LIFT-A-LOFT APX16 Guide

LIFT-A-LOFT APX16 - GASOLINE
MANUAL NUMBER APX16092602
EFFECTIVITY: 09/26/02
G
GA AS SO OL LI IN NE E P PO OW WE ER RE ED D
S
Sc ci is ss so or r L Li if ft t V Ve eh hi ic cl le e
APX16-1036S thru APX16-1037S
REV 00
LIFT-A-LOFT CORPORATION
9501 SOUTH CENTER ROAD MUNCIE, IN 47302-9443
P.O. BOX 2645 MUNCIE, IN 47307-0645
Phone Number [phone]
Fax Number [phone]
A
A
P
P
X
X
1
1
6
6
Property of American Airlines
Maintenance

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
CONTENTS
Page 1
09-26-02
MAINTENANCE
CHAPTER 2
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
Purpose of Scissor Spreaders............................................... 1 ...................2
Location of the Spreaders...................................................... 1 ...................2
Use of the Spreaders............................................................. 1 ...................2
Grease & Oil Products Chart (Fig 1)......................................................... 1 ...................3
Lube/Service Points (Fig 2)....................................................................... 1 ...................4
Lube/Service Chart.................................................................................... 1 ...................6
(1) Engine....................................................................................... 1 ...................6
(2) Battery ...................................................................................... 1 ...................8
(3) Vehicle General ........................................................................ 1 ...................8
(4) Suspension............................................................................... 1 ...................8
(5) Steering .................................................................................... 1 ...................8
(6) Brakes....................................................................................... 1 ...................9
(7) Vehicle Flooring & Steps........................................................... 1 ...................9
(8) Labels & Placards..................................................................... 1 ...................9
(9) Hoses & Fittings........................................................................ 1 ...................9
(10) Controls .................................................................................... 1 .................10
(11) Transmission ............................................................................ 1 .................10
(12) Lights........................................................................................ 1 .................10
(13) Tires.......................................................................................... 1 .................10
(14) Hydraulic System...................................................................... 1 ................ 10
(15) Scissor Related......................................................................... 1 ................ 11
(16) Stabilizers ................................................................................. 1 ................ 12
(17) Cylinder Related ....................................................................... 1 ................ 12
(18) Platform Surface....................................................................... 1 ................ 12
(19) Paint & Appearance.................................................................. 1 ................ 12
(20) Platform & Guardrails................................................................ 1 ................ 12
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LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
CONTENTS
Page 2
09-26-02
CHAPTER 2 - Continued
(21) (Opt) Oiler Filter System........................................................... 1 ................ 13
(22) (Opt) Compressor .................................................................... 1 ................ 13
MAINTENANCE RECORDS...................................................................... 1 .................14
TROUBLESHOOTING............................................................................... 2 ..................1
1. General.............................................................................................. 2 ..................1
Device Activation Chart.................................................................... 2 ...................2
Limit Switches & Their Location ....................................................... 2 ...................3
TROUBLESHOOTING CHART................................................................... 2 ...................4
REMOVAL/ INSTALLATION...................................................................... 3 ..................1
1. General............................................................................................. 3 ..................1
Hydraulic (O-Ring) Fitting Torque Chart................................ 3 ...................1
Hex Head Bolt & Nut Torque Chart........................................ 3 ...................2
2. Engine/ Transmission Carriage......................................................... 3 ..................3
3. Cylinder- Steering............................................................................. 3 ..................7
4. Cylinder Seals................................................................................... 3 ..................7
5. Radiator............................................................................................ 3 ..................8
6. Seat ................................................................................................. 3 ..................9
7. Battery .............................................................................................. 3 ..................9
8. Vehicle Wheels................................................................................. 3 ..................9
9. Drive Shaft........................................................................................ 3 ................10
10. Drive Axle ......................................................................................... 3 ................10
11. Shifter ............................................................................................... 3 ................11
12. Accelerator Cable and Pedal............................................................ 3 ................12
13. Exhaust System................................................................................ 3 ................12
14. Steer Axle......................................................................................... 3 ................12
15. Steering Column............................................................................... 3 ................13
16. Master Cylinder/Booster Assembly................................................... 3 ................14
17. Brake Pedal...................................................................................... 3 ................15
18. Parking Brake, Cable, and Lever...................................................... 3 ................15
19. Alternator/Voltage Regulator............................................................. 3 ................16
20. Gauges ............................................................................................ 3 ................17
21. Switches ........................................................................................... 3 ................17
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LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
CONTENTS
Page 3
09-26-02
Chapter 2 – Continued
22. Lights................................................................................................ 3 ................18
23. Bulbs................................................................................................. 3 ................18
24. Scissor Cylinders.............................................................................. 3 .................19
25. Stabilizer Cylinder............................................................................. 3 .................21
26. Hydraulic Valves – General .............................................................. 3 .................22
27. Cylinder Seals – General.................................................................. 3 ................ 22
28. Hydraulic Motor for Compressor (Opt.)............................................. 3 .................23
29. Compressor (Opt.)............................................................................ 3 ................ 25
30. Turbine Oil Pump/Motor Assy (Opt.)................................................. 3 ................ 25
31. Brake Pads – Rear ........................................................................... 3 .................26
32. Brake Pads – Front........................................................................... 3 .................28
33. Traversing Cylinder (Opt.)................................................................. 3 .................30
REPAIR ..................................................................................................... 4 ..................1
1. General............................................................................................. 4 ..................1
2. Hydraulic Steering, Turbine Oil Pump/Motor, or Compressor Sys.... 4 ...................1
3. 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
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LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
CONTENTS
Page 4
09-26-02
WARNINGS: AND CAUTIONS:
APPEARING IN THIS CHAPTER
WARNING & CAUTION SECTION PAGE
WARNING: 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: Do not work under platform without scissor
spreader in place. 2 10
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 3
CAUTION: Do not forget to close petcock at bottom of
radiator. 3 8
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LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
CONTENTS
Page 5/6
09-26-02
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 19
CAUTION: Do not over-tighten hydraulic fittings 3 20, 21, 22
WARNING: Vehicle must be fully supported before working
under unit. 3 21
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 27, 29
WARNING: Use caution when removing cylinder. An assistant
will be needed to support the cylinder to prevent
injury. 3 30
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LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
CONTENTS
09-26-02
THIS PAGE
LEFT
BLANK
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 1
09-26-02
SERVICING
1. GENERAL
This chapter outlines the information required for performing the basic maintenance,
lubrication, and service of the APX16 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.
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 2
09-26-02
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 its components can be safely made.
LOCATION OF THE SPREADERS: The safety scissor spreader is located at rear of the
vehicle on the upper scissor crossmember. (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 crossmembers. 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.
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 3
09-26-02
Point of Lubrication Capacity/
Amount Type
Gasoline Engine Crankcase 7 quarts*
(6.6 L)
*when
replacing filter
canister
Use Motorcraft oil or equivalent that meets
Ford spec. ESE-M2C153-E and API category
SG or SH. 10W-30 viscosity for temps -10
o
F
to 90
o
F. (See Chapter 5-Ford Service
Manual for oils used in other temperatures)
Gasoline Engine Coolant 17 quarts (16L) Quality ethelene glycol based fluid 50/50 mix.
Automatic Transmission 12 quarts
(11.4L) Automatic Transmission Fluid which meets Dexron R2 specification
Hydraulic Reservoir & System 15 gal (57L) Dexron R2
Brake Fluid Reservoir & System 1 quart (1L) Brake fluid that surpasses Fed. standard 116
and meets specs. W-B-680 & SAEJ1703
Axle - Rear “Drive” 5 quarts (4.7L) Any quality 80W90 oil
Wheel Bearings As needed NLGI weight 2-2-1/2; Mobil #77 or #28
grease; Mo-Lith #2 (Fiske 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 Replace old material Quality pressure applied grease containing lithium
Air Compressor Crankcase (Optional) 1 quart (1L) SAE 30 – 65°F & up (18°C & up) SAE
20 – 32°F to 65°F (-0°C to 18°C) SAE 10
– 0°F to 32°F (-18°C to –0°C)
Window Tracks, Vinyl Door Zippers As needed Silicon spray lubricant
Other engine specifications on page 1-3-1 and Ch 5
GREASE & OIL CHART – Figure 1
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 4
09-26-02
APX16 Lube/Service Points
Figure 2
(Opt.)
Compressor
(Opt.)Oiler
System
12
7
18
3
1
2
6
20
15
10
16
SPREADER
21
10
17
22
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 5
09-26-02
REAR
4
6
12
12
APX16 Lube/Service Points
FRONT
4
6
1
11
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LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 6
09-26-02
NO
ITEM
FREQUENCY
1 ENGINE
OIL: Check oil level on dipstick. 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. The system may not hold the
complete capacity specified.
Gasoline – Every 100 hours or
seasonally (per Ford)
FUEL FILTER: Replace to ensure
reliable operation.
Annually or 1000 hours
AIR FILTER: Replace to ensure smooth
engine operation.
Daily Inspection
Change as needed
BELTS: Check Fan and Alternator belts
for tension. Deflection should equal ½
inch in one direction. Coat well with
quality belt dressing to provide less
squeaking and less slipping in wet
conditions.
Every 300 hours or every 3 months
BOLTS: (over entire engine) Check and
tighten all bolts as required per Torque
Specifications – Chapter 5, (Engine
Service Manual).
Annually
COOLANT LEVEL: Check overflow tank
for coolant level.
Daily Inspection
COOLANT SYSTEM – Clean system of
rust and replace mixture Annually
LUBRICATION/ SERVICE CHART
The frequency of engine lubrication has
been proposed by Lift-A-Loft. See
Preventative Maintenance Schedule Ch 5 in
the Engine Operator’s Manual for other
information.
SEE PAGE 3 FOR
LUBRICANTS
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 7
09-26-02
NO
ITEM
FREQUENCY
1 ENGINE (CONT.)
CARBURETOR AREA: Spray carburetor
cleaner into the primary, (with engine at
fast idle) over the throttle plate and other
surfaces until engine begins to accept
cleaner with less of a tendency to die
(Approx. 10 oz.). Spray clean the exterior
of the carburetor including the throttle and
choke linkage.
Every 300 hours or (3) months
PCV VALVE: Replace to ensure reliable
operation.
Annually
PLUGS: Clean and regap to .045 or
replace.
Annually
DISTRIBUTOR: Check interior and
exterior condition of cap and rotor cap.
Lube the capstan area.
Annually
WIRES: Inspect wires for melted areas
and other damage that could allow spark
jump.
Annually
SEE PAGE 3 FOR
LUBRICANTS
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LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 8
09-26-02
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.
Every 300 hours or every 3 months
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.).
Every 300 hours or every 3 months
4 SUSPENSION
Check security of mounting hardware.
Add pressure grease to fittings on each
shackle to fill cavity (4 places).
Every 300 hours or every 3 months
5 STEERING
Check level of Steering Fluid. Check for
leaks.
Daily inspection
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 300 hours or every 3 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
SEE PAGE 3 FOR
LUBRICANTS
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 9
09-26-02
NO ITEM FREQUENCY
6
BRAKES
Check brake fluid level. Check for leaks. Daily inspection
These vehicles have no pad wear
indicators. 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.
Every 300 hours or every 3 months
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
SEE PAGE 3 FOR
LUBRICANTS
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 10
09-26-02
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
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 Check condition & press. (80lbs) Daily inspection
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.
Every 300 hours
or (3) months
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
SEE PAGE 3 FOR
LUBRICANTS
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 11
09-26-02
NO
ITEM
FREQUENCY
14 HYDRAULIC SYSTEM (Cont.)
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
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.
Every 100 hours or every 1 months
SEE PAGE 3 FOR
LUBRICANTS
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 12
09-26-02
NO ITEM FREQUENCY
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.
Every 100 hours or every month
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. Every 100 hours or every month
18 PLATFORM SURFACE
The platform surface must be kept free of
debris, oil, tools and other items that
would inhibit firm footing.
Daily inspection
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.
Periodically as needed
20 PLATFORM GUARD RAILS & PLATES
See that guard rails are properly
installed. Check guard rail mounts and
pins for cracked welds.
Every 100 hours or every month
SEE PAGE 3 FOR
LUBRICANTS
Property of American Airlines

LIFT-A-LOFT APX16 - G ASOLINE
CHAPTER 2
SECTION 1
Page 13
09-26-02
NO ITEM FREQUENCY
21 (Opt.) OILER FILTER SYSTEM (oiler)
DESICCANT FILTER: (Located on top of
reservoir behind seat.) Unscrew and
replace with new Des-Case DC3.
Daily inspection
Desiccant material will change from
blue to pink. Time will vary
according to humidity at your
location.
DUAL INLINE MOISTURE FILTERS:
(Located in turbine oil line behind rear
bumper.) Unscrew canister end cap.
Remove cartridge (puffed and milky when
change is needed.) Replace cartridge
being careful to center spring in cartridge
and end cap. Screw cap onto filter and
check for leaks.
When fully saturated, flow will be
shut down.
INLINE PARTICLE FILTER: (Located on
passenger side of oil tank in turbine oil
line.) Spin off old filter, spin on new filter.
Annually or as needed.
22 (Opt.) COMPRESSOR
Change crankcase oil Every 100 hours or every 1 month.
INTAKE AIR FILTER Examine weekly. Replace as
necessary.
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