manual number apx20-lp110618 · 2019-07-17 · lift-a-loft apx20-lp diesel manual number...

LIFT-A-LOFT APX20-LP Diesel

MANUAL NUMBER APX20-LP110618 EFFECTIVITY: 11-06-2018

APX20-LP Scissor Lift Vehicle

MAINTENANCEMANUAL

APX20-LP1063 & Up

REV 04

LIFT-A-LOFT CORPORATION9501 SOUTH CENTER ROAD MUNCIE, IN 47302-9443

P.O. BOX 2645 MUNCIE, IN 47307-0645

Phone Number (765) 288-3691 Fax Number (765) 284-1023

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CHAPTER 2 CONTENTS

Page 1 11-06-2018

CHAPTER 2

MAINTENANCE Section Page SERVICING .............................................................................................. 1 ............... 1

1. General ........................................................................................ 1 ............... 1 2. Lubrication & Service ................................................................... 1 ............... 1 3. Records ....................................................................................... 1 ............... 1 4. Leasing or Renting ...................................................................... 1 ............... 1 5. Scissor Framework Access ......................................................... 1 ................ 2

A. Purpose of Scissor Spreaders .......................................... 1 ................ 2 B. Location of the Spreaders ................................................ 1 ................ 2 C. Use of the Spreaders ....................................................... 1 ................ 2

Grease & Oil Chart (Fig 1) ......................................................................... 1 ................ 3 Lube/Service Points (Fig 2) ........................................................................ 1 ................ 4 Lube/Service Chart .................................................................................... 1 ................ 6

(1) Engine ....................................................................................... 1 ................ 6 (2) Battery ....................................................................................... 1 ................ 7 (3) Vehicle General ........................................................................ 1 ................ 7 (4) Suspension ............................................................................... 1 ................ 7 (5) Steering ..................................................................................... 1 ................ 7 (6) Brakes ....................................................................................... 1 ................ 8 (7) Vehicle Flooring & Steps ........................................................... 1 ................ 8 (8) Labels & Placards ..................................................................... 1 ................ 8 (9) Hoses & Fittings ........................................................................ 1 ................ 8 (10) Controls ..................................................................................... 1 ................ 9 (11) Transmission ............................................................................. 1 ................ 9 (12) Lights ........................................................................................ 1 ................ 9 (13) Tires .......................................................................................... 1 ................ 9 (14) Hydraulic System ...................................................................... 1 .............. 10 (15) Scissor Related ......................................................................... 1 .............. 11 (16) Stabilizers ................................................................................. 1 .............. 11 (17) Cylinder Related ....................................................................... 1 .............. 12 (18) Platform Surface ....................................................................... 1 .............. 12 (19) Paint & Appearance .................................................................. 1 .............. 12 (20) Platform & Guardrails ................................................................ 1 .............. 12

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CHAPTER 2 CONTENTS

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CHAPTER 2 - Continued

MAINTENANCE RECORDS ...................................................................... 1 .............. 13 TROUBLESHOOTING ............................................................................... 2 ............... 1

1. General ........................................................................................ 2 ............... 1 2. Troubleshooting Chart ................................................................ 2 ............... 1

Device Activation Chart .......................................................... 2 ................ 2 Vehicle Control System .......................................................... 2 ................ 3 Vehicle Control System Overview .......................................... 2 ................ 4 Master Diagnostic Center Display Mode ................................ 2 ................ 5 Master Diagnostic Center Diagnostic Mode ........................... 2 ................ 5

Example: Stabilizers Will Not Retract .......................... 2 ................ 6 Lower Master Control (GP400) Input / Output Allocations ..... 2 ................ 7 Lower Slave Control (GP450) Input / Output Allocations ....... 2 ................ 8 Limit Switches & Their Location ............................................. 2 ................ 9

TROUBLESHOOTING CHART .................................................................. 2 .............. 10 REMOVAL/ INSTALLATION ...................................................................... 3 ............... 1

1. General ....................................................................................... 3 ............... 1 2. Engine/ Transmission Carriage .................................................. 3 ............... 1 3. Cylinder- Steering ....................................................................... 3 ............... 5 4. Cylinder Seals ............................................................................ 3 ............... 5 5. Radiator ...................................................................................... 3 ............... 6 6. Seat ........................................................................................... 3 ............... 6 7. Battery ........................................................................................ 3 ............... 7 8. Vehicle Wheels ........................................................................... 3 ............... 7 9. Drive Shaft .................................................................................. 3 ............... 7 10. Drive Axle ................................................................................... 3 ............... 8 11. Shifter ......................................................................................... 3 ............... 9 12. Accelerator Pedal ....................................................................... 3 ............... 9 13. Exhaust System .......................................................................... 3 ............... 9 14. Steer Axle ................................................................................... 3 ............. 10 15. Steering Column ......................................................................... 3 ............. 11 16. Master Cylinder/Booster Assembly ............................................. 3 ............. 11 17. Brake Pedal ................................................................................ 3 ............. 12 18. Parking Brake ............................................................................. 3 ............. 13 19. Gauges: Engine Parameters Display .......................................... 3 ............. 13 20. Switches ..................................................................................... 3 ............. 14

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CHAPTER 2 CONTENTS

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Chapter 2 - Continued

21. Lights .......................................................................................... 3 ............. 14 22. Bulbs .......................................................................................... 3 ............. 14 23. Scissor Cylinders ........................................................................ 3 .............. 15 24. Stabilizer Cylinder ....................................................................... 3 .............. 17 25. Hydraulic Valves – General ........................................................ 3 .............. 17 26. Cylinder Seals – General ............................................................ 3 ............. 18 27. Brake Pads – Rear ..................................................................... 3 .............. 19 28. Brake Pads – Front ..................................................................... 3 .............. 21 29. Traversing Cylinder .................................................................... 3 .............. 22

REPAIR ..................................................................................................... 4 ............... 1

1. General ........................................................................................ 4 ............... 1 2. Hydraulic Steering, Pumps, etc. .................................................. 4 ................ 1 3. Hydraulic Components – Valves etc ............................................ 4 ............... 1 4. Electrical Components ................................................................. 4 ............... 2

Quick Disconnect Fittings ........................................................ 4 ................ 2 5. Brake Booster .............................................................................. 4 ................ 4 6. Brake Booster Master Cylinder .................................................... 4 ................ 6 7. Brake Bleeding – Pressure Bleeding ........................................... 4 ................ 8 8. Brake Bleeding – Bench Bleeding ............................................... 4 ................ 8 9. Other Components ...................................................................... 4 ............. 10 10. Adjustments ................................................................................ 4 ............. 10

A. Wheel Alignment ............................................................... 4 ............. 10 B. Transmission Shifter .......................................................... 4 ............. 10 C. Engine, Drive Train & Related ........................................... 4 ............. 10

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CHAPTER 2 CONTENTS

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WARNINGS: AND CAUTIONS: APPEARING IN THIS CHAPTER

WARNING & CAUTION SECTION PAGEWARNING: Neglected or delayed lubrication and service can

cause excessive wear on components and machine members, and can compromise unit safety and reliability.

1 1

CAUTION: Lubricate the unit at specified intervals and after concentrated cleanings. 1 1

WARNING: Never attempt to hold the scissors open during maintenance and service operations by hydraulic pressure, by blocking or other potentially hazardous 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 periods of long-term storage. Proper lubrication is essential for safety.

1 2

WARNING: Check to ensure that all Warning, Caution, Capacity, and Information labels, placards and stickers are on the unit, and are clear and free of damage.

1 12

WARNING: Do not work under platform without scissor spreader in place. 2 16

WARNING: Place the cab ignition switch OFF. Disconnect battery cables before servicing the engine or other electrical circuits.

3 1

WARNING: Use extreme caution when disconnecting lines. Avoid all sparks or open flames. Sudden sprays of fuel are possible when line is removed.

3 2

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WARNINGS: AND CAUTIONS: APPEARING IN THIS CHAPTER (cont.)

WARNING: Never attempt to hold the scissors open during maintenance operations by hydraulic pressure, by blocking or other potentially hazardous means! Always use the safety scissor spreader during these situations. Death or serious personal injury may result.

3 15

CAUTION: Do not over-tighten hydraulic fittings 3 17, 18

CAUTION: Do not allow caliper to hang by the brake line or brake line damage may occur. Support the caliper or wire to frame.

3 20, 21

WARNING: Use caution when removing cylinder. An assistant will be needed to support the cylinder to prevent injury.

3 22

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CHAPTER 2 CONTENTS

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BLANK

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CHAPTER 2 SECTION 1

Page 1 11-06-2018

SERVICING

GENERAL This chapter outlines the information required for performing the basic maintenance, lubrication, and service of the APX20-LP Vehicle. Regular lubrication at prescribed intervals, in conjunction with an inspection program outlined in Chapter 1, Section 2, Figure 2 will help assure operators of having a safe, reliable unit and will contribute to longer unit service life.

WARNING: Neglected or delayed lubrication and service can cause excessive wear on components and machine members, and can compromise unit safety and reliability.

1. LUBRICATION & SERVICE

The following section helps to identify the areas and components, which require checking and lubrication. This section also suggests the frequency of service in typical unit use. The information provided in this table should be considered the maximum time between lubrication and service activities. Lubrication 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 and lubrication at regular intervals, service personnel are encouraged to establish and maintain a record of the lubrication and related work performed on the vehicle using the form following the Lubrication/ Service section as a guide. This type of record will assist in having the unit serviced, maintained, and lubricated on a regular basis. Further, it will provide assurance to operating personnel that the unit has been checked and lubricated and is ready for safe, reliable operation.

3. LEASING OR RENTING

When unit is to be used by personnel outside the direct control of the owner (i.e. rented or leased) it should be given a complete Maintenance/Service check before release and upon return, using the Maintenance Record as a guide. Additional provisions should be made to ensure that all recommended maintenance is performed while the machine is out of direct control of the owner.

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CHAPTER 2 SECTION 1

Page 2 11-06-2018

4. SCISSOR FRAMEWORK ACCESS

When checking, inspecting, or servicing scissors or components within the scissors framework the use of the scissors spreader IS essential for safety!

THE PURPOSE OF THE SCISSOR SPREADERS: The safety scissor spreader is provided with the unit to hold the scissor mechanism mechanically open so that checks, inspection, service, and maintenance of the scissor or it’s components can be safely made. LOCATION OF THE SPREADERS: The safety scissor spreader is located at rear of the vehicle on the upper scissor cross member. (Reference: Figure 2.) THE USE OF THE SPREADERS: 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, allowing the spreader to swivel into position between the cross members. Then lower the platform until the full weight of the scissor mechanism is borne and held by the spreader. WARNING: Never attempt to hold the scissors open during maintenance and service operations by hydraulic pressure, by blocking or other potentially hazardous means! Always use the scissors spreader during these operations, otherwise death or serious personal injury may result.

CAUTION: Lubricate the unit at specified intervals, after cleaning or after periods of long-term storage. Proper lubrication is essential for safety.

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CHAPTER 2 SECTION 1

Page 3 11-06-2018

Point of Lubrication Capacity/ Amount

Type

Engine Crankcase 14 quarts (13.2L)

Use API classification CF (See Engine Oil Chart in Ch5 Sect 3 Pg 25 for oils used at various temperature ranges)

Automatic Transmission 8.8 quarts (8.4L)

Automatic Transmission Fluid which meets Dexron R6 specification

Hydraulic Reservoir & System 20 gal (75.7L) MP ATF (Dexron R2 Equivalent or higher) LAL# R09011)

Brake Fluid Reservoir & System 1 quart (1L) Brake fluid which surpasses Fed. standard 116 and meets specs. W-B-680 & SAEJ1703

Axle - Rear “Drive” 5 quarts (4.7L) Quality 80W90 oil

Wheel Bearings As needed NLGI weight 2-2-1/2; Mobil #77 or #28 grease; Mo-Lith #2 (Fiske Bros.)

Engine Carriage Tubing, Cylinder Rod; Panel Hinges; Panel Latches; Brake Pedal Pivot Points; Front Seat Track; Cam Roller Tracks – Top & Bottom

As needed Quality petroleum multi-purpose spray lubricant

Fittings “Zerks” on Top and Bottom of Steering Knuckle; Leaf Spring Shackles; Scissor Shafts; Cam Rollers

Replace old material

Quality pressure applied grease containing lithium

FIGURE 1 Other engine specifications on page 1-3-1 and Ch 5

GREASE & OIL CHART (See Ch5) – Figure 1

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CHAPTER 2 SECTION 1

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APX20-LP Lube/Service Points Figure 2

12

7

18

3

1

2

6

20

15 10

16

10

17

SPREADER

12

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CHAPTER 2 SECTION 1

Page 5 11-06-2018

REAR

4

612

12

APX20-LP Lube/Service Points

FRONT

4

6

111

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CHAPTER 2 SECTION 1

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NO ITEM FREQUENCY1

ENGINE (See Ch 5 for more complete details) OIL: Check oil level on dip stick. Check for leaks.

Daily Inspection

OIL CHANGE: Allow engine to cool adequately. Drain oil from oil pan (drain plug). Unscrew oil filter (to avoid spillage- be prepared for filter’s release from engine). Add new filter and replace plug. Add oil and begin checking level on dipstick.

(First oil change 50 hours) Every 500 hours or (4) months

FUEL FILTER: Replace to ensure reliable operation.

Annually or 1000 hrs

AIR FILTER: Replace to ensure smooth engine operation.

Daily Inspection. Change as needed

BELTS: Check Fan and Alternator belts for tension. Deflection should equal 1/2 inch in one direction. Coat well with quality belt dressing to provide less squeaking and less slipping in wet conditions.

Every 400 hours or (4) months

BOLTS: (over entire engine) Check and tighten all bolts as required per Torque Specifications - Chapter 5, (Engine Service Manual).

Annually

LUBRICATION/ SERVICE CHART

SEE PAGE 3 FOR LUBRICANTS

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CHAPTER 2 SECTION 1

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NO ITEM FREQUENCY 2

BATTERY Check specific gravity. Clean battery with baking soda and water. Remove terminals, brush and re-apply protective battery grease. Battery is maintenance-free and does not need fluid.


3 VEHICLE - GENERAL LATCHES, HINGES, HOOKS: Spray lubricate latches and hinges and operate multiple times to distribute material. Remove excess to avoid contamination of clothing (etc.).


4 SUSPENSION Check security of mounting hardware. Add pressure grease to fittings on each shackle to fill cavity (4 places).


5 STEERING Check level of Steering Fluid. Check for leaks.


Keep cylinder mounting areas at rod end and butt end free of accumulated dirt and debris. Keep cylinder rod clear of dirt, paint, and contaminants. Check cylinder area at rod and ports for signs of leakage. Apply oil to cylinder rod surface.

Every 200 hours or every 2 months

Grease (King Pin) fittings at top (2.5 oz) and bottom (1 oz) of the steering knuckle to replace old material. Wipe away excess.

Every 300 hours or every 3 months


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NO ITEM FREQUENCY 6 BRAKES

Check brake fluid level. Check for leaks.

Daily Inspection

Use flashlight to check thickness of brake pads through sight hole (or at ends of caliper). See that the pads are of a safe thickness from end-to-end. Pads are bonded to their mountings and contain no rivets.


Remove 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, debris and other items to ensure firm footing.

Daily Inspection

8 LABELS AND PLACARDS (Reference the DRESS drawing) The labels and placards are standard safety equipment that must be kept clean and in-place.

Daily Inspection

9 HOSES AND FITTINGS Check all hoses for cracks, abrasions, and wear. Check fittings for wear or damage to connections.

Daily Inspection

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NO ITEM FREQUENCY 10 CONTROLS

Watch for vehicle control malfunction. Daily Inspection

Cycle check all controls to ensure they operate freely and without restriction. Check Emergency Controls.

Daily Inspection

11 TRANSMISSION (see Ch 5) Check fluid level.

Daily Inspection

Check security of linkage fasteners.

Annually

12 LIGHTS Obtain assistance in checking Headlights, Turn Signals, Running & Brake lights.

Daily Inspection

13 TIRES / WHEELS Check tire condition & pressure (135lbs)

Daily Inspection

Check Wheel Torque 325 ft-lbs

Monthly

09-19-2017

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NO ITEM FREQUENCY 14

HYDRAULIC SYSTEM FILLER-BREATHER: Ensure that cap remains in place.

Daily Inspection

Remove strainer basket and clean with solvent if necessary. Clean breather element by filling cap with solvent and dumping.


OIL LEVEL: Oil level should be kept within 1" of the top of the reservoir (or center of sight gauge). Note: This should be checked with the platform fully lowered.

Daily Inspection

RETURN LINE FILTER: Remove and replace with correct filter element.

Annually

SUCTION LINE STRAINER: Clean Strainer.

Annually

HYDRAULIC FLUID: Drain, (Via reservoir drain plug) flush and fill reservoir.

Annually


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NO ITEM FREQUENCY 15

SCISSORS RELATED MOUNTING CLEVISES: Check all clevises and collars for cracked welds and any other signs of overloading and abuse. Also check 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 for wear. A Retaining (snap) ring should be on the end of each shaft and should be free of damage.

Every 100 hours or every month and after cleaning or long term unit storage.

ROLLERS: Check condition of (2) Cam Rollers which travel along tracks on the base and (2) which travel along tracks at bottom of platform. Check roller tracks for debris.


TRAVERSING DECK: (optional) Check tracks and operation


16

STABILIZERS Keep cylinder mounting area at rod end and butt end free of accumulated dirt and debris. Keep cylinder rod clean and free of dirt, paint, and contaminants. Check cylinder area at rod and ports for signs of leakage.

Daily Inspection

Apply oil to cylinder rod surface.



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NO ITEM FREQUENCY 17 CYLINDER RELATED

Keep cylinder mounting areas at rod end and butt end free of accumulated dirt and debris. Keep Cylinder rod clear of dirt, paint, and contaminants. Check cylinder area at rod and ports for signs of leakage.

Daily Inspection

Apply oil to cylinder rod surface.


18

PLATFORM SURFACE The platform surface must be kept free of debris, oil, tools and other items that would inhibit firm footing.

Daily

19 PAINT AND APPEARANCE Through normal use, certain portions of the unit may need touch-up painting. Paint, in one gallon cans, and in aerosol spray cans, is available from Lift-A-Loft Corporation. WARNING: Check to ensure that all Warning, Caution, Capacity, and Information labels, placards and stickers are on the unit, and are clear and free of damage.

Periodically as needed

20 PLATFORM GUARD RAILS & PLATES See that guard rails are properly installed. Check guard rail mounts and pins for cracked welds.



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MAINTENANCE RECORD Model______________________ Date in Service___________________________ Unit Serial Number___________________________

LUBE/SERVICE ACTIVITY See Lube/ Service Chart for details

Performed

1 2 3 4 5 6 7 8 9 10 11 12

1 ENGINE OIL – Check

1 ENGINE COOLANT – Check

1 ENGINE AIR FILTER – Check

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 HOSES & FITTINGS – Check for damage or wear

10 CONTROLS Watch for malfunction & missing ID Plates.

10 CONTROLS – Check for proper operation

11 TRANSMISSION – Check fluid level, check for leaks

12 LIGHTS – Check all lights for proper operation.

13 TIRES – Check condition & pressure (135 lbs)

Performed by- Date of completion-

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MAINTENANCE RECORD

Model______________________ Date in Service___________________________ Unit Serial Number___________________________


LUBE/ SERVICE INTERVAL Months or Operating Hours

14a FILLER-BREATHER – Cap in place.

14c HYDRAULIC FLUID LEVEL Check level of fluid.

17 STABILIZERS Clean, check for damage & lube

17 CYLINDER RODS & MOUNTINGS – Clean & free of contaminants


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MAINTENANCE RECORD



Performed

1 2 3 4 5 6 7 8 9 10 11 12

13 WHEEL LUG TORQUE Check for 325 ft-lbs

15 SCISSOR MOUNTING CLEVISES – Check for 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. Lube

15 TRAVERSING PLATFORM (optional) – Check tracks and operation

16 STABILIZER CYLINDER – Lube cylinder rod surface

17 LIFT CYLINDER – Oil rod surface

20 PLATFORM GUARDRAILS & PLATES – Installed, no cracked welds


100

hrs

Mon

thly

09-19-2017

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CHAPTER 2 SECTION 1

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MAINTENANCE RECORD



Performed

1 2 3 4 5 6 7 8 9 10 11 12

1 ENGINE OIL CHANGE – DIESEL

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 places)

5 STEERING -Clean & oil cylinder rod

5 STEERING KING PINS – Clean & grease

5 STEERING KNUCKLE – Clean & grease

5 TIE ROD ENDS – Clean & grease

6 BRAKES – Check pads

14 HYDRAULIC SYSTEM – Remove & clean strainer basket


300

hrs

3 M

onth

s

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11-06-2018

MAINTENANCE RECORD


LUBE/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 11 121 ENGINE BOLTS – Torque per Ch 5 6 BRAKES Remove calipers and check pads for cracks

14 RETURN LINE FILTER: Remove and replace with correct filter element.

14 SUCTION LINE STRAINER: Clean Strainer.

14 HYDRAULIC FLUID: Drain, flush, and fill reservoir.

1 FUEL FILTER – Change

19 PAINT & APPEARANCE


As

Nee

ded

Ann

ually

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CHAPTER 2 SECTION 1

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CHAPTER 2 SECTION 2

Page 1 11-06-2018

TROUBLESHOOTING

1. GENERAL Regular lubrication and service, will significantly minimize the need for troubleshooting this unit; however, any piece of mechanical equipment in regular usage can malfunction. When troubleshooting this unit use the schematic drawings as well as chart information that follows. If factory assistance is then required, personnel familiar with the unit will be pleased to aid in the troubleshooting process. Trouble shooting the engine is covered in the engine section of Chapter 5.

2. TROUBLESHOOTING CHART

The troubleshooting chart (Figure 1) presented on the up-coming pages will help in diagnosing problems. Because of different working environments 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, and remedies.

NOTE: It is important to realize that whenever attempting to troubleshoot a unit,

symptoms may overlap with each other. Thus, it is best to check all of the possibilities associated with a symptom to be sure that the right components are being repaired or replaced.

• Whenever disconnecting a hydraulic hose to check for leakage from a valve or cylinder, always plug or cap hose to prevent excessive oil loss. Also, position a receptacle to catch the oil from the valve or cylinder port being observed.

• Whenever a troubleshooting or repair procedure causes oil to be lost from the

hydraulic system, remember to refill the system before operating the unit.

UNIT NOTES:

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CHAPTER 2 SECTION 2

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DEVICE ACTIVATION CHART

X – DEVICE ACTIVATED A - BELOW 8 FT ONLY B – ABOVE 2 FT ONLY C – BELOW 2 FT ONLY

UPPER CONTROLS

LOWER CONTROLS

EN

GIN

E R

UN

NIN

G

STAR

T

CO

MPR

ES

SO

R (o

pt)

PLA

TFO

RM

– R

AIS

E

PLA

TFO

RM

– L

OW

ER

STA

BIL

IZE

RS

– R

AIS

E

STA

BIL

IZE

RS

- LO

WER

TRA

VE

RS

E –

IN (o

pt)

TRA

VE

RS

E –

OU

T (o

pt)

PLA

TFO

RM

– R

AIS

E

PLA

TFO

RM

– L

OW

ER

STA

BIL

IZE

RS

– R

AIS

E

STA

BIL

IZE

RS

- LO

WER

TR

AV

ER

SE

– IN

(op

t) TR

AV

ER

SE

– O

UT

(opt

)

POWER RELAY X X X X X X X X X X X X X X XTRAVERSE-IN SOLENOID (opt) X X TRAVERSE-OUT SOLENOID (opt) X XPLATFORM SPEED LOWER SOLENOID (SOFT LOWER) B B

PLATFORM – LOWER SOLENOID (CYLINDER HOLDING VALVES) X X

PLATFORM – RAISE SOLENOID X X STABILIZERS RAISE SOLENOID C C STABILIZERS LOWER SOLENOID X X UNLOADING VALVE SOLENOID X X X X X X X X X X X X XIGNITION RELAY X X X X X X X X X X X X X X XFUEL RELAY X X X X X X X X X X X X XPLATFORM RETRACTED SWITCH (optional) A A

NEUTRAL SAFETY / PARKING BRAKE SWITCH ACTUATED X X X X X X X X X X X X X X

START RELAY X COMPRESSOR SOLENOID (opt) X

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DRIVE MIN 5%

INPUTS P15-1 ON

ELEV. TILT, SHUTDOWN1=LIFT&DRIVE

DIAGNOSTICS: INPUTS

SETUPS: TILT SETUPS

TS100 MENU: DIAGNOSTICS

TS100 MENU: ADJUSTMENTS

TS100 MENU: SETUPS

EVERTHING OK XXXXXXXXXXXXXXX

Press and hold “ESC” button for 5 – 10 seconds to enter

EZcal Mode

VEHICLE CONTROL SYSTEM

Diagnostic Center display located inside Lower Control Station at top right after opening enclosure.

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Vehicle Control System Overview:

The Lower Control Station enclosure contains the main vehicle system control board and the Master Diagnostic Center (along with the hydraulics). The Slave Control Board is located in the Upper Control Station enclosure and is connected to the Main Control System board by two (2) signal wires, while the Master Diagnostic Center uses four (4) signal wires. The Main Control System board uses inputs and outputs to control the various control functions of this unit. See the spreadsheet of inputs and outputs along with the notes of devices activated. Use these spreadsheets along with the wiring schematics and Master Diagnostic Center to diagnose problems.

Lower Control Station

Hydraulic Manifold

Master Diagnostic Center

Vehicle System Control Board

Red Light, Steady ON When Operational – Blinks When

Fault is Detected

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MASTER DIAGNOSTIC CENTER DISPLAY MODE:

With lower enclosure open, all Emergency Stop buttons in the out position, and the both engine switches in the ON position the display should read EVERYTHING OK if there are no problems. You can also check any function by activating a function and watching display show the function in progress. If a function fails because of an interlock, that interlock will also be displayed. (Example: trying to raise the platform without lowering stabilizers.)

MASTER DIAGNOSTIC CENTER DIAGNOSTIC MODE:

With lower enclosure open, all Emergency Stop buttons in the out position, and the both engine switches in the ON position, press and hold the ESC button for 5 – 10 seconds to enter the Menu.

• From the Menu screen scroll left or right to “Adjustments” to view setting enter by Lift-A-Loft for your unit. These cannot be changed without Lift-A-Loft help.

o Elevation: 8% (activates soft lower) o Stowed: 3% (platform down) o Height Max: 1% (stabilizers must be down before lifting platform) o Height Cab Guard: 25% (setting to allow platform traverse when 8 ft

level is reached & stop lower below 8 ft unless traversed in) o Other settings not used

• From the Menu screen scroll left or right to “Run System Test” to run a test of

the entire system (if desired). Press Enter to activate and check all devices connected to the Vehicle System Control Board. After the system test one of the key switches must be turned OFF the ON again to reset the Diagnostic Center.

• From the Menu screen you can also scroll left or right to “Diagnostics” and

press Enter to find the various Input and Output circuits. Using the GP400 and GP450 spreadsheets included in this section and the Wiring Diagram / Schematic each circuit can be defined and tested. The GP400 (lower enclosure) Input or Output circuits are listed first with the GP450 (upper control station enclosure) listed within the Input or Output menu.

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Example If Stabilizer Will Not Retract:

GP400 Lower Enclosure: (Lower Enclosure ENABLE must be held to test Lower Control station) • Test P6-4 (Output) Stabilizer Retract Coil & (NOTE: test p7-10 (Input) or pp3-

12 (Input) only when platform down coils) • Test P6-14 (Output) Stabilizer Raise Light & (NOTE: test p12-1 and p15-2

(Input)) • Test P7-10 (Output) Stabilizer Retract Switch GP450 Upper Enclosure: • Test PP3-12 (Input) Stabilizer Raise • Test PP4-2 (Output) Stabilizer Raised Light

(Also consider testing P5-12; P6-10; P6-13; P7-8; P8-14; P15-5; PP3-2; PP3-3; PP3-7; PP5-14; PP5-15)

When testing has found the problem circuit, start at the controller and work toward the device testing the wiring and wire connectors. Use wiring diagram / schematic for tracing wiring and connections.

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Lower Master Control GP400 I/O allocations

PINS OUTPUT / INPUT CIRCUIT CIRCUIT DESCRIPTIONP1-1 CAN1H P1-2 CAN1L P1-3 Shield P5-2 (opt) High side 2A output Trav out (platform extend) coil b+ when p7-7 or pp3-9 (see note e)P5-3 (opt) High side 2A output Trav in (platform retract) coil b+ when p7-8 or pp3-6P5-4 High side PWM output Platform lower coil b+ when p7-6 or pp3-5 (see note f)P5-5 High side 2A output Platform lower coil b+ when p7-6 or pp3-5 (see note f)P5-6 High side 2A output Platform raise (lift) coil b+ when p7-5 or pp3-4 (see note d)P5-9 High side 2A output Start output b+ when p15-4 or pp3-1 (see note k)P5-12 High side 2A output Ignition output b+ when p15-6 and pp5-2 (see note b & c)P5-14 High side 2A output Park brake light b+ when p15-5P6-1 High side 2A output Compressor coil b+ when pp3-7 (see note h)P6-2 High side 2A output Lower alarm b+ when p7-6 or pp3-5

P6-4 High side 2A output Stab retract coilb+ when p7-10 or pp3-12 (only when platform down)

P6-5 High side 2A output Stab extend coil b+ when p7-9 (see note z)P6-7 High side 2A output Soft lower coil b+ when p5-4 and p5-5 b+ (see note g)P6-8 High side 2A output Soft lower coil b+ when p5-4 and p5-5 b+ (see note g)P6-10 High side 2A output Unloader coil b+ during raise, traverse, stabilizers & compressorP6-13 High side 2A output Power relay supply b+ when p15-6P6-14 High side 2A output Stab raise light b+ when p15-1 and p15-2P6-15 High side 2A output Stab lower light b+ when p15-3P7-1 B+ Digital Input E stop (Valve supply) b+

P7-2 B+ Digital Input Ground select (Valve & Logic supply) b+ when lcs over ride button pushed

P7-4 B+ Digital Input Platform select Logic supply default mode (dash ign switch main on/off)P7-5 B+ Digital Input Platform raise (lift) sw b+ when pushedP7-6 B+ Digital Input Platform lower (lift down) sw b+ when pushedP7-7 (opt) B+ Digital Input Trav. Out (platform extend) sw b+ when pushedP7-8 (opt) B+ Digital Input Trav. In (platform retract) sw b+ when pushedP7-9 B+ Digital Input Stab. Ext sw b+ when pushedP7-10 B+ Digital Input Stab. Retract sw b+ when pushedP8-2 Safe Analog Input Ezfit output pin2 P8-13 GND Ezfit B- pin3 P8-14 GND Battery negative P12-1 CAN2H P12-2 CAN2L P12-3 Shield P15-1 B+ Digital Input Stab prox 1 sw (stowed) b+ when lh stab fully retracedP15-2 B+ Digital Input Stab prox 2 sw (stowed) b+ when rh stab fully retracedP15-3 B+ Digital Input Stab down press sw b+ when both stabs fully extendedP15-4 B+ Digital Input Start sw dash b+ when trying to startP15-5 B+ Digital Input Park brake sw b+ when park brake set (see note a & b)P15-6 B+ Digital Input Dash ignition sw b+ when when switch in ign positionP15-7 B+ Digital Input Trans in neutral sw b+ when transmission in neutral (see note a & b)P15-10 B+ protected Supply Ezfit supply pin1 Note: all lights to be cycled on at start up

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Upper Slave Control GP450 I/O allocations

PINS OUTPUT / INPUT CIRCUIT CIRCUIT DESCRIPTIONPP1-1 & PP2-1 CAN1H PP1-2 & PP2-2 CAN1L PP1-3 & PP2-3 Shield PP3-1 B+ Digital Input Start from key switch b+ when pushedPP3-2 (opt) B+ Digital Input platform retracted limit switch b+ when deck fully traversedPP3-3 B+ Digital Input Enable upper control b+ when pushedPP3-4 B+ Digital Input Pendant Platform raise b+ when pushedPP3-5 B+ Digital Input Pendant Platform lower b+ when pushedPP3-6 (opt) B+ Digital Input Pendant platform retract b+ when pushedPP3-7 B+ Digital Input Compressor on b+ when pushed (see note h)PP3-9 B+ Digital Input Pendant plat extend b+ when pushedPP3-10 B+ Digital Input Pendant enable b+ when pushedPP3-11 B+ Digital Input Stabilizer lower b+ when pushedPP3-12 B+ Digital Input Stabilizer raise b+ when pushed PP4-1 High side 2A output UCS light b+ when pp5-2PP4-2 High side 2A output Stab Raised light b+ when p15-1 and p15-2PP4-3 High side 2A output Stab lowered light b+ when p15-3

PP5-2 B+ Digital InputIgnition from Key switch (Valve & Logic supply b+ when switch in ignition position

PP5-13 CAN Terminator link connect to P5-15PP5-14 GND Battery negativePP5-15 CAN Terminator link connect to P5-13

Note a: b+ before any function allowed. Note b: if p15-1; p15-2 and pp3-14 are not b+ and either input removed then kill p5-12 Note c: if platform not stowed and p15-5 or p15-7 are not b+ then kill p5-12 Note d: allowed to raise to a set height before p15-3 b+ after that height p15-3 must be b+ (8ft) (max ht to raise without stabs down) Note e: no function until platform is above CABGUARD (with optional traverse function) Note f: function allowed until lowered to a set height (8ft) then if pp3-2 not b+ function to cease until deck is traversed in and pp3-2 is b+ Note g: b+ until deck lowered to a set height (1 to 2ft) then kill outputs Note h: kill p6-1 and flash pp4-4 when other functions are done (platform raise, lower, traverse or stabilizers) then when other function is done resume p6-1 if pp3-7 still on, also kill p6-1 and flash pp4-4 and kill p5-12 if inputs p15-5 or p15-7 are removed Note m: Pp3-14 b+ to allow p5-2 and / or p5-3 Note k: do not allow unless p15-5 and p15-7 set Note z: for stabilizer extend and retract we do not want the function to quit just because the stabilizer position switches get made. I need to keep the function going so I can build pressure to seat the locking valve. example: in current program when you raise the stabilizers and the retracted prox switches get made the function cuts out. Do not want that.

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Switches and Their Location

(Proximity Switch) STABILIZERS LIMIT SWITCH – Activated (Stabilizers raised) to allow unit to be driven.

PARKING BRAKE SAFETY SWITCH (on parking brake under unit) – Will not permit engine to be started or functions to operate unless parking brake is set.

PLATFORM TRAVERSE LIMIT SWITCH (under

platform) – Will not permit platform to lower beyond 8 ft ith t l tf f ll

PRESSURE SWITCH – Activated pressure switch (in hydraulic line at stabilizer) to allow lift.

NEUTRAL SAFETY SWITCH (on shifter) – Will not permit engine to be started or functions to operate unless transmission is in neutral.

SCISSOR ANGLE SENSOR 8 ft LIMIT Will not permit platform to traverse unless platform raised above 8 ft. (optional) PLATFORM LOWERED– Indicates to neutral safety switch and parking brake switch if the platform is completely lowered. Engine will die if attempts are made to drive unit without platform lowered. MAXIMUM HEIGHT– Stops raise at 20 ft.

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CHAPTER 2 SECTION 2

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SYMPTOM CAUSE REMEDY

1. ENGINE WILL NOT START (See Ch 5)

Starter Motor Failure If a firm "rap" to the starter housing (while the key is in “Start “ position) activates starter, then the armature is locking up or the solenoid is sticking, starter is going bad.

Won’t crank →

Starter Solenoid Failure (Chattering sound on occasional start-ups.)

Replace Device.

Battery discharged. Recharge or replace.

Vehicle not in neutral. Place in neutral

Parking Brake not set Set brake

Starter Relay defective. Check for voltage & ground at coil. Check continuity through coil. Correct wiring or replace device.

Starter wiring bad. Inspect and/ or replace.

Parking Brake or Neutral Safety Switch failed

Check and / or replace

Vehicle Controller Problem Check Input / Output from Vehicle Controller Ch2, Sec 2, Pg 3

TROUBLESHOOTING CHART FIGURE 1

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1. ENGINE WILL NOT START (See Ch 5)

Plugged fuel filter. Replace filter.

Will crank → Faulty fuel pump.

Replace.

Check all fuses in fuse box & lower enclosure.

Replace as needed.

Both Key Switches “ON”.

Turn to “ON”.

Injector pump stuck Refer to Ch 5 to repair or replace


2. ENGINE RUNNING POORLY Poor Idle →

Injector pump stuck

Refer to Ch 5 to repair or replace

Intake manifold leak. Test and replace gasket.

Check for cracks or warpage.

Contaminated or old fuel. Drain and replace.

Valve Train failure/ internal engine failure.

Refer to Chap. 5

Most Complete Engine Troubleshooting Guide in Chapter 5 Pro

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3. ENGINE DIES WHEN SHIFTED OR BRAKE RELEASED

Compressor in “ON” position

Move to “OFF”

Platform not retracted and fully lowered

Retract and lower

Stabilizers not fully raised

Fully raise stabilizers

Side decks not fully retracted

Retract

4. NO STEERING FUNCTION

Steering mechanism (i.e. tie rod) obstructed or damaged.

Inspect and remove obstruction. Replace damaged parts. Pump is running →

Clogged Filter or Filler- breather cap, collapsed or leaking hydraulic line or Fluid Shut Off Valve (handle) closed.

Change filter; Clean cap; Open valve. Reroute or replace hose.

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 bucket replace seals.

System Relief Valve set too low.

Access the Valve through Driver’s side engine tunnel cover. Place gauge at test port and maintain steering pressure value between 900-1100 psi. Adjust via set screw until vehicle steers easily with engine at idle and vehicle stationary.

Pump defective. Replace pump.

Dirt in Flow Valves Clean Valves

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5. TRANSMISSION SLOW OR ROUGH INITIAL

ENGAGEMENT

Improper oil level; Contaminated oil; Clutch/ Band problems; Filter clogged.

Refer to Chapter 5,

6. SLOW TO STOP Broken or 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. Refill fluid reservoir.

Water in brake area. Depress brakes lightly while moving to dry.

Low hydraulic pressure. Find cause and repair.

Metal-to-metal at the brake pad area .

Replace pads and check rotor.

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7. LOSS OF ALL CONTROLS and/or PUMP/MOTOR FUNCTION SPEED IS REDUCED

Engine/pump failure. Check engine/pump.

Repair/replace pump.

Hydraulic line failure. Replace hydraulic lines.

Hydraulic fluid level low. Fill reservoir with approved fluid.

Blown fuse. Replace fuse (in lower control panel.)

Control button malfunction. Use unit schematic and layout to locate device.

Solenoid failure (located on each lift cylinder, lower control station, & behind lower control station.)

Use unit schematic and layout to locate device, replace as necessary.

Electrical wire severed. Replace with equivalent wire.

Directional valve will not return to closed center position due to dirt or defective seals.

Remove, clean valve, replace seals if necessary. Reassemble and test. If problem continues, consider other causes or replace valve.

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8. UNIT CONTINUES T0 RESPOND TO A MOMENTARY ACTUATION OF A CONTROL BUTTON

Control button malfunction. Remove, clean, and test. Replace if necessary.

Directional valve will not return to center position due to dirt or defective seals.

Remove, clean valve, replace seals if necessary. Reassemble and test. If problem continues, consider other causes or replace valve.


9. PLATFORM WILL NOT MAINTAIN ELEVATED POSITION

Lift cylinder seal leaking slowly. Seal shrinkage after installation (Caused by chemically induced solvent action.)

Disconnect rod end hydraulic hose (cylinder tank return) from reservoir and hold end in bucket. Raise platform as high as possible. If oil streams out hose each time platform is fully raised, cylinder is leaking. Alt. Method: Raise platform 3/4 way and allow to set overnight. Raise platform completely and check return hose for more than minimal amounts of oil. Check each lift cylinder individually. Reconnect hose. Replace cylinder seals if defective.

Failure of static seal. Scored lip of seal due to passage of sharp particles under seal. Seal lip nicked or cut during installation. (If leak starts immediately after seal installation.)

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9. (Continued) Cylinder holding valve malfunctioning.

Disassemble and clean spool & check valve with solvent. Replace seals if necessary. Reassemble and test. If problem continues consider other causes or replace valve.

10. PLATFORM WILL NOT LOWER

Obstruction in scissor assembly or under platform.

Raise platform slightly and remove obstruction.

WARNING: Do not work under platform without scissor spreader in place.

"Lower" coils on cylinders will 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.

8 Feet limit switch engaged. Check deck traverse, side extensions, and stabilizers. If all are retracted check each switch and angle sensor and items related to angle sensor

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CHAPTER 2 SECTION 3

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REMOVAL AND INSTALLATION

1. GENERAL

This section contains procedures for the replacement of various parts. It is important that the procedures are followed closely and associated Warnings heeded for the safety of personnel. Before proceeding to service any part, read through the entire 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.

2. ENGINE/TRANSMISSION CARRIAGE: (Total task time - 45 min. average)

Removal: (Task time - 15 minutes average) Electrical Connections

(1) Disconnect the negative terminal from the battery and alternator bracket.

(2) Disconnect the positive terminal from the starter motor and alternator.

(3) Unplug the engine control unit quick disconnect located on the driver side engine compartment.

PRE-REMOVAL NOTE:

Before beginning, be sure to perform the following steps:

(1) Park on level ground and chock the wheels. (2) Make sure that the transmission is in neutral. (3) Set the parking brake. (4) Turn the APX-LP unit off. (5) Allow the engine to cool.

A LIST OF TOOLS IS PROVIDED IN FIGURE 1.

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Fluid Connections (1) Disconnect the fuel lines at the fuel filter.

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 reservoir valve at the tank (behind driver's seat.) Disconnect both hydraulic lines at the pump (driver's side of engine.)

Mechanical Connections

From Inside the Cab (1) Disconnect the parking brake cable.

(2) Disconnect transmission shift cable from transmission.

From Right Side of the APX20-LP (3) Disconnect the exhaust pipe at the header flange. Disconnect oxygen

sensor connections

From Under the APX20-LP (4) Disconnect the drive shaft from the transmission by removing the four

bolts in the companion flange.

(5) Remove the clamp securing the steering hoses to the engine carriage support channels (as applicable).

(6) Remove the engine carriage bolts.

Overhead Crane Method (or Similar device)

(1) Connect chains to the lifting eyes located on either side of the engine.

(2) Pull the engine forward until the mid point of the engine is past the engine cowling.

(3) Reattach the chains for lifting.

(4) Raise the engine up enough to ensure that the bell housing and oil pan

bolts do not catch on the APX-LP frame cross members. Make sure that the transmission coolant lines to not catch during removal.

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(5) Slide the engine carriage assembly forward until it is out of the APX-LP chassis.

Forklift Method

(1) Slowly, insert the forks under the engine carriage until carriage is fully supported.

(2) Pull the engine forward until the mid-point of engine is past the engine

cowling.

(3) Raise the engine up enough to ensure that the bell housing and oil pan bolts do not catch on the APX-LP frame cross members. 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-LP

chassis. Installation: (Task time - 30 minutes average)

Reverse the removal procedure and perform the following after completing all steps.

(1) If using an overhead crane, the engine carriage will need to be pushed in by some other means to complete installation. Push on the engine carriage frame to accomplish this.

(2) Start the engine and let it idle briefly. (Be sure to open gate valve on

hydraulic reservoir.)

(3) Activate the steering system by turning steering wheel back and forth several times.

(4) Crack open the hydraulic lines on the steering cylinders to bleed out any

air.

(5) Turn the engine off.

(6) Add oil to engine as needed.

(7) Add fluid to the steering reservoir as needed.

(8) Add transmission fluid as needed.

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Tool & Tool Placement for Engine Change Out Under Radiator 7/16 Hand Wrench Flat Blade Screwdriver 7/16 Crow Foot Wrench With Long Socket Adapter 7/16 Hand Wrench 1/2 Hand Wrench Driver Side Cab Floor 3/4 Hand Wrench 11/16 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 Socket Below Transmission Shifter Cable 9/16 End Wrench Needle Nose Pliers Below Exhaust/Drive Shaft Disconnect 9/16 Hand Wrench 5/8 Hand Wrench Ratchet Below Engine Carriage 1-1/8 Socket

Air Impact Driver or Long Extension on Ratchet Prope

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3. STEERING CYLINDER Removal:

(1) Disconnect battery.

(2) Disconnect hydraulic hoses from steering cylinder. Note position of hoses so they can be reinstalled correctly, thus avoiding broken or pinched hoses when unit is placed in service. Plug hoses and cylinder to keep dirt from entering hydraulic system.

(3) Remove 3/4” lock nut from rod and butt end bearing tangs of cylinder.

(4) Remove cylinder for repair or replacement.

Installation:

(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 wrench, unscrew head cap (locking ring) and

remove. (2) Pull rod out of cylinder tube, removing head at the same time. (3) Remove head from rod. (4) Cut piston seal and O-ring to remove from piston. (5) Roll new O-ring into piston groove and install new piston seal. (6) Remove all head seals, noting locations. (7) Install new head seals. (8) Coat rod and inside of head with automatic transmission fluid and slide

head onto rod, being careful not to damage seals.

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(9) Coat the inside of the open end of cylinder tube with automatic transmission fluid 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 pipe wrench.

5. RADIATOR

Removal: (1) After radiator has sufficiently cooled, open petcock at bottom of radiator

to drain the coolant.

(2) Disconnect both upper and lower hoses from the inlet and outlet.

(3) Disconnect the transmission coolant lines from transmission cooler.

(4) Remove the bolts securing the shroud to the radiator.

(5) Remove passenger side support at the radiator.

(6) Remove to bolts at bottom of radiator and lift radiator from unit.

Installation: (1) Reverse the above procedure. (2) Fill radiator with coolant (3) Start engine and let run briefly, checking coolant level until thermostat

opens. (4) Check radiator and add coolant as needed. (5) Repeat until radiator does not require coolant

6. SEAT

Removal: (1) Remove the four nuts on the underside of the wheel well below the seat.

(2) Lift the seat vertically to remove.

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Installation: (1) Reverse the above procedure.

7. BATTERY

Removal: (1) Disconnect battery cables. Be sure to remove the negative cable first.

(2) Remove the bolt securing the battery hold down to the fire wall and lift

the hold down 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. 8. VEHICLE WHEELS:

Removal: (1) Block the wheels of the axle from which the tire is not being removed.

(2) Elevate the axle such that the tire to be removed is off of the ground. (3) Remove the lug nuts. (4) Dismount the tire/wheel assembly from the axle hub.

Installation: (1) Reverse the above procedure. Be sure to torque each lug nut (325 ft-lbs

or 441 n-m) in a criss-cross pattern to assure even torque and wheel centering.

9. DRIVESHAFT

Removal: Fig 2 (1) Remove the four bolts (1) securing the

driveshaft (1) to the rear axle (2). (2) Remove the four bolts securing the

driveshaft to the companion flange on the transmission.

(3) Slide the rear section from carrier bearing.

1 2

Fig 2

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(4) Remove the two bolts (3) holding the carrier bearing (4) to the frame. NOTE: Support drive shaft as carrier bearing is removed.

(5) Remove the four bolts holding the front section of the drive shaft to the parking brake disk.

(6) Remove front section of the drive shaft.

Installation: (1) Reverse the above procedure.

(2) Be sure to use a thread locking compound when reinstalling the bolts.

10. DRIVE AXLE

Removal: (1) Elevate the unit by supporting either its frame rails or the front and rear

bumpers.

(2) Release the parking brake.

(3) Remove both rear wheels.

3

4

5 6 7

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(4) Disconnect the brake line at the fitting above the differential housing. (Fig 3 Item1).

(5) Disconnect the parking brake cable from the

brake by removing the bolt from the clevis.

(6) Disconnect the parking brake cable from its bracket at the rear axle by loosening the jam nuts. One of them will have to be removed at the clevis end so that the cable can be removed from the bracket.

(7) Remove the four bolts securing the driveshaft

to the axle companion flange. (See Driveshaft Removal) Do not allow the parking brake disk to fall. Insert cardboard wedges between the pads of the parking brake to prevent loss of the pads.

(8) Remove the bolts securing the shocks to the rear axle. (9) Support the rear axle. Remove the u-bolts. (10) Lower the rear axle and pull it out from under the vehicle.

Installation: (1) Reverse the above 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 cable from its mount on the shifter by removing the nut from the

cable’s swivel end fitting. Be sure to note and mark its location. (3) Remove the bolts securing the shifter unit to the dash panel. (4) Pull the shifter out from the front side of the dash.

Installation:

1

Fig 3

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(1) Reverse the above procedure. (2) Be sure to install the cable in the same hole from which it was removed. (3) Check transmission action before returning the vehicle to service.

12. ACCELERATOR CABLE AND PEDAL

Removal: (1) From underneath the vehicle, pull the boot back to expose the cable

attachment. (2) Loosen the jam nuts at the cable end and remove it from its mount. (3) From inside the cab, remove the bolts securing the pedal assembly to the

floor and lift it upward to remove.

Installation: (1) Reverse the above procedure. (2) Be sure to check the throttle cable adjustment before returning the vehicle

to service.

Note: Throttle pedal travel 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 or oxygen sensors

attached to that part. (2) Remove any bracket bolts if a mounting band is securing the part. (3) Twist the part to free the connection between it and the adjacent

components and remove.

Installation: (1) Reverse the above procedure as it applies to each component.

14. STEERING AXLE

Removal:

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Fig 5

1

Fig 6

1

(1) Elevate the APX20-LP by supporting either its frame rails or the front and rear bumpers.

(2) Remove both front wheels. (3) Disconnect the brake lines from the frame mounted bulkheads. (4) Disconnect both hydraulic hoses from the steering cylinder. (5) Remove the bolts securing the shocks to the front axle. (6) Support the front axle. Remove the bolts passing through the front leaf

spring eyes. (7) Remove the u-bolts. (8) Lower the front axle and pull it out from under the vehicle.

Installation:

(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 the

steering lock to lock and check the fluid level in the steering reservoir. 15. STEERING COLUMN

Removal: (1) Remove the horn button cover.

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(2) Remove the steering wheel.

(3) Remove the turn signal switch from the steering column. (4) Remove the horn wire from the clip on the steering column.

(5) Remove the thumb screws from the upper edge of the dash and lower it.

(6) Remove the hydraulic hoses from the back of the steering pump unit. (Fig

5 Item 1) Be careful not to spill hydraulic oil in the dash. (7) Remove the nuts from the studs on the front side of the dash (Fig 6 Item 1)

and remove the steering pump.

Installation: (1) Reverse the above procedure for installation.

(2) After allowing the engine to come to operating temperature, check the fluid

level in the steering reservoir. 16. MASTER CYLINDER/BOOSTER 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 fluid reservoir. (2)

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Note: Be ready to catch fluid from reservoir or block end of brake reservoir line.

(3) From inside the cab, remove the brake pedal return spring, the cotter pin, and clevis pin from the booster pushrod. Remove rubber boot (Fig 8 Item 4) from booster pushrod.

(4) Remove the four bolts securing

the master cylinder/booster assembly.

(5) Remove both hydraulic lines (Fig

7 Item 3) from booster being sure to mark their locations.

(6) From inside the driver’s side front compartment, tilt the master cylinder/booster assembly upward and slide forward to remove.

Installation:

(1) Reverse the above procedure. (2) Be sure to bleed the reservoir and each brake caliper. (See Ch 3, Sect 4) (3) Check for leaks and re-bleed as

necessary. 17. BRAKE PEDAL

Removal: (1) Remove 4 bolts (1) holding knee guard

(2) in position. (2) Remove the cotter pin and clevis pin

(3) from the master cylinder pushrod/pedal attachment.

(3) Remove 3 bolts from the brake pedal

mount (4). (4) Slide the pedal assembly out to remove.

4

1

3

Fig 8

2

Fig 7

12

3

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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 over tightened. 18. PARKING BRAKE

Removal: (1) Release the parking brake to remove tension in the cable. (2) From under the vehicle, remove the bolt that passes through the cable end

clevis and the parking brake actuator arm.

(3) 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 adjust to achieve proper

cable throw and tension before returning the vehicle to service. 19. GAUGES: ENGINE PARAMETERS DISPLAY

Removal: (1) Remove the two thumb screws from the dash panel and lower it.

(2) Unplug wiring from display.

(3) Remove the fasteners securing the display to the dash panel and pull the

gauge out from the front side of the dash.

Installation: (1) Reverse the above procedure: install display, plug unit into wiring, close

dash panel, and reinstall two thumb screws.

NOTE: Any part of the Vehicle controller that is replaced will necessitate reprogramming the unit.

20. SWITCHES: IGNITION, HEAD LIGHTS

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Removal: (1) Remove the two thumb screws from the dash panel and lower it. (2) Carefully disconnect the wires/contact block from the back side to the

switch to be removed and mark their location. (3) From the front side of the dash, remove the nut securing the switch to the

dash panel. On the ignition switch, remove the knob before the nut.

Installation: (1) Reverse the above procedure. (2) Be sure that the wires are correctly connected. Check the wiring prints if

necessary. 21. LED LIGHTS: HEAD LIGHTS, BRAKE, TURN, DRIVING, BACK-UP

Removal: (1) Head Lights: From inside the front compartments, disconnect the terminal

block from the back side of the head light lamp. From outside the vehicle, remove the screws securing the head light to the cab and pull the head light assembly from the opening.

(2) Brake/Turn/Driving Lights: Unplug the quick disconnect connector that is

behind the tail light assembly. From front of the light, remove the screws securing it to its mounting plate. Pull the light assembly out of its mount.

(3) Back-Up Lights: Unplug the quick disconnect connector that is behind the

back-up light assembly. From in front of the light, remove the screws securing it to its mounting plate. Pull the back-up light assembly out of its mount.

Installation:

(1) Reverse the above procedure. 22. BULB REPLACEMENT: HEAD LIGHT, STOP/TAIL/TURN, BACK-UP

Removal:

(1) Shifter: Remove the two screws securing the shifter position indicator plate from the front side of the shifter. Remove the bulb and replace.

Installation:

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(1) Reverse the above procedure. 23. SCISSOR CYLINDERS: Removal:

(1) Raise platform high enough to allow scissor spreader to be placed into position to support scissor assembly. (Refer to instructions on Chapter 2, Section 1, Page 2 and Figure 2 in Chapter 2, Section 1, Page 3 for instructions on the use of the scissor spreader.)

WARNING: Never attempt to hold the scissors open during maintenance operations by hydraulic pressure, by blocking or other potentially hazardous means! Always use the safety scissor spreader during these situations. Death or serious personal injury may result.

(2) Disconnect battery.

(3) Disconnect hydraulic 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 eliminating dirt from entering hydraulic system.)

(4) Disconnect electrical leads from holding valve. (5) Disconnect holding valve assembly and remove (to avoid damage to

holding valve.) (6) Place holding strap around upper end of cylinder to secure cylinder from

falling. (7) Remove socket-head cap screw nut and drive screw through clevis pin and

collar. (Remove top end first.) (8) Drive out upper cylinder clevis pin. Note location and quantity of washers

while removing pins. Assistance will be required when removing pins to hold and remove cylinder.

(9) Lower top end onto supports (wooden 2” X 4” or other.) Use hoist or other

device when lowering cylinder to avoid injury.

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(10) Remove lower socket-head cap screw nut and drive screw through clevis pin and collar.

(11) Drive out lower clevis pin. Note location and quantity of washers. (12) Remove and replace/repair cylinder.

Reinstallation:

(1) Install bottom cylinder clevis pin first. Assistance or a hoist will be required for positioning the cylinder. Align screw hole in pin with screw hole in collar, before reinserting. Replace any washer that was removed.

(2) Pull top of cylinder 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 hydraulic hose.

CAUTION: Do not over-tighten hydraulic fittings.

(5) Reconnect electrical leads. (6) Reconnect battery. (7) Raise platform slightly and remove scissors spreader and place in storage

position. (8) Check hydraulic fluid level now and at the end of step 6.

(9) Raise and lower platform several times and inspect seals and fittings for oil

leaks. (10) Bleed air from cylinders by loosening bleed screws located at the rod end

of each cylinder. Re-tighten when finished.

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24. STABILIZER CYLINDERS Removal:

(1) Disconnect hydraulic lines at ends of cylinder. (Inner access panel on

upper section of stabilizer housing.) (Plug hoses and ports.)

(2) Remove six 1/2-20 X1/2” hex head bolts and washers. (3) Stabilizer will now be free to be removed. (4) Remove stabilizer foot, if needed. (5) Take cylinder to workbench and repair or replace cylinder.

Reinstallation:

(1) Reinstall stabilizer foot. (2) Position cylinder and reinstall six mounting bolts with washers.

(3) Reinstall hydraulic lines.


(4) Check hydraulic fluid level now and at the end of step 6. (5) Raise and lower stabilizers several times and inspect seals and fittings for

oil leaks. (6) Remove vehicle from supports.

25. HYDRAULIC VALVES - General

Removal: (1) Clean hydraulic valves on manifold with solvent and brush before removing

hydraulic components to prevent system contamination. (2) Disconnect all lines and tag for later identification. (3) Remove mounting bolts. (4) Remove suspect valve and place in a clean container or on clean surface

for further inspection or disassembly.

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Reinstallation:


(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 for correct assembly.

NOTE: Remove all caps and port plugs before reconnecting hydraulic lines. (4) Tighten connections at hydraulic fittings. (5) Use Teflon paste for pipe thread-type connections. (6) Tighten manifold mounting bolts at this time.

26. CYLINDER SEALS - GENERAL: Disassembly & Reassembling:

(1) Using a pipe or spanner wrench, unscrew head cap (locking ring) and remove.

(2) Pull rod out of cylinder tube, removing head at the same time. (3) Remove head from rod. (4) Cut piston seal and O-ring to remove from piston. (5) Roll new O-ring into piston groove and install new piston seal. (6) Remove all head seals, noting locations. (7) Install new head seals. (8) Coat rod and inside of head with hydraulic oil and slide head onto rod,

being careful not to damage seals.

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(9) Coat the inside of the open end of cylinder tube with hydraulic oil 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) Disassemble valves one from the other.

Reinstallation:

(1) Connect valves together with the same connectors used when disassembling.

(2) Reattach to bracket. (3) Reconnect hydraulic lines to original ports. (4) Reconnect electrical connections to original positions. (5) Test for full function and leaks.

(1) Remove hydraulic lines from

hydraulic motor marking for re-assembly.

27. BRAKE PADS – REAR

Removal: (1) Remove wheels (procedure #8.)

(2) Remove bolt from top front of

caliper. (Fig 13, Item 1)

(3) Drive out retaining clip. (Fig 13, Item 2)

(4) Swing caliper forward and down,

releasing lower section of caliper from mount, and pull away from disc.

1 2

Figure 13 Rear Brake

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(5) Inspect rotor for damage or warping. If damage or warping is present, rotors

must be turned or replaced. (6) Inspect caliper pistons and cylinders for leakage around seals. If leakage is

present, replace seals or caliper assembly. Installation: (1) Use 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 which will prevent overflows. If the reservoir becomes full and threatens to overflow, remove some of the fluid and discard. (Never reuse brake fluid.)

(3) Install new brake pads with friction material facing the disc, making sure all

holding clips are in place.

(4) Slide brake caliper over the disc, starting the lower section into its locating groove.

(5) Rotate and place the upper caliper into position then slide the retaining clip

(Item 2) into place and replace bolt. Tighten bolt (Item 1) firmly.

(6) Bleed brakes at bleeding screw (Item 3.)

(7) Replace brake fluid in master cylinder with new fluid from a fresh 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. 28. BRAKE PADS – FRONT Removal:

(1) Remove wheels as in procedure #8.

(2) Remove allen bolt from holding clip (Fig 14, Item 1.)

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(3) Drive out retaining clip (Fig 14, Item 2.)

(4) Swing caliper away from

disc, releasing upper section of caliper from mount and pull away from disc.


(5) Remove old brake pads from caliper, noticing how pads are installed.

(6) Inspect rotor for damage or

warping. If damage or warping is present, rotors must be turned or replaced.

(7) Inspect caliper pistons and cylinders for leakage around seals. If leakage is

present, replace seals or caliper assembly.

Installation: (1) Use 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 which will prevent

overflows. If the reservoir becomes full and threatens to overflow, remove some of the fluid and discard. (Never reuse brake fluid.)

(3) Install new brake pads with friction material facing the disc, making sure all

holding clips are in place. (4) Slide brake caliper over the disc, starting the upper section into its locating

groove.

Front Brake

1 2

3

Figure14

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(5) Rotate and place the lower caliper into position then slide the retaining clip (Item 2) into place and replace bolt. Tighten bolt (Fig 14, Item 1) firmly.

(6) Bleed brakes at bleeding screw (Fig 14, Item 3.)

(7) Replace brake fluid in master cylinder with new fluid from a fresh 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.

29. TRAVERSING CYLINDER: (optional)

Removal: (1) Lift platform and insert scissor spreader. (2) Lower onto spreader to relieve pressure.

(3) Traverse platform slightly to relieve pressure on traversing cylinder. (4) Depress control station "EMERGENCY STOP" button to prevent accidental

movement of unit.

(5) Remove hydraulic lines attached to cylinder, marking for re-assembly.

(6) Remove cotter pins holding shoulder pins in place.

(7) With an assistant, remove shoulder pins holding cylinder in place to platform and carriage.

(8) Remove pins one at a time, supporting cylinder as pins are removed.

WARNING: Use caution when removing cylinder. An assistant will be needed to

support the cylinder to prevent injury.

Reinstallation: (1) Place end of cylinder in position to align pin. (2) Replace pin and swivel opposite end into position

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(3) Replace second pin and replace cotter pins in both ends. (4) Replace hydraulic fittings in marked location. (5) Pull "EMERGENCY STOP" button out. (6) Refill hydraulic system now and after cycling system to remove air

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REPAIR

1. GENERAL

This section contains general instructions for repair of components in the APX-LP. The need for repair is usually identified during normal and periodic servicing or operation of the vehicle. Normal service and operation of the unit will usually provide ample indication of impending component wear and malfunction. A. Engine/ Chassis (Refer to Chapter 5, Section 1 through Section 15 of this

manual) Refer to the Ford Owner’s Guide (Chapter 5) for specific information.

B. Transmission (Refer to Chapter 5) this manual.)

2. HYDRAULIC STEERING A. Replacement or repair of a hydraulic pump is needed when a pump makes

noise and careful inspection proves the system to not be low hydraulic fluid level or other starving type malfunctions. Careful analysis of the hydraulic oil on a periodic 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.

Most malfunctions of hydraulic components are related to contamination (dirt particles jamming or plugging the internal working elements of the component). Remove faulty component and clamp in a vise. Carefully disassemble the component and lay the parts, in order of disassembly, on a clean cloth. Examine each component part and the body for dirt, metal chips, scaring, cracks or breaks, and worn seals. Clean parts with a light spray solvent (oil base). Reject and replace parts if scored, binding, or otherwise non-repairable. Install new seals where old seals show wear, clean and reassemble parts which are otherwise not damaged. Contamination, especially metal chips, indicates that one or more hydraulic components such as the pump, hydraulic motor, or cylinder may be wearing out. Early repair of this condition will help prevent malfunction and further damage to other hydraulic components. Pro

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A. Steering, Lift, and Stabilizer Cylinders Cylinders should be inspected for external leaks, internal wear, and scored or rusty piston rods. Results will determine the need and extent of repairs. (See Chapter 2, Section 3 for removing and replacing seals etc.). Electrical solenoids for control valves and pressure relief valves are replaceable.

4. ELECTRICAL COMPONENTS

Control switches, circuit breakers, meter, and control valve solenoids are not normally considered to be repairable. The normal procedure is to remove and replace these components when defective. Wire terminals should be cleaned, inspected for signs of corrosion, and repaired as necessary.

Assembly Instructions for Quick Disconnect Fittings The purpose of this section is to assist you in 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 rear or wire side of the connector, the views shown are of the rear grommet.

Step by step instructions for crimping, inserting, and removing contacts are described below.

Contact Crimping

Strip 1/4" (6.3mm) insulation from wire. Raise selector knob and rotate until arrow is aligned with wire size to be crimped. Loosen lock nut, turn adjusting screw in until it stops.

Insert contact, turn adjusting screw counter-clockwise out until contact is flush with indentor cover. Tighten lock nut.

Insert wire in contact, contact must be centered between indicators, close handles until handles contact the stop. Release handles and remove crimped contact.

Inspect terminal to insure that all strands are in crimp barrel. NOTE: Tool must be readjusted for each type/size of contact.

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Contact Insertion NOTE: As a general rule, all square quick disconnect fittings will have an orange wedge lock inserted at this time. Place in correct alignment and push into connector grommet until a positive snap is felt.

Contact Removal:

NOTE: If orange wedge lock is in place (Square Connectors), the wedge lock must be removed. Using a small screwdriver, pry the orange wedge lock out of connector grommet.

Grasp the contact-wire assembly between the thumb and forefinger on the wire 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 fingers in the connector will snap behind the shoulder of the contact and lock it in place. A slight tug will confirm that it is properly sealed.

With rear insert toward you, snap the appropriate size plastic tool over the wire of the contact to be removed.

Slide the tool along the wire into the insert cavity until it engages the contact and resistance is felt. The contact retaining clip will be in the unlocked position.

Pull the contact-wire assembly out of the connector.

Figure 1 Figure 2

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5. BRAKE BOOSTER (See parts Breakdown Ch 4, Fig 18) Split the booster section from the master cylinder section by removing the three cap screws & lock washers holding the sections together. Disassembly: (1) Drain fluid from unit before disassembling. (2) Remove push rod (1) and boot (2) from

power assist section. (3) Loosen end plug (3) using a spanner wrench and remove internal parts

assembly (22) from housing (16). (4) Remove spring (15) and retainer (14) from internal parts assembly. (5) Remove end plug (3) from piston (8). Remove O-ring (4) from end plug.

Remove retaining ring (7), cup (6), and back up ring (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 must be taken when removing piston ring. (7) Remove retaining ring (13) from piston (8). CAUTION: Retaining ring is under

tension from spring (9). (8) Remove piston (12) from piston (8). Remove retaining ring (7), cup (6), and

back up ring (5) from bore of piston (12). Not all models use retaining ring (7). NOTE: Care must be taken so as not to scratch piston bore (12).

(9) Remove spring (9) from piston (8). (10) Remove cup (6) and back up ring (5) from housing (16). NOTE: Care must be

taken as not to scratch housing bore when removing cup and back up ring. (11) Remove plug (21) from housing (16) and remove O-ring (20) from plug (21). (12) Remove spring (19), shim(s) (18) and valve stem (17) from housing (16). Be

aware of the number of shim(s) (18) removed for reassembly purposes.

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Assembly: NOTE: Use only hydraulic oil in power assist section.

NOTE: Lubricate all rubber components from repair kit with clean type fluid

used in the system. (1) Clean all parts thoroughly before assembling. (2) Install valve stem (17), shim(s) (18), and spring (19) in housing (16). Install the

same number of shims (18) as were removed. NOTE: Valve stem must move freely in housing.

(3) Install new O-ring (20) on plug (21). Install plug (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) in end plug

(3). Not all models use retaining ring (7). Note direction of cup. (6) Install spring (9) on piston (8). (7) Install new back up ring (5), new cup (6), and new retaining ring (7) in piston

(12). Not all models use retaining ring (7). Note: Care must be taken not to mar the piston bore.

(8) Install piston (12) over spring (9) and piston (8). (9) Install new retaining ring (13) on piston (8). (10) Install new piston ring (11) on piston (10). Note: Care must be taken when

installing piston ring. (11) Install piston (10) on Piston (8). Note direction of piston (10). (12) Install new O-ring (4) on end plug (3). (13) Install end plug (3) on piston (8). (14) Install retainer (14) over piston (12) and install spring (15) over retainer (14).

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(15) Install entire internal parts assembly (22) into housing (16) bore. Use a spanner wrench to torque end plug to 30-40 lbs-ft (40-55 Nm).

(16) Install new boot (2) on end plug (3) and install push rod (1) into boot.

6. BRAKE MASTER CYLINDER (See parts Breakdown Ch 4, Fig 17) Split the booster section from the master cylinder section by removing the three cap screws & lock washers holding the sections together. (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 piston assembly (18) from housing. (5) Remove retaining ring (6), piston assembly (13), spring (14), and cups (15 &

17) from piston (16). (6) Remove retaining ring (12), cage (11), tapered spring (10), ball (9), and O-ring

(8) from piston (7). (7) Remove spring (19), retaining ring (20), and piston assembly (21) from housing.

Note: Be careful not to scratch or mar housing bore. (8) Use a wooden dowel to push assembly (22) out of large bore end of housing. (9) Remove retaining ring (28) from end of housing. (10) Remove two adapters (27), valves (25), and springs (24) from housing. Reassembly:

NOTE: Use only hydraulic oil in power assist section.

NOTE: Lubricate all rubber components from repair kit with clean type fluid used in the system.

(1) Clean all parts thoroughly before assembling.

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(2) Install new retaining ring (28) in flange end of housing (23). (3) Remove protective plastic cap from end of new piston assembly (22). (4) Install piston assembly (22) into large bore end of housing. Note direction of

piston assembly. (5) Install new piston assembly (21) in housing. Note direction of piston. (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) Install new O-ring (8), new ball (9), new tapered spring (10), new cage (11), and

new retaining ring (12) in piston (7). Note direction of cage and spring. (10) Install spring (14), piston assembly (13), and new retaining ring (6) in piston

(16). (11) Install piston assembly (18) and spring (5) in housing. Note direction of piston

assembly. (12) Install new seat (2) in new retainer (3) and install in end plug (1). Torque

retainer 12-14 lbs-ft (16-19Nm). (13) Install new O-ring (4) on end plug (1) and install end plug in housing. Torque

25-35 lbs-ft (34-47 Nm). (14) Install new O-rings (26) on new adapters (27). Install new springs (24), new

valves (25), and new adapters (27) in housing. Torque adapters 45-50 lbs-ft (61-68 Nm).

7. BRAKE BLEEDING PROCEDURES – PRESSURE BLEEDING

(1) Master cylinder must be mounted to power assist section.

(2) Fill reservoir with proper fluid.

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(3) Be certain all fittings are tight to avoid leaking. (4) DO NOT DEPRESS PEDAL. (5) Connect pressure bleeder into reservoir. Recommended bleeding pressure is

30 psi (2.07 bar) maximum. NOTE: Make sure to use correct pressure bleeder for type fluid used in system.

(6) Open bleeder screw closest to master 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 close the bleeder screw. (8) Remove pressure bleeder. (9) Open bleeder screw at master cylinder. Actuate cylinder to remove any

residual air. Tighten bleeder screw before permitting pedal to return. (10) Actuate pedal several times. If pedal is spongy, check for system leaks and

repeat bleeding process. (11) Fill reservoir to within 1/2" (13mm) of top. Install filler plug and torque 25-30

lbs-ft (34-41 Nm). 8. BRAKE BLEEDING PROCEDURES – BENCH BLEEDING

(1) This process can be done in a bench vise or on the vehicle with master cylinder mounted to power assist section.

(2) Remove master cylinder filler cap assembly. (3) Connect a length of tubing to an outlet port and immerse the other end below

the fluid level in the master cylinder reservoir. Keep reservoir fluid within 1/2" (13mm) of inside reservoir top.

(4) Actuate master cylinder piston with a smooth object, large enough to hold the

small internal piston from coming out. Slowly stroke and release master cylinder piston. See NOTE following. Repeat until air bubbles in reservoir have ceased.

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CHAPTER 2 SECTION 4

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NOTE: Care must be taken so as not to over stroke the cylinder. The cylinder does not incorporate a piston stop. Over stroking this cylinder may cause it to leak from push rod end of cylinder. Maximum recommended stroke for this cylinder is 1.25 inches (31.8mm).

(5) Remove tubing. 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 all plumbing connections before continuing to step 7.

(7) Bleed remaining air from system by depressing brake pedal and opening

bleeder fitting closest to master cylinder. Close bleeder fitting before brake pedal is released. Continue to next bleeder port. In all cases the bleeder fittings must be closed before the brake pedal is released or air will be pulled in through the bleeder and ingest unwanted air into the system.

(8) Fill reservoir to within 1/2" (13mm) of inside reservoir top. Install filler plug and

torque to 25-30 lbs-ft (34-41 Nm). (9) Be certain all fittings are tight to avoid any leaking. (10) Activate pedal several times. If brake pedal feels spongy, check for system

leaks and repeat bleeding process. 9. OTHER COMPONENTS

The following mechanical devices may be disassembled and repaired with available service parts by using the Detailed Parts List information in Chapter 4, Section 4 and in Chapter 5 (See also Chapter 4, Section 3 for parts listing.)

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10. ADJUSTMENTS A. Wheel Alignment

The camber (outward or inward wheel tilt at the top), and caster (steering axis rotation) angles of the axle assembly are permanent in nature and are non-adjustable form the axle manufacturer. The toe-in (wheels towing inward or outward) man be verified and set for proper tracking and handling. To adjust, position the wheels straight ahead and set the dimension from center-to-center of the tie rod end balls to 51-7/8". (Ref Illustration Chapter 5)

B. Transmission Shifter When reinstalling the shifter cable to the transmission (such as after removal and installation of the Ford Power Train 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.

C. Engine, Drive Train, & Related See Chapter 5 to locate the specific item in question.

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CHAPTER 3 OVERHAUL AND MAJOR REPAIR

Section Page OVERHAUL INFORMATION ...................................................................... 1 .................... 1

1. General ....................................................................................... 1 .................... 1 A. Engine/Transmission Carriage ........................................ 1 .................... 1 B. Engine Overhaul .............................................................. 1 .................... 1 C. Transmission Overhaul .................................................... 1 .................... 1

2. Special Tools .............................................................................. 1 .................... 1

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OVERHAUL INFORMATION

1. GENERAL Compliance with the recommended service, lubrication, inspection, and maintenance schedules should preclude the necessity for scheduling complete overhaul on the basis of hours of operation or years of service.

A. Engine/Transmission Carriage:

Remove carriage as shown in Chapter 2, Section 3, Page 1. The Engine - Transmission parts break-down in the Engine – Drive Train, Chapter 5, will assist in part recognition.

B. Engine: Refer to the Engine Service Manual beginning Chapter 5, Section 3,

Page 1 for engine reference.

C. Transmission: Refer to the Service Manual (Chapter 5, Section 5, Page 1) for transmission overhaul reference.

Note: Torque specifications for the Engine are located in Chapter 5, Section 4 and Transmission torque specifications are in Chapter 5, Section 5.

2. SPECIAL TOOLS

A. Engine: See Chapter 5, Section 3, Page 44 for special tools.

B. Transmission: See Chapter 5, Section 5, Page 75 for special tools.

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manual number apx20-lp110618 · 2019-07-17 · lift-a-loft apx20-lp diesel manual number...

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