CYLINDER REPLACEMENT procedure in this manual. SPACER TUBE RUNNER SWITCH CABLE CONNECTOR SCREW CLAMP 8. Disconnect runner switch cable from flexible cable near bottom of runner as shown in FIG. 29-2. Then, unfasten runner switch cable clamp from runner by removing lock nut (FIG. 29-2).
REPLACING PARTS RUNNER REPLACEMENT - Continued LOCK WASHER (2 PLACES) NOTE: Keep shims in the same position on each pad when pads are removed. The same shims must be reinstalled with each pad. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 10. Unbolt the upper and lower pad assemblies and shims (FIGS. 301A & 30-1B) from runner (FIG. 30-1C). BOLT (2 PLACES) UPPER PAD FIG. 30-1A LOCK WASHER (2 PLACES) FIG. 30-1C BOLT (2 PLACES) LOWER PAD FIG. 30-1B 11.
ROLL PIN UPPER PIN FLOW CONTROL VALVE LIFTING HYDRAULIC LINE FIG. 31-1 14. Lower cylinder slowly a few inches to gain access to hydraulic line connector. Plug the lifting line to prevent cylinder from compressing. HYDRAULIC LINE CONNECTOR & ELBOW (CAP ELBOW WHEN DISCONNECTED) COLUMN LIFTING LINE (SHOWN PLUGGED) 15. Disconnect hydraulic line from elbow on top of cylinder (FIG. 31-2). Then cap the elbow. FIG. 31-2 31 11921 Slauson Ave. Santa Fe Springs, CA.
REPLACING PARTS RUNNER REPLACEMENT - Continued 16. Twist and walk runner out of column (FIG. 32-1). Then lay runner and cylinder on the ground. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 RUNNER FIG. 32-1 CAUTION LOWER PIN ROLL PIN Prevent damage to cylinder rod. Be careful removing cylinder from runner. RUNNER 17. Remove roll pin and lower pin from runner (FIG. 32-2). Pull cylinder from runner. FIG.
BOLTS LOCK WASHERS SWITCH & BRACKET OPENING FOR SWITCH REMOVING SWITCH FROM RH RUNNER FIG. 33-1 CAUTION Avoid making sharp bends in wiring. 19. If RH runner is being replaced, reinstall switch, bracket, and cable in runner as follows. Make a wire fish by feeding 8 feet of small gauge wire through switch opening in runner (FIG. 33-1). Pull wire through channel at lower end of runner. Leave enough wire at the switch opening to attach to switch cable, and enough wire to pull at the lower end of runner.
REPLACING PARTS RUNNER REPLACEMENT - Continued CAUTION Prevent damage to cylinder rod. Be careful inserting cylinder in runner. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 20. Slide rod end of lifting cylinder in top of runner (FIG. 34-1). Then reinstall lower pin and roll pin (FIG. 34-2). TOP OF RUNNER CYLINDER INSERTING CYLINDER IN RUNNER FIG. 34-1 ROLL PIN LOWER PIN RUNNER FIG.
RUNNER FIG. 35-1 22. Remove cap from elbow on top of cylinder (FIG. 35-2). Then re-connect power down line to elbow. HYDRAULIC LINE CONNECTED TO ELBOW LINE UP HOLES COLUMN LIFTING LINE (SHOWN PLUGGED) 23. Remove plug from lifting line (FIG. 35-2). Then, raise the cylinder to line up the holes on cylinder and column. FIG. 35-2 35 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 21. Stand the runner and cylinder upright. Twist and walk runner into column (FIG. 35-1).
REPLACING PARTS RUNNER REPLACEMENT - Continued 24. Holding the cylinder firmly, reinstall upper pin and roll pin (FIG. 36-1). Then, reconnect lifting line to flow control valve (FIG. 36-1). ROLL PIN UPPER PIN FLOW CONTROL VALVE 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 LIFTING HYDRAULIC LINE FIG. 36-1 NOTE: If roller bracket was unbolted from tandem rollers, reinstall bracket when tandem rollers are reinstalled at bottom of runner. 25.
27. Bolt the upper and lower pads (FIGS. 37-1A & 37-1B) on the runner (FIG. 37-1C). BOLT (2 PLACES) UPPER PAD FIG. 37-1A LOCK WASHER (2 PLACES) BOLT (2 PLACES) CAUTION To prevent damage to twin hydraulic hoses and flexible cable, ensure the hoses and cable are routed correctly inside the spring guard and are not twisted. Cable must not be wrapped around the hydraulic hoses. FIG. 37-1C LOWER PAD FIG. 37-1B NOTE: If replacing LH runner, skip steps 28, 29, 30, & 31. SPRING GUARD 28.
REPLACING PARTS RUNNER REPLACEMENT - Continued 31. To reinstall opening/closing cylinder, do the opening/closing cylinder replacement steps in the OPENING/CLOSING CYLINDER REPLACEMENT procedure in this manual. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 32. Use a forklift or eqivalent lifting device to lift platform and line it up with attaching points on the LH runner (FIG. 38-1) and RH runner. FIG. 38-1 33.
PLATFORM INBOARD EDGE RAMP EDGE RAMP 35. Use control box to lower (DOWN) platform on jack stands (FIG. 39-1) so inboard edge is 4” below ramp edge. 4” JACK STAND (AND JACKSTAND NOT SHOWN) FIG. 39-1 NOTE: The runner cover, with the “ALIGN ARROWS” decal, is installed on the LH runner. NOTE: If a new cover is being bolted on the LH runner, the serial plate must transferred from old cover to new cover. Also, a new “ALIGN ARROWS” decal must be installed on the new cover. 36.
HYDRAULIC SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION “A” VALVE “M” SOLENOID “A” VALVE “B” VALVE “M” SOLENOID “B” VALVE 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 “E” VALVE (HIDDEN FROM VIEW) “E” VALVE GRAVITY DOWN PUMP/MOTOR (POWER UNIT WITH HOSES) FIG. 40-1 GRAVITY DOWN PUMP/MOTOR (POWER UNIT WITH STEEL LINES) FIG. 40-2 “A” VALVE “B” VALVE “C” VALVE “M” SOLENOID “E” VALVE “D” VALVE POWER DOWN PUMP/MOTOR (POWER UNIT WITH HOSES) FIG.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 HYDRAULIC SCHEMATIC, SINGLE PUMP GRAVITY DOWN FIG.
HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC, DUAL PUMP GRAVITY DOWN 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FIG.
CAUTION NOTE: See TABLE 43-1 for information on the numbered hoses in this illustration. If hoses are disconnected, ensure face seal o-rings are in place before reconnecting hose. RH COLUMN CHANNEL GUARD VEHICLE FOLD/ UNFOLD LINE LIFTING LINE RETURN LINE RETURN LINE (TO PUMP RESERVOIR) 1 2 4 3 LH COLUMN TEE 6 FOLD/ UNFOLD LINE 5 LIFTING LINE RETURN LINE LIFTING LINE GRAVITY DOWN PUMP FIG. 43-1 GRAVITY DOWN PUMP BOX INSTALLATION: REQUIRED HOSES & PLASTIC TUBING 3 FT. 10 FT. 20 FT.
HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC, SINGLE PUMP POWER DOWN 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FIG.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 HYDRAULIC SCHEMATIC, DUAL PUMP POWER DOWN FIG.
HYDRAULIC SYSTEM DIAGRAMS POWER DOWN HYDRAULIC LINES IDENTIFICATION CAUTION NOTE: See TABLE 46-1 for information on the numbered hoses in this illustration. If hoses are disconnected, ensure face seal o-rings are in place before reconnecting hose. FOLD/UNFOLD LINE RH COLUMN 11921 Slauson Ave. Santa Fe Springs, CA.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 ELECTRICAL SYSTEM DIAGRAMS WIRING SCHEMATIC, GRAVITY DOWN FIG.
ELECTRICAL SYSTEM DIAGRAMS SINGLE PUMP BOX, GRAVITY DOWN 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 (From receptacle on pump box wall) FIG.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 DUAL PUMP BOX, GRAVITY DOWN FIG.
ELECTRICAL SYSTEM DIAGRAMS WIRING SCHEMATIC, POWER DOWN 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FIG.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 SINGLE PUMP BOX, POWER DOWN (From receptacle on pump box wall) FIG.
ELECTRICAL SYSTEM DIAGRAMS DUAL PUMP BOX, POWER DOWN 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FIG.
“D” VALVE MOLDED CABLE (LH) (REF) R5 P5 LH COLUMN LEFT CYLINDER PUMP BOX R1 P10 PUMP BOX MOLDED EXTENSION CABLE (REF) P1 R2 CONTROL BOX (REF) RH COLUMN RIGHT CYLINDER R6 P2 P6 ALIGN MARKS P7 ALIGNING ROUND CONNECTORS FLEXIBLE CABLE (REF) MOLDED HARNESS (RH) (REF) MOLDED SWITCH & CABLE (REF) P8 R8 P4 P9 R9 NOTE: Connector references are not marked on parts. FIG. 53-1 53 R4 BMRA INTERCONNECT HARNESS (REF) 11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING PLATFORM WILL NOT RAISE, MOTOR WILL NOT RUN NOTE: For dual pump system, check secondary pump and motor first. 1. Check for 12.6 volts dc input to motor solenoid by using voltmeter between terminal A (FIGS. 49-1 and 49-2) and ground. If there is no power to the motor solenoid, make sure pump box master disconnect switch is ON and circuit breaker is set. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 2.
TERMINAL”B” (LOAD) TERMINAL”C” (SOL. +) BATTERY CABLE TERMINAL”A” (B+) TYPICAL MOTOR SOLENOID ELECTRICAL CONNECTIONS (PUMP SHOWN IS FROM GRAVITY DOWN UNIT WITH HOSES) FIG. 55-1 GROUND (-) CABLE MOTOR SOLENOID TERMINAL”A” (B+) TERMINAL”C” (SOL. +) BATTERY (+) CABLE TERMINAL”D” (SOL. -) TERMINAL”B” (LOAD) TYPICAL MOTOR SOLENOID ELECTRICAL CONNECTIONS (PUMP SHOWN IS FROM GRAVITY DOWN UNIT WITH STEEL LINES) FIG. 55-2 55 11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING PLATFORM WILL NOT PICK UP RATED CAPACITY 1. Check for unequal cylinder operation (lagging cylinder first). GRAVITY DOWN LIFTGATES: Lower the platform to the ground. Disconnect the RETURN HOSE at the bottom of each column. Place a large container under cylinder to catch fluid. Set control box toggle switch to UP position to raise platform. Check if fluid is streaming from the fitting.
TYPICAL PUMP REMOVED TO CHECK AND CLEAN FILTER (PUMP SHOWN IS FROM POWER DOWN UNIT WITH HOSES) FIG. 57-1 PUMP FILTER TYPICAL PUMP REMOVED TO CHECK AND CLEAN FILTER (PUMP SHOWN IS FROM GRAVITY DOWN UNIT WITH STEEL LINES) FIG. 57-2 57 11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING PLATFORM RAISES HALFWAY & STOPS 1. Check the hydraulic fluid level in the reservoir. GRAVITY DOWN LIFTGATES: Lower the platform to the ground. Clean dirt and fluid from top of reservoir in pump box. Fill the reservoir to correct level indicated on sight glass (pump box). POWER DOWN LIFTGATES: Raise the platform to bed height. Fill the reservoir to correct level indicated on sight glass (pump box). 11921 Slauson Ave. Santa Fe Springs, CA.
TERMINAL”B” (LOAD) TERMINAL”C” (SOL. +) BATTERY CABLE TERMINAL”A” (B+) TYPICAL MOTOR SOLENOID ELECTRICAL CONNECTIONS (PUMP SHOWN IS FROM GRAVITY DOWN UNIT WITH HOSES) FIG. 59-1 GROUND (-) CABLE MOTOR SOLENOID TERMINAL”A” (B+) TERMINAL”C” (SOL. +) BATTERY (+) CABLE TERMINAL”D” (SOL. -) TERMINAL”B” (LOAD) TYPICAL MOTOR SOLENOID ELECTRICAL CONNECTIONS (PUMP SHOWN IS FROM GRAVITY DOWN UNIT WITH STEEL LINES) FIG. 59-2 59 11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING PLATFORM RAISES HALFWAY & STOPS - Continued 5. Check for bent parts on the Liftgate that could interfere with normal operation. NOTE: Do the BLEEDING HYDRAULIC SYSTEM procedure in this manual with the following step. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 6. Remove assembled pump and motor from reservoir (FIGS. 57-1 and 57-2). Check if pump filter is clogged. Clean clogged filter and flush contaminated fluid from reservoir.
TYPICAL PUMP REMOVED TO CHECK AND CLEAN FILTER (PUMP SHOWN IS FROM POWER DOWN UNIT WITH HOSES) FIG. 61-1 PUMP FILTER TYPICAL PUMP REMOVED TO CHECK AND CLEAN FILTER (PUMP SHOWN IS FROM GRAVITY DOWN UNIT WITH STEEL LINES) FIG. 61-2 61 11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING PLATFORM RAISES AND LOWERS UNEVENLY NOTE: Do the BLEEDING HYDRAULIC SYSTEM procedure in this manual with the following step. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Reverse the two 3/8” high pressure hose connections on output side of flow divider as shown in FIG. 62-1. Raise the platform. If the uneven platform position is the opposite of original symptom, replace flow divider.
3. Lower the platform to the ground and remove the pressure compensation valve (FIG. 63-1) located at the top of each column. Check if pressure compensation valves are contaminated. Disassemble, try to move plunger with small screwdriver, and then clean each valve if required (FIG. 63-1). Reinstall or replace each valve if necessary. “D” VALVE (REF) CYLINDER (REF) FLOW CONTROL VALVE SCREWDRIVER FIG. 63-1 4. Check for bent parts on the Liftgate that could interfere with normal operation.
TROUBLESHOOTING PLATFORM WILL NOT FOLD 1. Check the hydraulic fluid level in the reservoir. GRAVITY DOWN LIFTGATES: Lower the platform to the ground. Clean dirt and fluid from top of reservoir in pump box. Fill the reservoir to correct level indicated on sight glass (pump box). POWER DOWN LIFTGATES: Raise the platform to bed height. Fill the reservoir to correct level indicated on sight glass (pump box). 11921 Slauson Ave. Santa Fe Springs, CA.
TERMINAL”D” (SOL. -) TERMINAL”B” (LOAD) TERMINAL”C” (SOL. +) BATTERY CABLE WHITE WIRE TERMINAL”A” (B+) TYPICAL MOTOR SOLENOID ELECTRICAL CONNECTIONS (GRAVITY DOWN POWER UNIT WITH HOSES IS SHOWN) FIG. 65-1 GROUND (-) CABLE MOTOR SOLENOID TERMINAL”A” (B+) TERMINAL”C” (SOL. +) BATTERY (+) CABLE TERMINAL”D” (SOL. -) TERMINAL”B” (LOAD) TYPICAL MOTOR SOLENOID ELECTRICAL CONNECTIONS (GRAVITY DOWN POWER UNIT WITH STEEL LINES IS SHOWN) FIG. 65-2 65 11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING PLATFORM WILL NOT FOLD - Continued ! WARNING Make sure Liftgate platform is open and resting on the ground before performing the following step. CAUTION To prevent damage when installing valve cartridges & coils, torque valve cartridge nut to 30 lbs.-in. max. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 4. The “E” solenoid valve (FIGS. 66-1 and 66-2) may be stuck in the “open” position. Remove the “E” solenoid valve (FIG. 63-1).
NUT COIL VALVE CARTRIDGE TYPICAL SOLENOID VALVE REMOVED & DISASSEMBLED FIG. 67-1 VALVE CARTRIDGE 1/8” CHECKING VALVE CARTRIDGE FIG.67-2 6. Check for bent parts on the Liftgate that could interfere with normal operation. 7. Check if hydraulic fluid is streaming from breather plug. 67 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 5. Reinstall “E” solenoid valve (FIG. 67-1) (if good) or a replacement. Torque valve cartridge to 30 lbs.-ft. and hex nut to 30 lbs.-in.
TROUBLESHOOTING PLATFORM WILL NOT UNFOLD ! WARNING Before doing the following procedure, set up guarded area around the platform to keep people from entering. NOTE: For dual pump system, check secondary pump and motor first. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Flow of hydraulic fluid may be restricted. Turn opener (unfolding) valve adjustment (FIGS. 68-1 and 68-2) counter-clockwise to open the valve.
WARNING Make sure Liftgate platform is open and resting on the ground before performing the following step. CAUTION To prevent damage when installing valve cartridges & coils, torque valve cartridge nut to 30 lbs.-in. max. 3. The “E” solenoid valve (FIGS. 69-1 and 69-2) may be stuck in the “open” position. Remove the “E” solenoid valve (FIG. 66-1). Next, check the valve cartridge as follows. Push on the plunger in the valve by inserting small screwdriver in the open end (FIG. 66-2).
TROUBLESHOOTING PLATFORM WILL NOT UNFOLD - Continued 5. Verify that relief valve pressure settings are correct. Refer to RELIEF VALVE PRESSURE SETTING procedure in this manual. Also, make sure opening flow control valve (in pump) is open. If correct pressure settings cannot be made or if pump runs hot with excessive noise, replace pump. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 6. Check for damage and corrosion at platform pivot points.
11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING PUMP RELIEF VALVE PRESSURE SETTING NOTE: The pump pressure is set at the factory; however, if adjustment is needed, use the following procedure. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Open the platform. Turn closer valve adjustment (FIGS. 69-1 and 69-2) all the way clockwise. Disconnect hose from folding port bulkhead fitting and connect 0-3000 PSI gauge to hose (FIGS. 69-1 and 69-2). 2.
3000 PSI GAUGE PUMP BLOCK COVER CLOSER (FOLD) VALVE ADJUSTMENT PRESSURE VALVE ADJUSTMENT (USE ALLEN WRENCH) CONNECTING PRESSURE GAUGE (DUAL PUMP POWER DOWN UNIT WITH HOSES IS SHOWN) FIG. 73-1 3000 PSI GAUGE OPENER (UNFOLD) VALVE ADJUSTMENT CLOSING (UNFOLD) BULKHEAD CONNECTOR COVER PUMP BLOCK CLOSER (FOLD) VALVE ADJUSTMENT PRESSURE VALVE ADJUSTMENT (USE SCREWDRIVER) CONNECTING PRESSURE GAUGE (DUAL PUMP GRAVITY DOWN UNIT WITH STEEL LINES IS SHOWN) FIG. 73-2 73 11921 Slauson Ave.
TROUBLESHOOTING - GRAVITY DOWN PLATFORM WILL NOT RAISE, MOTOR RUNS 1. Check the hydraulic fluid level in the reservoir. GRAVITY DOWN LIFTGATES: Lower the platform to the ground. Clean dirt and fluid from top of reservoir in pump box. Fill the reservoir to correct level indicated on sight glass (pump box). POWER DOWN LIFTGATES: Raise the platform to bed height. Fill the reservoir to correct level indicated on sight glass (pump box). 11921 Slauson Ave. Santa Fe Springs, CA.
11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING - GRAVITY DOWN PLATFORM WILL NOT LOWER NOTE: For dual pump system, check secondary pump and motor first. NOTE: Numbers for the electrical terminals shown in the illus tration are not stamped on valve coil. Numbers shown are for reference only. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Try lowering platform (activate DOWN toggle switch). Only the motor solenoid and “B” valve (both located in the pump box) (FIGS.
WARNING Make sure Liftgate platform is open and resting on the ground before performing the following step. CAUTION To prevent damage when installing valve cartridges & coils, torque valve cartridge nut to 30 lbs.-in. max. 2. The “D” solenoid valve (FIG. 72-3) may be stuck in the “open” position. Remove the “D” solenoid valve (FIG. 77-1). Next, check the valve cartridge as follows. Push on the plunger in the valve by inserting small screwdriver in the open end (FIG. 77-2).
TROUBLESHOOTING - GRAVITY DOWN PLATFORM LOWERS SLOWLY NOTE: For dual pump system, check secondary pump and motor first. NOTE: Numbers for the electrical terminals shown in the illustration are not stamped on valve coil. Numbers shown are for reference only. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Check if the “B” solenoid valve coil (FIGS. TYPICAL 78-1 and 78-2) (located in the pump TERMINAL-1 box) is getting power.
WARNING Make sure Liftgate platform is open and resting on the ground before performing the following step. CAUTION To prevent damage when installing valve cartridges & coils, torque valve cartridge nut to 30 lbs.-in. max. NUT 2. The “B” solenoid valve (FIGS. 74-1 and 74-2) may be stuck in the “open” position. Remove the “B” solenoid valve (FIG. 79-1). Next, check the valve cartridge as follows. Push on the plunger in the valve by inserting small screwdriver in the open end (FIG. 79-2).
TROUBLESHOOTING - POWER DOWN PLATFORM WILL NOT RAISE, MOTOR RUNS 1. Check the hydraulic fluid level in the reservoir. GRAVITY DOWN LIFTGATES: Lower the platform to the ground. Clean dirt and fluid from top of reservoir in pump box. Fill the reservoir to correct level indicated on sight glass (pump box). POWER DOWN LIFTGATES: Raise the platform to bed height. Fill the reservoir to correct level indicated on sight glass (pump box). 11921 Slauson Ave. Santa Fe Springs, CA.
WARNING Make sure Liftgate platform is open and resting on the ground before performing the following step. CAUTION To prevent damage when installing valve cartridges & coils, torque valve cartridge nut to 30 lbs.-in. max. 3. The “E” solenoid valve (FIG. 81-1) may be stuck in the “open” position. Remove the “E” solenoid valve (FIG. 81-2). Next, check the valve cartridge as follows. Push on the plunger in the valve by inserting small screwdriver in the open end (FIG. 81-3).
TROUBLESHOOTING - POWER DOWN PLATFORM WILL NOT LOWER NOTE: For dual pump system, check secondary pump and motor first. NOTE: Numbers for the electrical terminals shown in the illustration are not stamped on valve coil. Numbers shown are for reference only. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Try lowering platform (activate DOWN toggle switch). Only the motor solenoid, “B” solenoid valve and “C” solenoid valve (located in the pump box) (FIG.
WARNING Make sure Liftgate platform is open and resting on the ground before performing the following step. CAUTION To prevent damage when installing valve cartridges & coils, torque valve cartridge nut to 30 lbs.-in. max. 2. The “D” solenoid valve (FIG. 78-2) may be stuck in the “open” position. Remove the “D” solenoid valve (FIG. 83-1). Next, check the valve cartridge as follows. Push on the plunger in the valve by inserting small screwdriver in the open end (FIG. 83-2).
TROUBLESHOOTING - POWER DOWN PLATFORM LOWERS SLOWLY NOTE: For dual pump system, check secondary pump and motor first. NOTE: Numbers for the electrical terminals shown in the illustration are not stamped on valve coil. Numbers shown are for reference only. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Try lowering platform (activate DOWN toggle switch). Make sure motor solenoid (located in the pump box) (FIG.
NUT 3. Reinstall “E” solenoid valve (if good) (FIG. 85-1) or a replacement. Torque valve cartridge to 30 lbs.-ft. and hex nut to 30 lbs.-in. VALVE CARTRIDGE TYPICAL SOLENOID VALVE REMOVED & DISASSEMBLED FIG. 85-1 VALVE CARTRIDGE 1/8” CHECKING VALVE CARTRIDGE FIG. 85-2 4. Check for bent and broken parts on the Liftgate that could interfere with normal operation. 5. Check both flow control valves. Refer to the flow control valve instructions in the procedure for PLATFORM RAISES AND LOWERS UNEVENLY.
