Leyman TLS3510RL Hide-A-Way User manual

Installation Manual
TLS3510RL Hide-A-Way®
Trailer Side Gate
LEYMAN MANUFACTURING CORPORATION
10335 Wayne Avenue
Cincinnati, OH 45242
1-866-LEYMAN-1 •1-866-539-6261 •513-891-6210
Fax [phone]
www.leymanlift.com
[email protected]
LML00084-04/20/17

2
TABLE OF CONTENTS
General Terminology
3
Gen. Spec. –Min. Mounting Space Req.
4
Before you install the Lift Gate
5
Pre-Installation of the Lift Gate
6
Side Door Mounting Information
7
Out Stop Mounting and Floor Thickness
8
Installation of the Lift Gate
9 - 10
Toggle Switch or Walk Around Installation
11 –12
Charge Line
13
Grounding Recommendations
14
Wiring Diagrams –Circuit Breaker and
Additional Options
15 –16
Installation Adjustments
17
Installation of Safety Decals
18
Final Installation Inspection
19
Recommended Oils and Lubrication
20
Operating Instructions
21
Operating the Optional Emergency Hand Pump
22
Maintenance Minder 2
23 - 25
Electric / Hydraulic diagram - Reference
26
Troubleshooting Guide
27
Notes
28

3
GENERAL TERMINOLOGY

4
GENERAL SPECIFICATIONS
CUSTOMER:
_____________________________________________________
MODEL:
TLS3510RL
CAPACITY:
3500 lbs.
TYPE:
Trailer Side Door Lift Gate
HYDRAULIC
PRESSURE:
2500PSI –Up Function
800PSI –In/Out Function
OPERATION:
Power up/Gravity down
Power in/out
SERIAL #:
_____________________________________________________
MINIMUM MOUNTING SPACE REQUIREMENTS
MINIMUM SPACE REQUIREMENTS NEEDED TO INSTALL THE TLS3510 SERIES GATE.
PLATFORM WIDTH
DIM. X = 90
DIM. X = 78
DIM. X = 66
DIM. X = 60
DIM. X WIDTH REQ.
27 1/2
95 3/4
PLATFORM WIDTH
72
48
60
42

5
BEFORE YOU INSTALL THE LIFT GATE
1. Check the lift gate for shipping damage.
2. Remove the shipping bands, etc. if the gate was shipped vertically, set the gate on the ground.
CAUTION –DO NOT INSERT FORKLIFT FORKS AT BOTTOM OF GATE NEAR DOOR.
Remove the shipping bands, etc. To set lift gate horizontal, chain or lash top cross tube
near chain anchor
3. Remove the box, open and read the installation manual. Check that all major parts have
arrived, such as the electrical box, optional mud flap (if ordered), etc.
4. Inspect the area under the trailer where the lift gate is to be mounted. Be sure the area is clear
of obstructions where the lift gate will be installed. Check the cross member material. If the
cross members are made of aluminum, the aluminum conversion kit (Option #133TLS) must
be ordered and used to mount the lift gate.
5. The use of a battery charger as the sole power source to operate the lift gate is unauthorized
and will prevent the lift gate from working properly. The lift gate must always be operated in
conjunction with at least one (1) 12 volt heavy duty lift gate battery. A minimum of 9.5 volts
must be maintained in order for the DOWN valve and 10.5 volts for the IN/OUT valves to
operate.
6. Read the following pages prior to beginning the installation.
A. Minimum mounting space requirements
B. Pre-installation of the lift gate.
C. Side door mounting information.
D. Installation of the lift gate.
E. Installation adjustments.

6
PRE-INSTALLATION OF THE LIFT GATE
1. Measure from the bottom of the cross members to the ground. If this measurement is less than
47 inches, spacers will not be required. This measurement must be 41.5 inches minimum in
order to yield 14 inches ground clearance for the gate. If the measurement is more than 47
inches, the amount in excess of 47 inches is the height of the spacer that must be added to the
four channels at the top of the Outer Slide. See Sketches 1 and 2.
2. Check the side door threshold. See Sketch 3. For the platform to properly enter the opening,
dimension “B” must be at least 1.5 times dimension “A”.

7
SIDE DOOR MOUNTING INFORMATION
Installation of Leyman side gates that are 42” wide are usually centered on the door opening
providing that the door opening is at least 42” wide.
For installation of Leyman side gates that are wider than the door opening, we recommend the gate
be offset to the rear of the trailer so when the door is open, it will not interfere with movement of the
platform.
Depending on the side door threshold, the platform may not fill the gap between the floor and the
platform. There are three options to correct this:
1. Notch the tip of the platform.
2. Add material to the tip of the platform (use a minimum thickness of 3/16” for proper
strength.)
3. Fabricate a flip plate to span the gap.
NOTE: End user option, material is not provided by Leyman.
MOUNTING ON “J” CHANNELS
NOTE: FILLER MATERIAL NOT SUPPLIED BY LEYMAN
NOTE: Mounting to aluminum cross members will require the use of kit #133TLS.

8
OUT STOP MOUNTING AND FLOOR THICKNESS
Determine the total floor thickness (vertical distance between the bottom of the cross-members
and the top of the floor inside the trailer). If that dimension is 10-1/2” or less, leave the Out Stops
mounted in the standard position. Mount Outer Slide rail face (fixed rail) flush with the rub rail.
If the total floor thickness dimension is larger than 10-1/2”, the Out Stops must be flipped around
as shown in the bottom half of the sketch below. In this case, the set screws in the Out Stops are
reversed as well. CAUTION! Out Stops must be adjusted so that Front Chain Anchor does not
strike Chain Cover Box.

9
INSTALLATION OF THE LIFT GATE
1. Mark the door opening on the vertical rub rail.
•For the 42” wide gate, mark the centerline of the door opening. For all others, mark the
leading edge of the door opening.
•NOTE: The centerline of the 42” wide gate is the center of the chain. Mark the centerline
on the channel. For all others mark the leading edge of the platform on the channel.
2. Raise the lift gate, use a lift truck. See the sketch below. Position the forks under the
spreaders (the four (4) three inch channels). Spread the forks as wide as possible.
CAUTION: Do not hit anything with the forks. Clamp the unit to the forks using two (2) “C”
clamps.
3. Pick the unit up, position it under the trailer. Line up the marks, which you put on the gate and
the rub rail. The front edge of the gate’s Outer Slide should be flush to the outside of the rub
rail. Weld the four (4) corners to the cross members.
4. Mount the electrical box. See the wiring drawings for location information. Drawings are
labeled “Toggle Switch Electrics or Walk-Around Electrics”. Finish wiring.
5. Install at least two (2) heavy-duty Dual Purpose or AGM batteries. Place rubber battery pads
under batteries. See sketch.

10
INSTALLATION OF THE LIFT GATE (cont.)
6. Fill oil tank using a recommended hydraulic oil, and install breather cap. Oil level should be 1”
from top of tank with platform on ground.
7. With switches, lift the gate upward, lift up on the auto lock handle. Drop the platform down six
inches. Run the gate outward. Lift the platform up to the door threshold. Check for the fit to
the door opening. Alter or adjust as needed. See the Installation Adjustments page for correct
order and steps.
CAUTION: Do not ride on the gate yet, when only partially welded.
8. Complete welding. Weld all channels along both sides to all trailer cross members.
9. Install charge line.
10. Install any other options.
11. Make any final adjustments if needed.
12. Touch-up any paint wherever necessary. Follow instructions on Extreme Shield Touch-Up
paint kit. All paint in the heat affected zone (weld area) must be removed and re-painted.
13. Install the safety decals. Reference page 18 for general placement.
14. Perform a Final Installation Inspection. Reference page 19.

11
TOGGLE SWITCH ELECTRICS - INSTALLATION
OPTION #182TLS

12
WALK AROUND ELECTRICS - INSTALLATION
OPTION #183TLS-DEUTSCH

13
CHARGE LINE
When installing the charge line, be sure the cable goes through three (3) “I” beams at the very least,
past the fifth wheel plate and the clear vinyl loom. Mount the remaining cable with loom clamps and
self tapping screws to the “I” beams.
Loom Clamp
Run the power line wire with wiring harness on lift gate.
The plug that is on the tractor must have a hot wire and ground wire to the lug that plugs into the
trailer.
USE “0” GAUGE CABLE AT MINIMUM
WE RECOMMEND THAT YOU USE AT
LEAST A 90 AMP ALTERNATOR ON THE
TRACTOR TO RECHARGE THE
BATTERIES ON THE TLS®.

14
GROUNDING RECOMMENDATIONS
FOR TRACTOR/TRAILER USING THE
MAINTENANCE MINDER 2® CONTROLLER
The Maintenance Minder2® requires a minimum of 10 volts in order for the TLS to operate.
Utilization of a single positive cable does not provide sufficient ground. Therefore, our
recommendation for grounding tractor/trailers with a TLS gate are as follows:
Two (2) cables, one (1) positive and one (1) negative, both running to the tractor batteries.
The Maintenance Minder 2® Controller requires that a minimum of 8 volts be maintained under load
in order for the TLS to operate.
NOTE:
The use of a battery charger as the sole power source to operate a TLS is unauthorized and will
prevent the TLS from working properly. The lift gate must always be operated in conjunction with at
least one (1) 12 volt heavy duty lift gate battery. A minimum of 9.5 volts must be maintained in order
for the DOWN valve and 10.5 volts for the IN/OUT valves to operate.

15
CIRCUIT BREAKER WIRING DIAGRAM

16
OPTION #155TLS LIGHTS AND SENSOR
ELECTRICAL CONNECTIONS
CONNECTION-USE LARGE
BUTT CONNECTOR
FOUR WIRES
FLASHER
BASE
P46483
TELEMECANIQUE XS630B1PBL2
OMRON E2A-M30LS15-WP-B2 2M
BALLUFF BES 516-3028-G-E4-Y-03
PEPPERL-FUCHS NBB15-30GM50-E3-M OR NBB15-30GM30-E3
BROWN + HOT
BLUE
BLACK
CONNECTION-USE LARGE
BUTT CONNECTOR
FOUR WIRES
FROM LIGHT
HARNESS ASSY
(AMBER LIGHTS)
TWO HARNESSES
FROM LIGHT AT FRONT OF
TRAILER (AMBER LIGHT.)
AMBER LIGHT (P46493) MUST
BE CONNECTED FOR COMPLETE
CIRCUIT TO FUNCTION PROPERLY.
WHITE
BLACK
BLACK
SENSOR OUTPUT TYPE PNP
(PREFERRED)
ELECTRICAL CONNECTIONS
PROXIMITY SENSOR
P46478
FROM LIGHT AT FRONT OF
TRAILER (AMBER LIGHT.)
AMBER LIGHT (P46493) MUST
BE CONNECTED FOR COMPLETE
CIRCUIT TO FUNCTION PROPERLY.
FROM LIGHT
HARNESS ASSY
(AMBER LIGHTS)
TWO HARNESSES
WHITE
BLACK
RELAY
P46487
CONNECTION-USE LARGE
BUTT CONNECTOR
FOUR WIRES
CENTER WIRE NOT USED
FLASHER
BASE
P46483
FLASHER
P46482
GROUND
WHITE
BLACK FROM PLATFORM
LIGHT ASSYS
(CLEAR LIGHTS)
TWO HARNESSES
ONE EA SIDE OF
PLATFORM
85
GROUND
86
87
87A
30
CENTER WIRE NOT USED
GROUND
WHITE
BLACK
20 AMP
CIRCUIT BREAKER
P46236
FROM PLATFORM
LIGHT ASSYS
(CLEAR LIGHTS)
TWO HARNESSES
ONE EA SIDE OF
PLATFORM
OMRON E2E-X18ME2 28703
TELEMECANIQUE XS2 M30NB370
BLACK
BLUE
BROWN + HOT
SENSOR OUTPUT TYPE: NPN
ELECTRICAL CONNECTIONS
PROXIMITY SENSOR
P46478
CONNECTION-USE LARGE
BUTT CONNECTOR
FOUR WIRES
BLACK
85
FLASHER
P46482
GROUND
RELAY
P46487
86
30
87A
87
20 AMP
CIRCUIT BREAKER
P46236
TO BATTERY + POST
TO BATTERY + POST

17
INSTALLATION ADJUSTMENTS
FLOOR
CROSS BEAMS
1/4 TO 1/2
STRAIGHT EDGE
SIDE DOOR THRESHOLD
OUT STOP ADJ
UP STOP ADJ IN STOP ADJ
PLATFORM TILT ADJ
AUTO LOCK AREA
1/4 LOCK PIN ON
PLATFORM
AUTO LOCK AREA
Step 1: The platform was preset at the factory to be level to the floor of the trailer within ¼”.
With a straight edge, check this. If it is okay, proceed to step 2. If not, let the platform
down to the ground. Remove the two (2) roll pins and the top tension arm pivot pins
(one on each side).
NOTE: One full turn moves the tip of the platform ¼” (turn the end in, this moves the tip
of the platform up, unscrewing moves the tip of the platform down.)
Make necessary adjustments. Replace pins, raise the platform up and check. Repeat if
necessary. Replace roll pins.
NOTE: Each side must be adjusted the same amount.
CAUTION: If this adjustment has been made, the in-stop must be adjusted to provide
the ¼” clearance with the auto locking pin (see sketch 2).
Step 2: Adjust the up stops. Platform should be even with the floor of the trailer. After adjusting,
tack weld the stops in place.
Step 3: Adjust the out stops. The tip of the platform should be ¼” to ½” from the edge of the
threshold.
Step 4: Adjust the in stops. See sketch 2 and adjust for the ¼” dimension.
SKETCH 2

18
INSTALLATION OF SAFETY DECALS
Apply decals in a prominent and easy-to-read location.
P55221
P55157 P55294 P55236 P55211
P55222 P55138 (on rub rail of trailer)
Leyman Manufacturing will replace safety stickers at any time FREE OF CHARGE.

19
FINAL INSTALLATION INSPECTION
CUSTOMER:
LOCATION:
VEHICLE#:
LIFT GATE MODEL#:
LIFT GATE SERIAL#:
= OK N = NOT APPLICABLE
WELDING/ADJUSTMENTS
Gate is welded secure to bottom of cross members
Up stops are adjusted (to set platform flush with floor of trailer) and tack welded to compression arm
Out stops adjusted (the platform should be ¼” to ½” from the edge of the threshold)
In stops adjusted (the auto lock pin should be ¼” gap from hook)
ELECTRIC’S
Check that battery holds downs are anchored securely
Check batteries for proper charge level.
Check all wiring connections for tightness (batteries, switches, etc.) and sealer has been applied.
Inspect and check all circuit breakers
Charge line/power line (through cross members with rubber grommets if this is the preferred method)
Charge line/power line (clamped to bottom of cross members with loom clamps)
Control wiring has been properly routed and secured
Check operation of toggle switches (or walk around if equipped)
Check operation of optional lights if equipped
HYDRAULIC/GREASE
Check reservoir for correct amount of fluid. Fluid level should be within 1” of the top of the tank.
Platform should be down on the ground when checking fluid level.
Refer to the Recommended hydraulic oil / lubrication page for type of oil and capacity.
Check hydraulic hoses and fittings for leaks
Check hydraulic cylinders for leaks
OPERATION OF GATE
Raise and lower lift gate. Observe for correct operation
Operate lift gate in-out. Observe for correct operation
PAINTING AND SAFETY STICKERS
Repaint where needed. Use Leyman Extreme Shield® touch-up kit provided.
Check hydraulic cylinder rods for over spray
Install all safety and operation stickers
SERVICED BY: _____________________________________________________________ DATE: ________________________________

20
RECOMMENDED HYDRAULIC OILS/LUBRICATION
HYDRAULIC OILS
Manufacturer
Type
Temp. Range
Level 1 Normal Conditions
Mobile
DTE 11
-15F to + 150F
Industry standard ISO-15
Shell
TELLUS-T15
-15F to + 150F
Chevron
RYKON ISO-15
-15F to + 150F
Level 2 Cold Conditions
Mobile
AERO-HFA
-50F to + 80F
Shell
AERO FLUID#4
-50F to + 80F
Chevron
AVIATION-A
-50F to + 80F
Mil
H-5606
-50F to + 80F
HYDRAULIC TANK CAPACITY
2 ½ gallons
LUBRICATION
Cam Rollers, Idler Sprockets,
Auto-Lock shaft, cylinder ends, if
grease fittings provided
Level 1 Normal Conditions NLGI #2
Level 2 Cold Conditions NLGI #1
NO CHASSIS or 5th WHEEL GR.
Grease –Lithium base
BATTERIES
Two (2) 12-Volt DC Group 31 Heavy-Duty Dual Purpose or AGM
ELECTRICAL COMPONENTS CONNECTIONS
Use Fluid Film Rust & Corrosion Protection by Eureka, except on Start Solenoid
On Start Solenoid, use Color Guard by Loctite, or Liquid Electrical Tape
AMPERAGE DRAW OF MOTOR
When raising platform (empty) approximately 115 AMPS @ 13.5 volts.
At bypass approximately 235 AMPS @ 13.5 volts
LIFTING PRESSURE SETTING
With platform at floor level and pump in bypass 2500 PSI
IN-OUT PRESSURE SETTING
When sliding gate in-out and pump in bypass 800 PSI
MINIMUM VEHICLE FLOOR HEIGHT LADEN
With any size of platform –vehicle floor height 48”
MAXIMUM VEHICLE FLOOR HEIGHT UNLADEN
With any size of platform –vehicle floor height 58”
APPROXIMATE TIMES EMPTY AT 80F WITH 2 GROUP 31 BATTERIES
Time up: 14 –18 seconds
Time down(gravity down): 12 –16 seconds