LIFT-A-LOFT APX16 Maintenance Manual Download

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LIFT-A-LOFT APX16 - G

ASOLINE

CHAPTER 2

CONTENTS

09-26-02

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Summary of Contents for APX16

Page 1: ...Sc ci is ss so or r L Li if ft t V Ve eh hi ic cl le e APX16 1036S thru APX16 1037S REV 00 LIFT A LOFT CORPORATION 9501 SOUTH CENTER ROAD MUNCIE IN 47302 9443 P O BOX 2645 MUNCIE IN 47307 0645 Phone N...

Page 2: ...s Chart Fig 1 1 3 Lube Service Points Fig 2 1 4 Lube Service Chart 1 6 1 Engine 1 6 2 Battery 1 8 3 Vehicle General 1 8 4 Suspension 1 8 5 Steering 1 8 6 Brakes 1 9 7 Vehicle Flooring Steps 1 9 8 Labe...

Page 3: ...rt 3 1 Hex Head Bolt Nut Torque Chart 3 2 2 Engine Transmission Carriage 3 3 3 Cylinder Steering 3 7 4 Cylinder Seals 3 7 5 Radiator 3 8 6 Seat 3 9 7 Battery 3 9 8 Vehicle Wheels 3 9 9 Drive Shaft 3 1...

Page 4: ...Motor Assy Opt 3 25 31 Brake Pads Rear 3 26 32 Brake Pads Front 3 28 33 Traversing Cylinder Opt 3 30 REPAIR 4 1 1 General 4 1 2 Hydraulic Steering Turbine Oil Pump Motor or Compressor Sys 4 1 3 Hydrau...

Page 5: ...ous means Always use the scissors spreader during these operations otherwise death or serious personal injury may result 1 2 CAUTION Lubricate the unit at specified intervals after cleaning or after p...

Page 6: ...during these situations Death or serious personal injury may result 3 19 CAUTION Do not over tighten hydraulic fittings 3 20 21 22 WARNING Vehicle must be fully supported before working under unit 3...

Page 7: ...LIFT A LOFT APX16 GASOLINE CHAPTER 2 CONTENTS 09 26 02 THIS PAGE LEFT BLANK P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 8: ...ion and checks are expressed in both hours and in months CAUTION Lubricate the unit at specified intervals and after concentrated cleanings 2 RECORDS To assist in implementing a program of maintenance...

Page 9: ...To use the scissor spreader properly first raise the platform sufficiently to permit the spreader to be inserted between the cross members Pull the pin s holding the spreader in the stowed position al...

Page 10: ...that surpasses Fed standard 116 and meets specs W B 680 SAEJ1703 Axle Rear Drive 5 quarts 4 7L Any quality 80W90 oil Wheel Bearings As needed NLGI weight 2 2 1 2 Mobil 77 or 28 grease Mo Lith 2 Fiske...

Page 11: ...16 GASOLINE CHAPTER 2 SECTION 1 Page 4 09 26 02 APX16 Lube Service Points Figure 2 Opt Compressor Opt Oiler System 12 7 18 3 1 2 6 20 15 10 16 SPREADER 21 10 17 22 P r o p e r t y o f A m e r i c a n...

Page 12: ...LIFT A LOFT APX16 GASOLINE CHAPTER 2 SECTION 1 Page 5 09 26 02 REAR 4 6 12 12 APX16 Lube Service Points FRONT 4 6 1 11 P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 13: ...operation Daily Inspection Change as needed BELTS Check Fan and Alternator belts for tension Deflection should equal inch in one direction Coat well with quality belt dressing to provide less squeaki...

Page 14: ...x 10 oz Spray clean the exterior of the carburetor including the throttle and choke linkage Every 300 hours or 3 months PCV VALVE Replace to ensure reliable operation Annually PLUGS Clean and regap to...

Page 15: ...SION Check security of mounting hardware Add pressure grease to fittings on each shackle to fill cavity 4 places Every 300 hours or every 3 months 5 STEERING Check level of Steering Fluid Check for le...

Page 16: ...ove calipers and check pads for cracks and defects that would indicate premature break down Replace if necessary at this time Annually 7 VEHICLE FLOORING and STEPS Flooring should be kept free of oil...

Page 17: ...Headlights Turn Signals Running Brake lights Daily inspection 13 TIRES Check condition press 80lbs Daily inspection 14 HYDRAULIC SYSTEM FILLER BREATHER Ensure that cap remains in place Daily inspecti...

Page 18: ...heck that all roll spring pins roll pins hex head retaining screws through cylinder pin are in place Every 100 hours or every month SHAFTS These units are permanently lubricated but should be checked...

Page 19: ...taminants Check cylinder area at rod and ports for signs of leakage Daily inspection Apply oil to cylinder rod surface Every 100 hours or every month 18 PLATFORM SURFACE The platform surface must be k...

Page 20: ...line behind rear bumper Unscrew canister end cap Remove cartridge puffed and milky when change is needed Replace cartridge being careful to center spring in cartridge and end cap Screw cap onto filte...

Page 21: ...level in overflow tank 5 STEERING FLUID LEVEL Check level check for leaks 6 BRAKES Check fluid level check for leaks 7 VEHICLE FLOORING STEPS Free of oil debris 8 LABELS PLACARDS Clean in place 9 HOSE...

Page 22: ...ICE ACTIVITY See Lube Service Chart for details LUBE SERVICE INTERVAL Months or Operating Hours 14a FILLER BREATHER Cap in place 14c HYDRAULIC FLUID LEVEL Check level of fluid 17 STABILIZERS Clean che...

Page 23: ...r cracked welds or damage and retaining hardware is in place 15 SCISSOR CAM ROLLERS Check related hardware 15 SCISSOR SHAFTS Check for wear or damage 15 SCISSOR ROLLERS Check rollers and roller tracks...

Page 24: ...BURETOR AREA Clean w spray cleaner 1 ENGINE BELTS Check dress fan alter 2 BATTERY Check specific gravity clean terminals 3 VEHICLE LATCHES HINGES HOOKS Clean lubricate 4 SHACKLE Check and lube 4 place...

Page 25: ...ue settings 1 ENGINE COOLANT Change 1 PCV VALVE Change 1 PLUGS Clean regap Replace if necessary 1 DISTRIBUTOR Check replace if necessary Lube capstan 1 WIRES Check and replace as necessary 6 BRAKE PAD...

Page 26: ...E SERVICE ACTIVITY See Lube Service Table for details LUBE SERVICE INTERVAL Months or Operating Hours 1 2 3 4 5 6 7 8 9 10 11 12 19 PAINT APPEARANCE 21 DESICCANT FILTER Behind cab Replace as needed 21...

Page 27: ...LIFT A LOFT APX16 GASOLINE CHAPTER 2 SECTION 1 09 26 02 THIS PAGE LEFT BLANK P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 28: ...nments and maintenance intervals it is impossible to foresee all of the types of problems that might arise during a unit s service life however this chart covers the most likely symptoms their causes...

Page 29: ...E IN TRAVERSE OUT IGNITION POWER RELAY X X X X X X X X X X X X X X X X APV LIFT POWER RELAY X X X X X X X X X X X X X X X X TRAVERSE IN SOLENOID X X TRAVERSE OUT SOLENOID X X PLATFORM SPEED LOWER SOLE...

Page 30: ...H on parking brake under unit Will not permit engine to be started or functions to operate unless parking brake is set GE128 1 NEUTRAL SAFETY SWITCH on transmission Will not permit engine to be starte...

Page 31: ...p or the solenoid is sticking starter is going bad Starter Solenoid Failure Chattering sound on occasional start ups Replace Device Battery discharged Recharge or replace Vehicle not in neutral Rectif...

Page 32: ...oid failure Replace 2 ENGINE RUNNING POORLY Poor Idle Vacuum leak Inspect visually for loose or broken hoses Intake manifold leak Test and replace gasket Check for cracks or warpage Contaminated or ol...

Page 33: ...alve handle closed Open valve Steering Cylinder Piston seals defective Disconnect rod end hydraulic hose from reservoir cylinder tank return hold end in bucket and extend cylinder If oil streams into...

Page 34: ...collapsed brake lines Inspect and replace lines Air in brake lines Bleed brake lines Brake Valve Dirt lodged on valve Disassemble and clean Low on brake fluid Find source of fluid leakage and repair R...

Page 35: ...nel Control button malfunction Use unit schematic and layout to locate device Solenoid failure located on each lift cyl lower control station behind lower control station Use unit schematic and layout...

Page 36: ...POSITION Lift cylinder seal leaking slowly Seal shrinkage after installation Caused by chemically induced solvent action Raise platform as high as possible Inspect area around piston shaft if oil leak...

Page 37: ...ill not shift due to dirt or defective seals Remove clean valve with solvent replace seals if necessary Reassemble and test If problem continues consider other causes or replace valve 10 Opt TURBINE O...

Page 38: ...r pump will not operate Remove clean valve with solvent replace seals if necessary Reassemble and test If problem continues consider other causes or replace valve Low volume hot air blows out of intak...

Page 39: ...LIFT A LOFT APX16 GASOLINE CHAPTER 2 SECTION 2 09 26 02 THIS PAGE LEFT BLANK P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 40: ...tire procedure and be familiar with the component being serviced WARNING Place the cab ignition switch OFF Disconnect battery cables before servicing the engine or other electrical circuits SAE Straig...

Page 41: ...ATE QUALITY MINIMUM COMMERCIAL QUALITY MEDIUM COMMERCIAL QUALITY BEST COMMERCIAL QUALITY MATERIAL LOW CARBON STEEL MEDIUM CARBON STEEL TEMPERED MEDIUM CARBON STEEL Q T MEDIUM CARBON ALLOY STEEL Q T MI...

Page 42: ...ct the fuel line from the fuel pump WARNING Use extreme caution when disconnecting lines Avoid all sparks or open flames Sudden sprays of fuel are possible when line is removed 2 Close the hydraulic r...

Page 43: ...nd of the transmission 4 Disconnect the drive shaft from the transmission by removing the four bolts in the companion flange 5 Disconnect the shifter cable and remove its mounting plate from the trans...

Page 44: ...Make sure that the transmission coolant lines to not catch during removal 4 Slide the engine carriage assembly forward until it is out of the APX chassis Installation Task time 30 minutes average Reve...

Page 45: ...6 Hand Wrench Top of Tunnel 4 Way Pocket Screwdriver 1 1 8 Hand Wrench Flat Blade Screwdriver 7 16 Hand Wrench Passenger Side Cab Floor 1 2 Socket With Long Extension and Driver 11 16 Socket 7 16 Sock...

Page 46: ...1 Install cylinder and tighten nuts to approx 100 ft lbs 2 Reconnect the hydraulic hoses 3 Reconnect battery and check operation 4 CYLINDER SEALS Seal Removal Installation 1 Using a pipe or spanner wr...

Page 47: ...d lines 5 Remove four 4 bolts on center section of front bumper 6 Remove bolts holding radiator to fan shroud 7 Lift radiator out of vehicle and take to work bench for repair replacement Installation...

Page 48: ...own out of the compartment 3 Lift the battery out of the side compartment Be careful not to damage the overflow tube Battery Installation 1 Reverse the above procedure reinstalling negative cable last...

Page 49: ...locking compound when reinstalling the bolts 10 DRIVE AXLE Removal Fig 2 Fig 3 1 Elevate the unit by supporting either its frame rails or the front and rear bumpers 2 Release the parking brake 3 Remo...

Page 50: ...e procedure for installation 2 Bleed the brakes Be sure to check the fluid level in the reservoir 11 SHIFTER Removal 1 Remove the thumb screws from the upper edge of the dash and lower it 2 Undo the c...

Page 51: ...can be adjusted by turning the pedal stop bolt in or out as needed 13 EXHAUST SYSTEM Removal 1 To remove individual components loosen any clamps attached to that part 2 Remove any bracket bolts if a m...

Page 52: ...nstallation 1 Reverse the above procedure for installation 2 Bleed the brakes Be sure to check the brake fluid level in the reservoir 3 After allowing the engine to come to operating temperature cycle...

Page 53: ...R ASSEMBLY Removal Fig 7 1 From inside the driver s side front compartment disconnect both brake lines 1 from the right side of the master cylinder 2 Disconnect the line from the firewall mounted flui...

Page 54: ...e brake pedal mount 3 3 Slide the pedal forward and down to remove Installation 1 Reverse the above procedure 2 Be sure that the pedal moves freely If it binds check to see if the bolts have not been...

Page 55: ...witch if applicable 9 Remove the four bolts securing the parking brake lever to the cab floor to remove Installation 1 Reverse the above procedure 2 Be sure to test the parking brake actuation and adj...

Page 56: ...auge out from the front side of the dash Installation 1 Reverse the above procedure 2 Be sure that the wires are correctly connected Check the wiring prints if necessary 21 SWITCHES IGNITION HEAD LIGH...

Page 57: ...e Pull the back up light assembly out of its mount Installation 1 Reverse the above procedure 23 BULB REPLACEMENT HEAD LIGHT STOP TAIL TURN BACK UP GAUGES Removal 1 Head Lights Remove the head light a...

Page 58: ...c hose from cylinder Note position and routing of hose so it can be reinstalled correctly thus avoiding a broken or pinched hose when unit is placed in service Plug hoses and cylinder ports eliminatin...

Page 59: ...inder until hole in cylinder end tang is aligned with hole in clevis and install cylinder clevis pin 3 Drive a new socket head cap screw into both top and bottom cylinder clevis pins 4 Reconnect hydra...

Page 60: ...bilizer support housing 5 Stabilizer will now be free to be removed from lower housing section 6 Drive pin from lower cylinder eyelet and remove cylinder 7 Repair or replace cylinder Reinstallation 1...

Page 61: ...o not over tighten hydraulic fittings See Chart 1 See that components are clean prior to assembly 2 Install manifold mounting bolts but do not tighten 3 Connect hydraulic lines observing location tags...

Page 62: ...and carefully slide piston into tube 10 Once piston is in tube slide head down and carefully fit into tube end 11 Slide head cap over rod and tighten down securely with spanner or pipe wrench 12 Disas...

Page 63: ...ulic motor marking for re assembly 7 Remove bolts holding hydraulic motor to motor mount 8 Remove motor 9 Repair or replace as necessary Reinstallation 1 Replace hydraulic motor onto motor mount light...

Page 64: ...pressor to loosen belt Remove belt 5 Remove bolts holding compressor to mounting bracket remove compressor 6 Repair or replace Reinstallation 1 Replace compressor onto mounting bracket and bolt down s...

Page 65: ...installation 1 Place pump or motor into location and bolt into same position as previous unit 2 Reattach all hydraulic and turbine oil lines as marked 3 Test unit for operation and oil leaks 4 Refill...

Page 66: ...large C clamp to compress caliper pistons Use caution to keep pistons even and level 2 Check master cylinder reservoir and maintain at a level that will prevent overflows If the reservoir becomes ful...

Page 67: ...can Do not allow master cylinder to become empty 8 Break in new pads by using brakes gently until friction material has taken a set to the caliper 32 BRAKE PADS FRONT Removal 1 Remove wheels as in pro...

Page 68: ...ders for leakage around seals If leakage is present replace seals or caliper assembly An exploded view may be found in Chapter 5 Section 9 Installation 1 Use large C clamp to compress caliper piston I...

Page 69: ...ylinder marking for re assembly 5 Remove cotter pins holding shoulder pins in place 6 With an assistant remove shoulder pins holding cylinder in place to platform and carriage 7 Remove pins one at a t...

Page 70: ...basis or when hydraulic components malfunction provides a good indication of system condition Drain and replace oil after examination and corrections have been made 3 HYDRAULIC COMPONENTS VALVES ETC M...

Page 71: ...n assembling the Deustsch electrical connectors This section describes the correct procedure to use when crimping inserting and removing contacts Since contacts are inserted and extracted from the rea...

Page 72: ...e approximately one inch behind the crimp barrel Hold the connector with the rear grommet facing you Push the contact straight into the connector grommet until a positive stop is felt The retaining fi...

Page 73: ...ng 5 from bore of end plug Not all models use retaining ring 7 NOTE Care must be taken not to scratch bore of end plug 3 6 Remove piston 10 from piston 8 Remove piston ring 11 from piston 10 NOTE Care...

Page 74: ...21 into housing 16 and torque to 30 40 lbs ft 40 55 Nm 4 Install new cup 6 and new back up ring 5 in housing 16 Note direction of cup 5 Install new back up ring 5 new cup 6 and new retaining ring 7 i...

Page 75: ...r 1 Drain fluid from unit before disassembling 2 Remove end plug 1 from housing 23 End plug is under tension of spring 5 3 Remove O ring 4 seat 2 and retainer 3 from end plug 1 4 Remove spring 5 and p...

Page 76: ...on 6 Install retaining ring 20 in housing NOTE Be careful not to scratch or mar housing bore 7 Install spring 19 in housing 8 Install new cups 15 17 on piston 16 Note direction and order of cups 9 Ins...

Page 77: ...aster cylinder outlet Most of the air contained in the system will escape by this route Close bleeder screw 7 Continue to the next bleeder screw and so on At each point when air bubbles disappear clos...

Page 78: ...ng This should be done quickly so the loss of fluid will be minimized 6 If cylinder was bench bled in a vise it must now be attached securely to the power assist section and mounted on vehicle Finish...

Page 79: ...in or Engine carriage assembly place shifter in neutral and adjust shifter cable nut and pinion with the transmission shift lever until a complete positive neutral is obtained B Engine Drive Train Rel...

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