Magliner LiftPlus User manual

1-800-MAGLINE (624-5463)
LiftPlus®
1
Serial #: _________________________________
Date of Purchase: ________________________
LiftPlus®
Maintenance Manual

1-800-MAGLINE (624-5463)
LiftPlus®
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Table of Contents
LiftPlus Toolkit........................................................................................................................................3
Safety Instructions.................................................................................................................................4
Removing Covers..................................................................................................................................5
Disconnecting/Connecting Battery ........................................................................................................6
Lift Screw Girdle and Upper Belt ...........................................................................................................7
Replacing Lower Belt.............................................................................................................................7
Motor Assembly.....................................................................................................................................8
Pulleys 1, 2-3.......................................................................................................................................10
Motor and Solenoid Body....................................................................................................................10
Motor Brake Pad .................................................................................................................................11
Lower Lift Screw Collar and Assembly................................................................................................13
Pulley 4................................................................................................................................................13
Lift Screw Thrust Bearing ....................................................................................................................14
Lift Screw Guide ..................................................................................................................................14
Trolley Assembly .................................................................................................................................16
Rear Rollers.........................................................................................................................................16
Front Rollers....................................................................................................................................... 17
Caster Assembly................................................................................................................................. 17
Disengaging/Engaging Brake Cable Ends ..........................................................................................19
Brake Cable Assembly ........................................................................................................................19
Brake Caliper Assembly ......................................................................................................................19
Adjusting the Brakes, Caliper ........................................................................................................ 20-21
Replacing Battery ................................................................................................................................22
Battery Box..........................................................................................................................................22
Circuit Breaker.....................................................................................................................................22
Lower Limit Switch...............................................................................................................................24
Upper Limit Switch...............................................................................................................................25
Power Switch; Up/Down Switch ..........................................................................................................26
Charging Light; Overload Light............................................................................................................26
Charging Input; Remote Control Input.................................................................................................27
Control Board Diagram.................................................................................................................. 28-29
Maintenance........................................................................................................................................30
Troubleshooting Guide ........................................................................................................................31
Advanced Troubleshooting Guide ................................................................................................. 32-34
Replacement Parts List ................................................................................................................. 54-56
Inspection / Maintenance Checklist................................................................................................ 57-63

1-800-MAGLINE (624-5463)
LiftPlus®
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• Standard Allen wrench set
• #1, #2 Phillips head screwdrivers
•Large at head screwdriver
•Micro at head screwdriver
• Standard socket wrench set
• Metric socket wrench set
• Standard combination wrench set
• Long handled magnetic driver with assorted Phillips and hex heads
• Crescent wrench
• Vise-grips
• Channel-lock pliers
• Dead blow hammer
• 1 lbs. hammer
• Needle Nose Pliers
• E-ring tool
• Pin punch set
• Wire stripper
• Wire cutter
• Wire crimper
• Cordless drill
• Drill bit set
• Blue thread locker
• Anti-static wrist strap
LiftPlus Toolkit

1-800-MAGLINE (624-5463)
LiftPlus®
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Maintenance/Repair Safety Instructions
•Wear safety glasses when performing maintenance or repairs.
•Always use the correct tool type and size required for the job.
•Be careful not to cause cosmetic blemishes while working on the LiftPlus.
•Be careful not to strip or cross thread any fasteners especially in aluminum parts.
•Be careful not to damage any wire insulation.
•Engage the parking brake before working on the liftplus unless you will be working on the
brake system.
•Do not Wear loose clothing, drawstrings, etc.
•Do not Use excessive force in any operation.
•Do not work on or around the drive or electrical components of the LiftPlus unless the
power switch is off and the battery is disconnected.
•Do not activate the motor unless all hands and tools are clear of the drive system.
•Do not disconnect wire connectors by pulling on their wires. Grip only the connectors
themselves.
•Do not contact the components of the control board with any metal tool.
•All replacements must be made with genuine Magliner parts.
General Safety Instructions
•Inspect before each use for damaged and loose fasteners/connections.
•Inspect the unit for cracks, wear or damage. Replace damaged components immediately.
•Keep hands and feet away from all moving parts.
•Never stand or sit on the work bench.
•Do not use this product to lift or to transport people.
•Never use as a step ladder.
•Never use on a moving vehicle.
•Never operate when any of the housing components have been removed.
•Keep all loose items away from the lift screw, as they may become entangled during use.
•Never use or store in wet environments or get any of the unit wet. The unit may be used
indoors or outside, but always use caution to keep the unit from getting wet; dry as soon as
possible.
•Never exceed 350 lbs. capacity. Damage to the lift and personal injury could result.
•Never raise or lower the work bench unless the unit is unfolded and the folding latch is
locked.
•Use extreme care when raising or lowering in close proximity to other objects. Hands
and other items may get pinched or injured as the moving attachment passes non-moving
objects.
•Never place a load’s center of gravity over the vise or work bench nose; always keep the
load center of gravity centered on the work bench.
•Never tilt the unit back with a raised load.
•Always check that the brakes are working correctly before operating with a load.
•Never walk away from the unit when the folding latch is in an unlocked position.
•Always keep the power switch off when the unit is folded.
•Never go over a curb or any other multi-level transition with a raised load.
•Do not operate when the battery charger is plugged in.
•Never attempt to open the battery. If the battery is cracked or leaking, do not recharge it - it
must be replaced.
•Always use a Magliner battery charger to charge your battery.

1-800-MAGLINE (624-5463)
LiftPlus®
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REMOVING COVERS
TOOLS NEEDED:
5/64” ALLEN WRENCH OR HEX DRIVER (BRAKE COVER)
7/64” ALLEN WRENCH OR HEX DRIVER (MOTOR COVER & TOP COVER)
Item Qty. Part Number
A Button head cap screw - #6-32 x 5/16” long 4 80360
B Brake cover 1 533506
C Button head cap screw - #6-32 x 5/8” long 2 80359
D Motor cover 1 533505
E Top cover 1 533502
F Battery cover 1 533501
A
B
Brake Cover Motor Cover/Top Cover
Note: when replacing the motor cover, move any protruding wires of the electrical assembly so they will be contained within the
cover; make sure the bottom tabs slip under the protruding tabs of the electrical mount plate.
If the brake cover is installed, slide the motor cover down so that the bottom tabs slip inside the brake cover and under the pro-
truding tabs of the electrical mount plate.
C
D
E
Fold the LiftPlus; pull latch tab on
top of the cover and slide down.
Battery Cover
F

1-800-MAGLINE (624-5463)
LiftPlus®
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LIFT DRIVE SYSTEM
DISCONNECTING/RECONNECTING BATTERY (disconnecting the battery is required for several processes in
this manual)
TOOLS NEEDED: NONE
1. Disconnecting the battery.
a. Fold the LiftPlus and remove battery cover.
b. Remove connectors off the positive and negative terminals.
c. Unfold and lock the LiftPlus.
2. Disconnecting the battery.
a. Fold the LiftPlus.
b. Slide the connectors onto the positive and negative terminals.
c. Install the battery cover; unfold and lock the LiftPlus.
Item Qty. Part Number
A Lift screw girdle 1 531115
B Belt 2 534118
C E-ring for 1/4” dia. shaft 1 221011
D E-ring for 3/8” dia. shaft 1 221012
A
B
D
C

1-800-MAGLINE (624-5463)
LiftPlus®
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LIFT SCREW GIRDLE AND UPPER BELT
TOOLS NEEDED: NEEDLE-NOSED PLIERS OR E-RING TOOL; LARGE FLAT SCREWDRIVER; DEAD-BLOW
HAMMER
Removal:
1. Turn off the LiftPlus and disconnect the battery.
2. Remove motor and top covers.
3. Remove the E-rings from the top of the Pulley shaft and lift screw
4. Remove the lift screw girdle. If necessary insert a large at blade screwdriver between the lift screw girdle and
the top of either Pulley and gently twist.
5. Remove the upper belt by lifting it over the top of Pulley 2-3 while slowly turning Pulley 1 by hand.
Installation:
1. Turn off the LiftPlus and disconnect the battery.
2. Wrap the upper belt around Pulley 4 and stretch it just over the top of Pulley 2-3.
3. Press the belt down over Pulley 2-3 while turning Pulley 1 by hand.
4. Install the lift screw girdle, tapping gently with a dead-blow hammer if necessary.
5. Connect the battery unless other work on the lift drive system is planned.
REPLACING LOWER BELT
TOOLS NEEDED: NONE
Removal:
1. Turn off the LiftPlus and disconnect the battery.
2. Remove the lift screw girdle and upper belt.
3. Lift the Lower Belt over the top of Pulley 1 while slowly rotating Pulley 1.
4. Slide the lower belt out between Pulley 2-3 and Pully 4
Installation:
1. Turn off the LiftPlus and disconnect the battery.
2. Slide the lower belt in between Pulley 2-3 and Pulley 4.
3. Wrap the lower belt around the bottom of Pulley 2-3 and stretch it just over the top of Pulley 1.
4. Press the belt down over Pulley 1, while hand turning Pulley 1.
5. Install the lift screw girdle and upper belt.
6. Connect the battery unless other work on the lift drive system is planned.

1-800-MAGLINE (624-5463)
LiftPlus®
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LIFT DRIVE SYSTEM (CONT.)
Item Qty. Part Number
Complete motor assembly includes:
A Motor - 12V DC 1 63024
B Solenoid and plunger assembly 1 63026
C Pulley 1 assembly 1 534106
D Pulley 2-3 assembly 1 534107
E Motor mount assembly 1 534102
F Motor brake lever 1 534111
G Motor brake pad 1 534112
H Flanged bushing - .250 ID x .375 OD x .38” long 2 534115
I Belt 2 534118
J Slotted spring pin - 1/2 x 1.5” long 1 81166
K Phillips head truss screw - #10-32 x .5” long 2 80348
L Flat washer - #10 2 80767
M Flat nylon washer - 3/8” 3 80766
N External ring - 7/16” 2 221014
O E-ring - 1/4” 2 221011
F
E
G
Item Qty. Part No.
P
Solenoid adapter
harness - 48” models
1 534421
Solenoid adapter
harness - 60” models
1 534422
Solenoid adapter
harness - 72” models
1 534423
Complete motor assembly also includes:
Motor Assembly Part No.:
48” models - 534100
60” models - 534100-60
72” models - 534100-72
K, L
B
B
B
A
D
C
H
I
I
O
M, N
J
P

1-800-MAGLINE (624-5463)
LiftPlus®
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MOTOR ASSEMBLY
TOOLS NEEDED: 3/16” MAGNETIC HEX DRIVER OR ALLEN WRENCH
Removal:
1. Turn off the LiftPlus and disconnect the battery.
2. Remove lift screw girdle and upper belt.
3. Disconnect the motor and solenoid wires from rest of the electrical assembly by pulling apart the mating
connectors. Do not pull on the wires themselves! If the connectors are difcult to separate try working them
loose with gentle twisting and rocking.
4. Remove one of the motor mount screws with a 3/16” magnetic hex driver or Allen wrench.
5. Hold the motor with one hand and pull gently outward while unscrewing the remaining motor mount screw.
Installation:
1. Turn off the LiftPlus and disconnect the battery.
2. Hold the motor mount against the column ensuring that all wires needed to connect the motor and solenoid
are accessible.
3. Be sure that the grommet to protect the upper limit switch wires is secure in its slot in the column. The motor
mount traps this grommet in place.
4. Install the two motor mount screws (with lock washers) using a 3/16” magnetic hex driver or Allen wrench.
5. Connect the motor and solenoid wires to their mating wires.
6. Install the lift screw girdle and upper belt.
7. Connect the battery unless other work on the lift drive system is planned.
Pulley 2-3 ASSEMBLY
TOOLS NEEDED: NEEDLE-NOSED PLIERS OR E-RING TOOL
Removal:
1. Turn off the LiftPlus and disconnect the battery.
2. Remove the motor assembly.
3. Remove the .25” E-ring on the pulley post.
4. Slide the Pulley 2-3 assembly off the post.
5. Remove the bronze bushings from the pulley.
Installation:
1. Turn off the LiftPlus and disconnect the battery.
2. Check to be sure that the pulley anges are securely welded to the Pulley.
3. Install the anged bronze bushings in either end of the Pulley 2-3 assembly.
4. Slide the Pulley 2-3 assembly onto the pulley post.
5. Install the .25” E-ring onto the pulley post in the lower groove.
6. Install the motor assembly.
Pulley 1 ASSEMBLY
TOOLS NEEDED: 1-2 lb. HAMMER; 1/8” PIN PUNCH
Note: excessive force can damage the Pulley or the Motor shaft. Be sure that you have the correct size
punch and align and support everything carefully.
Removal:
1. Turn off the LiftPlus and disconnect the battery.
2. Remove the motor assembly.
3. Place the motor assembly on a hard, at, and stable surface with one of the long at sides of the motor mount
facing down.
4. Align Pulley 1 so that the split roll pin is vertical.
5. Using a 1/8” pin punch and a 1-2lb hammer drive the pin through until it clears the motor shaft.

1-800-MAGLINE (624-5463)
LiftPlus®
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6. Use careful steady blows, and:
a. Stop frequently to check the alignment of pin and punch.
b. Do not overdrive the pin
c. Be careful not to damage the pulley with a misaligned punch.
Installation:
1. Turn off the LiftPlus and disconnect the battery.
2. Slide the Pulley 1 onto the motor shaft.
3. Carefully align the holes in the motor shaft and Pulley 1 so that both are vertical.
4. Push a 1/8” by 1.5” long split roll pin into the top of the slot in Pulley 1.
5. Place the motor assembly on a hard, at, and stable surface with one of the long at sides of the motor mount
facing down.
6. Using a 1-2lb-hammer deliver gentle blows to the pin until it enters the hole in the motor shaft.
7. Using a 1/8” pin punch and a 1-2lb hammer continue to dive the pin until it is fully engaged with the slot on
Pulley 1.
a. Use careful, steady blows.
b. Stop frequently to check the alignment of pin and punch.
c. Do not over drive the pin.
d. Be careful not to damage the Pulley with a misaligned punch.
8. Install the motor assembly.
MOTOR
TOOLS NEEDED: #2 OR #3 PHILLIPS SCREWDRIVER
Removal:
1. Turn off the LiftPlus and disconnect the battery.
2. Remove the motor assembly.
3. Remove Pulley 1
4. Unscrew the screws holding the motor to the motor mount and remove the motor.
5. Slide the Pulley 2-3 assembly off the post.
Installation:
1. Turn power switch off and disconnect the battery.
2. Install the motor onto the motor mount, being careful to trap the motor brake lever under the lock washers.
3. Make sure that the washers are not deforming the motor brake lever and that the solenoid plunger and motor
brake lever have free range of motion.
4. Install Pulley 1.
5. Install the motor assembly onto the LiftPlus
SOLENOID BODY
TOOLS NEEDED: MINIATURE FLAT SCREWDRIVER, CHANNEL-LOCK PLIERS (optional), BLUE
THREADLOCKER
Removal:
1. Turn off the LiftPlus and disconnect the battery.
2. Remove the motor cover.
3. Remove the motor assembly.
4. Grip the solenoid body with a pair of channel-locks and twist if from right to left to loosen it.
5. Insert a small at-blade screwdriver between the solenoid hex nut and the motor mount to prevent the nut
from spinning.