THIEMAN LRST-40 User manual

StowAwAy
LRST-40
OWNERS MANUAL/PARTS LIST
IMPORTANT! KEEP IN VEHICLE!
!
PLEASE READ AND UNDERSTAND THE CONTENTS OF THIS
MANUAL BEFORE OPERATING THE EQUIPMENT.
TAILGATES, INC.
600 East Wayne Street
Celina, Ohio 45822
Phone: [phone] Fax: [phone]
www.thiemantailgates.com
HIEMAN
NTEA
THE ASSOCIATION FOR THE WORK TRUCK INDUSTRY
TM
MEMBER

TABLE OF CONTENTS
PARTS ORDERING PROCEDURE ..................................2
SAFETY INFORMATION & WARNINGS ............................ 3-7
OPERATING INSTRUCTIONS .....................................8
MAINTENANCE GUIDE & MONTHLY INSPECTION AND MAINTENANCE .. 9-11
SEMI-ANNUAL INSPECTION AND MAINTENANCE ...................11
DECAL MAINTENANCE - INSPECTION AND LOCATION OF DECALS.....12
TRUNNION, LIFT ARM, IDLER ARM, AND OPTIONAL REAR
END PROTECTION ............................................13
PLATFORM - TORSION SPRING ASSIST ASSEMBLY .................14
CART STOP ASSEMBLY-OPTIONAL ...............................15
SPACER ASSEMBLY ...........................................16
ELECTRICAL PICTORIAL........................................16
PUMP ASSEMBLY - TOGGLE AND PUSHBUTTON CONTROL ..........17
PUMP PARTS.................................................18
SNUBBER KIT ................................................19
TROUBLE SHOOTING GUIDE ................................. 20-23
FOR YOUR RECORDS
Model No. _____________________________ Date Purchased _________________________
Serial No. _____________________________
NOTE: When ordering parts be sure to include this information!
Your Thieman Tailgate is constructed of top quality material and is warranted to be free
from defects in material and workmanship under normal use. With routine maintenance and
proper operation this liftgate will provide long lasting service and dependability.
PARTS ORDERING PROCEDURE
When ordering parts, please include all the information asked for below. If this informa-
tion is not available, a complete written description or sketch of the required part will help
Thieman identify and deliver the needed part to you.
THE FOLLOWING INFORMATION MUST BE INCLUDED:
1. Serial Number - Thieman liftgate serial numbers can be found on the tag located on the
outside of the curb side mounting plate.
2. Model Number and Capacity.
3. Platform size and Material - Steel or Aluminum.
4. Part number.
5. Description.
6. Quantity required.
2.

3.
SAFETY INFORMATION
This is the safety alert symbol. This manual uses this symbol combined with the Signal
Words below, which together, alert you of potential personal injury hazards. Obey all safety
messages throughout this manual, including those that follow the Signal Words below,
to avoid personal injury or death. Each Signal Word is explained below.
SIGNAL WORDS used in this manual
DANGER – Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
Related information will follow
WARNING – Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
Related information will follow
CAUTION – Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
Related information will follow
!
!
!
!
DANGER
WARNING
CAUTION

4.
WARNING!
1. DO NOT operate this Thieman liftgate without the Owner’s Manual for this model present
on the vehicle and without all decals present and legible, as guides for proper liftgate
operation and maintenance (see the “Decal Maintenance - Inspection and Location of
Decals” section of this manual). For replacement Owner’s Manuals, decals, etc. call
Thieman at 419-586-7727. For the latest manuals and warnings for each liftgate, visit our
website at www.thiemantailgates.com. Note: manuals and warnings update regularly.
2. The vehicle must be securely and properly braked on level ground before using the liftgate.
3. All protective covers and guards must be in place before operating the liftgate.
4. Before using liftgate, check for signs of improper maintenance or damage (unusual noises,
vibrations, fails to operate freely, missing hardware, cracked welds…etc. See the sections
in this manual with “Maintenance” in the title – refer to “Table of Contents” on Page 2). DO
NOT use the lift if these are evident. Only an authorized Thieman distributor is qualified to
do repairs on the liftgate. DO NOT attempt to do your own repairs or modify this liftgate.
Altering this product will void all warranties and may damage the liftgate or even cause
serious injury. If any repairs, adjustments, or maintenance not covered in this manual are
required, contact your nearest Thieman distributor or call Thieman at 419-586-7727.
5. THIS IS NOT A PERSONNEL LIFT. Because of the pinch point between the platform and
the truck, fall hazards, unstable loads, etc., riding the lift may cause severe personal injury
or death. ALWAYS stay clear of the liftgate when in operation. Do NOT ride the liftgate.
6. Make certain the areas, in which the platform will open or close, are clear before opening
or closing the platform.
7. Use this liftgate ONLY for its intended purpose of loading/unloading cargo between truck
bed and ground. It is NOT to be used for anything other than this. The ground is defined
as the surface the truck is parked on.
(Warnings continued on following pages)
IMPROPER OPERATION OF THIS LIFTGATE MAY RESULT IN SERIOUS PERSONAL INJURY
AND/OR DEATH. DO NOT operate this liftgate unless you have been properly instructed and
have read and understood the Owner’s Manual and all of its warnings, operating instructions
and all decals.
The following list of warnings is to be read and understood before operating the LRST40
series liftgate. The numbered list begins below and continues on the following pages.
!WARNING

5.
8. DO NOT use this liftgate to load or unload cargo from any elevated surface such as a
dock, sidewalk, raised concrete slab, etc. A truck’s suspension WILL squat under load,
and may cause loads to become unstable. Also, this effectively changes the “bed height”
of the truck, so the liftgate may not function properly on an elevated surface and may bind
and damage the liftgate. Additionally, if the ENTIRE liftgate platform is not supported by
the elevated surface, this partially supported condition WILL create unintended loads on
the liftgate components and MAY LEAD TO A SUDDEN LIFTGATE FAILURE.
9. DO NOT OVERLOAD THE LIFTGATE. Each liftgate has a specific maximum capacity for
lifting and lowering. The standard maximum rated capacity of the LRST40 series liftgates is
4,000 lbs.
WARNING note:Special options can lower the maximum rated capacities below
those shown above. Be certain you know what the maximum rated capacity is for your
particular liftgate.
10. NEVER off-center the load on the platform, from side to side or away from truck as this
may overload the liftgate. The center of weight of the load should NEVER be placed
beyond the center of the platform load surface, away from truck. Loads should be placed
close to platform edge nearest truck. See figure 1.
WARNING note: On the LRST model liftgate, off-center loading away from the truck
may cause the nose of the platform to tilt downward severely when lowering from
the truck bed level, greatly increasing the risks of falling loads. PAY ATTENTION
when lowering loads, to ensure the platform is staying level. If the platform begins
to tilt downward while lowering and before reaching ground, STOP LOWERING
IMMEDIATELY. Raise the load back to bed level so the load can be centered properly.
If this problem continues while lowering with the load properly centered, raise the load
back to truck bed level and place the load back into the truck. Stop using the liftgate and
contact the proper maintenance personnel, as stiff pivots on the liftgate can contribute to
this condition. DO NOT operate this liftgate, if this condition exists.
11. NEVER allow any part of the load to extend beyond the edges of the platform’s flat load
surface. Overhanging objects increase the risks of tipping loads due to unstable loading
or snagging these objects on surroundings and THESE OBJECTS COULD ALSO STRIKE
OR CRUSH OPERATORS OR BYSTANDERS.
12. NEVER lift or lower unstable loads.
13. NEVER operate liftgate if platform load surface is slippery.
14. Make certain the areas above and below the liftgate platform and other moving liftgate
parts, are clear before, and at all times during, operation of the liftgate. Do NOT allow
anyone to stand around the platform where a falling load could land on them.
15. Load and unload the platform from the rear and not from the side of the platform.
16. Never operate lift trucks on or over any part of the platform.
(Warnings continued on following pages)

6.
17. Follow all sections in this manual with “Maintenance” in the title – refer to “Table of
Contents” on Page 2.
18. NEVER move vehicle unless platform is properly stowed and power is off. An open
liftgate on a moving vehicle poses a serious traffic hazard.
19. ALWAYS stow liftgate in transit position when not in use. Liftgates left in their open
positions, may create hazards for people and vehicles passing nearby.
20. Take care to retain cargo during transit. Liftgates are not designed to retain objects on
the truck. Improperly retained objects may fall from the vehicle and pose serious traffic
hazards and larger objects could shift and damage the liftgate or truck.
21. NEVER adjust the bolts between the upper and lower lift arms. This is a factory setting
and should NOT be tampered with or the tilting action of the liftgate can be affected,
which can be dangerous.
22. Any time the vehicle is washed, this liftgate MUST be inspected to MAKE SURE all parts
are properly lubricated and have the appropriate protectants. Failure to replace lubricants
and protectants after washing the vehicle, may lead to improper operation of the liftgate,
accelerated corrosion, and possible component failure.
(Warnings continued on following pages)

7.
ΧΝ ΜΝΣ
ΝΕΕ Β∆ΜΣ∆Θ ΚΝ≅Χ
∋ϖξ εθνλ σθτβϕ(
ς≅ΘΜΗΜΦ
Ξ∆Ρ
ΧΝ ΜΝΣ
ΝΕΕ Β∆ΜΣ∆Θ ΚΝ≅Χ
∋ρηχδ σν ρηχδ(
ΦΘΝΤΜΧ
ΦΘΝΤΜΧ
Ξ∆Ρ
ΜΝ
ΧΝ ΜΝΣ
κνχ νθ τµκνχ
εθνλ θλο δµχ νε οκσενθλ
ϖησγ οκσενθλ νεε φθντµχ−
3560/4/Φ
ΜΝ
Ξ∆Ρ
ΜΝ
ΟΚ≅ΣΕΝΘΛ
Θ≅ΛΟ
ΟΚ≅ΣΕΝΘΛ
ΝΕΕ
ΦΘΝΤΜΧ
ΓΗ∆Λ≅Μ
An improperly positioned load can overload the liftgate and result in sudden liftgate failure and/
or increased risks to personnel of being hit or crushed by loads. IMPROPERLY POSITIONED
LOADS MAY RESULT IN SERIOUS PERSONAL INJURY AND/OR DEATH. Always position
loads properly on the liftgate platform. Follow information below on how to position loads
properly.
POSITION LOADS PROPERLY ON PLATFORM
 NEVERo-centertheloadontheplatform,fromsideto side or away fromtruck asthis
may overload the liftgate. The center of weight of the load should NEVER be placed beyond
the center of the platform load surface, away from truck. Loads should be placed close to the
platform edge nearest truck. If a load is not uniformly distributed, then the heaviest portion
should be closest to the edge of the platform nearest the truck. NEVER allow any part of the
loadtoextendbeyondtheedgesoftheplatform’satloadsurface.
!WARNING
FIG. 1
DO NOT OVERHEAT THE HYDRAULIC PUMP
Exceeding the duty cycle of the hydraulic pump, can overheat many components,
including the gear pump, the hydraulic motor, the motor start solenoid, valve coils, etc., and
signicantlyshortentheexpectedlifeofthesecomponents.Inextremecases,immediate
damage to the pump or related components may occur. Refer to the Thermal data below.
THERMAL DATA: To avoid overheating the motor do not operate this unit for more than 5
cycles/ 10 minutes with the maximum load. The motor then must be allowed to completely
cool down to ambient temperature before cycling the lift again. This unit also has a 10% duty
cycle, which means the liftgate can be cycled no more than 2 cycles/10 minutes constantly
with the maximum load.

8.
OPERATING INSTRUCTIONS
1. UNLATCH
A. Raise liftgate by pushing switch to UP position, until stow pins
are tight against nylon pads of spacer.
B. Push spacer handle down with finger tips to disengage spacer
latches and maintain this position through next step C.
C. While holding spacer handle down, lower liftgate by pushing
switch to DOWN position, until stow pins are clear of spacer
latches. Release spacer handle.
2. UNFOLD
D. Lower liftgate by pushing switch to DOWN position, and
stop once arms contact the ground.
E. Grasp curb side platform handle and rotate platform out
to horizontal position.
F. Unfold platform extension until horizontal.
3. RAISE OR LOWER
G. Push switch to UP position to raise liftgate. Platform levels, then raises off ground.
H. Push switch to DOWN position to lower liftgate. Once arms contact the ground,
continue holding switch in DOWN position, until platform nose tilts downward and
touches ground.
4. STORE FOR TRANSIT
I. Raise or lower liftgate with switch, so arms are on ground
and platform is horizontal, with platform nose off ground.
J. Grab platform nose and fold platform extension over on
top of main section of platform.
K. Lift from underside of platform and fold
entire platform upward. Grab platform
handle on curb side to lower platform
inward against nylon kicker roller.
L. Raise liftgate by pushing switch to UP position.
M. Continue raising liftgate until the stow pins on both sides of the
liftgate have powered up tight against the nylon pads on the spacer.
MAKE SURE stow pins are engaged in latches. DO NOT lower stow
pins on latches.
IMPROPER OPERATION OF THIS LIFTGATE MAY RESULT IN SERIOUS PERSONAL
INJURY AND/OR DEATH. DO NOT operate this liftgate unless you have been properly
instructed and have read and understood the Owner’s Manual and all of its warnings,
operating instructions and all decals.
!WARNING
UP
DOWN
RAISE
LOWER

9.
MAINTENANCE GUIDE
The following inspection and maintenance operations should be performed at the
recommended intervals or anytime the liftgate shows signs of abuse, and improper or
abnormal operation.
MONTHLY INSPECTION AND MAINTENANCE
Operate the liftgate throughout its entire operational cycle and check the following:
1. Check that there are no unusual noises or vibrations.
2. Check that the when the truck is on level ground and the platform is in its "leveled" and
unloaded position that the entire load surface is level or toed up at the ramp tip so that
when the usual load is placed on it, it becomes leveled under load. For instructions on
adjusting leveling screw and platform toe. See figure 2.
3. Check platform height relative to the spacer. If platform is lower, adjust cylinder on low side
with a 15/16 wrench to obtain necessary height.
4. Check for apparent damage to the liftgate such as bent or distorted members, any
cracked welds, etc., which may have resulted from overloading or abuse.
5. Check for any excessive wear in the following pivot areas (Note: For bushed pivots, if the
gap between pin and bushing exceeds 1/32 of an inch, the bushing should be replaced.
For pivots without bushings, replace worn components if gap between pin and pivot
exceeds 1/32 of an inch. Refer to parts breakdowns in this manual):
A. Aluminum Platform hinge shoulder bolts, pins, and bushings.
B. All cylinder pins and bushings.
C. All pins and bushings joining liftarm or idler arms to trunnion or platform.
IMPROPER MAINTENANCE OF THIS LIFTGATE MAY RESULT IN SERIOUS PERSONAL
INJURY AND/OR DEATH. Never use a liftgate, that has not been properly maintained.
Follow all maintenance outlined in this manual, beginning with “Maintenance Guide” thru and
including “Decal Maintenance - Inspection and Location of Decals”.
!WARNING

10.
14. Lubrication of the LRST 40 series liftgate should be as follows for all user conditions:
Area of Tailgate Type of Lubrication Frequency
Spacer Latches SAE 10 to SAE 20 oil 50 cycles
Pump Oil Change See Chart Below Yearly
NOTE: Many pivot points of the LRST 40 have special bushings which do not require
lubrication, but must be inspected regularly for wear to avoid costly repairs or component
failures.
15. Check the pump relief pressure and also the motor amperage at this pressure. These
values should be as follows:
Model Max Amp Draw Relief Pressure (psi)
LRST 40 255 2650
Acceptable
Fluids
Exxon Univis J-26
Dexron III
Exxon Superflo ATF
Shell Spirax S3 ATF MD3
Shell Aero Fluid 4
Mobil Aero HFA
Exxon Univis J-13
MIL H-5606
Temperature
Range
-75 to 165° F
-20 to 130° F
-50 to 80° F
HYDRAULIC FLUID CHART
D. Kicker arm pins, bushing, white nylon roller, etc.
E. Stow pins or nylon pads on spacer.
F. Rear Impact Guard (optional) pins and bushings.
6. Check that ALL pins, bolts, hardware, etc. are in place and retained by their proper
retainers.
7. Check that all protective covers and guards are properly in place and secured.
8. Check finish of steel parts, if in poor condition, then repair finish if possible. Any rusted
parts should be replaced.
9. Check condition of non-painted parts, replace if corrosion exists. Eck from Vannay.com
should be used to prevent corrosion between dissimiliar metals. Do not use Never Seez or
similar anti-seize products which contain abrasives that may harm the bushings.
10. Check snubbers, while platform is in stored position, to make sure they are slightly
compressed by platform. If not, they should be relocated or replaced. Lack of properly
installed snubbers can greatly increase wear rate of liftgate during transit.
11. Check for oil leaks in these areas:
A. Lift cylinders
B. Hydraulic hoses - replace if they show signs of wear or cracking.
C. Hydraulic fittings - tighten or replace as may be required to stop leakage.
12. Check the oil level in the hydraulic reservoir. With the liftgate in the stowed position, the oil
should be within 1/2 inch from the top of the reservoir. See chart below for oil applications.
13. Check that all wiring and battery cable connections are tight and free of corrosion.

11.
SEMI-ANNUAL INSPECTION
1. Perform the procedures outlined in the “Monthly Inspection and Maintenance.”
2. Repaint original painted components as necessary to prevent rust and corrosion from
reducing structural integrity of original components.
3. Inspect pump motor by:
A. Disconnecting battery cable
B. Remove motor end cover
C. Examine the armature brushes for wear. (Brushes should be replaced if they are less
than 1/8” long).
D. Clean all residue out from inside of the motor housing.
E. Apply several drops of light weight machine oil to the armature shaft bearing in the
motor end cover and reassemble the motor end cover.
4. If the hydraulic oil in the reservoir is dirty:
A. Unfold platform and lower platform to the ground. Raise platform to bed height so
cylinders are fully retracted. Support platform in this position with a lift truck or crane.
B. Drain the oil from the hydraulic system and flush the entire system.
C. Remove reservoir from pump and clean suction line filter. Also, clean out any
contaminants inside reservoir. Remount reservoir when completed.
D. Replace the oil as outlined in Section 12 under Monthly Maintenance and Inspection.

12.
LIST OF DECALS AND LOCATIONS
Item Part Name Part Number
1 Warning Decal-Off Center 4671050
2 PTO Decal 4650140
2 Fast Idle Decal 4650150
3 No Riding Decal 4609
4 Operating Decal 4669
5 Capacity Decal 4000# 4650130
6 Warning Decal 4604
7 Warning Decal 4681
8 Caution Decal 4650770
9 Handle Decal 4605
10 Warning Decal-High Pressure 4620
11 Wiring Decal 4614
12 Reflector (3) 5705
IMPROPER MAINTENANCE OF THIS LIFTGATE MAY RESULT IN SERIOUS PERSONAL
INJURY AND/OR DEATH. Liftgate decals provide important information, which is vital for
proper and safe operation of the liftgate. Replace any decals which are missing or which are
not fully legible. DO NOT operate liftgate unless all decals are legible and are properly
located.
!WARNING
DECAL MAINTENANCE - INSPECTION AND LOCATION OF DECALS

13.
TRUNNION, LIFT ARM, IDLER ARM, AND *OPTIONAL REAR END PROTECTION ASSEMBLY
Item Part Number Description Qty.
1 31411 Trunnion asm - Includes item 21 1
2 31410 Lift arm asm - Includes items 5,6,18,19,20,21,22,23 1
3 31388-002 Idler arm asm RH - Includes item 22 1
4 31388-001 Idler arm asm LH - Includes item 22 1
5 5071 Pin 6
6 5708-009 Spring pin 6
7 5708-001 Spring pin 1 or *7
8 5024 Pin 1 or *5
9 31633 HD Kicker asm - Includes items 10,11,12,21 1
10 5781008 Retaining ring 2
11 5775 Roller 1
12 5001400 Pin 1
13 5100180 Spring 2
14 8427570 Screw .44-14 x 2.50 1
15 8120396 Flatwasher .50 1
16 9414073 Locknut .44 2
17 4101-017 Chain 1
18 8108-005 Set screw .38 2
19 4220240 Nylon insert 2
20 8271771 Screw .75-10 x 2.00 2
21 5504-001 Bushing 7 or *9
22 5504-014 Bushing 8
23 5504-015 Bushing 2
24 5789 Wear pad 2
25 8109-012 Screw .25 x .75 4
26 5701910 Bolt .44-14 x 1.50 1
*27 5073 Fold pin 2
*28 27123 Support arm 2
*29 3016 Collar 4
*30 5504-005 Bushing 2
*31 31400 Guard weld - Includes item 21 1
*32 31399-001 Fold arm weld-LH - Includes item 30 1
*33 31399-002 Fold arm weld-RH - Includes item 30 1
34 8103-019 Locknut .25 4

14.
PLATFORM-TORSION SPRING ASSIST ASSEMBLY
Item Part Number Description Qty.
1 3442 Platform asm - Items 2 thru 7 1
1 3445-001 Platform asm (single ramp cart stop) 1
1 3445-002 Platform asm (dual ramp cart stop) 1
2 31401 Platform main section 1
3 31407 Platform extension 1
3 31439-001 Platform extension (single ramp cart stop)-see page 10 1
3 31439-002 Platform extension (dual ramp cart stop)-see page 10 1
4 8119 Shoulder bolt .62 2
5 8106-009 Lockwasher .62 2
6 8106-008 Lockwasher .50 2
7 9414074 Locknut 2
8 5504-013 Bushing 2
9 4220240 Nylon insert 2
10 8108-005 Set screw .38 2
11 8114-002 Screw 1.00-8 x 2.00 2
12 5072 Stow pin 2
13 5708-001 Spring pin .25 x 2.00 4
14 5708-009 Spring pin .25 x 2.50 2
15 31379 Roller asm 2
16 5504-014 Bushing 2
17 3057 Spring tube 2
18 5101260 Spring 2
19 5074 Pin 2
20 5070 Pin 2
21 31405 Pivot hinge weld-LH 1
22 31406 Pivot hinge weld-RH 1
23 5708-013 Spring Pin .25 x 3.00 2

15.
CART STOP ASSEMBLY - OPTIONAL
Item Part Number Description Cart Stop Type
Single Dual
1 31439-001 Cart Stop Extension Asm. (Single Cart Stop)-includes items 2-9 1
1 31439-002 Cart Stop Extension Asm. (Dual Cart Stop)-includes items 2-9 1
2 31436-001 Cart Stop Sub Weld (Single Cart Stop) 1
2 31436-002 Cart Stop Sub Weld (Dual Cart Stop) 2
3 5076-002 Pin 1 2
4 5110 Torsion Spring 4 4
5 5764-001 Retaining Ring-.44 12 16
6 5076-001 Pin 5 6
7 2811 Latch Bar 1 2
8 5101160 Latch Spring 1 2
9 5708-010 S.S. Spring Pin .19 x .75 4 4

16.
SPACER ASSEMBLY
Item Part Number Description Qty.
1 3502-001 Spacer asm - Includes items 2 thru 8, (96") 1
1 3502-002 Spacer asm - Includes items 2 thru 8, (102") 1
2 31549-001 Control shaft (96" Spacer) 1
2 31549-003 Control shaft (102" Spacer) 1
3 5701043 Handle grip 1
4 27117 Latch 2
5 2901170 Lever 2
6 5101100 Spring 2
7 5703 Pad 2
8 8449646 Self-tap screw 4

17.
PUMP ASSEMBLY-TOGGLE AND PUSHBUTTON CONTROL
Item Part Number Description Qty.
1 4404 Pump asm - Includes items 2 thru 5 1
2 4421420 Pump bracket 1
3 4420410 Breather 1
4 4423520 Motor 8111 1
5 4468 Solenoid 1
6 8180122 Bolt .38-16 x 1.00 5
7 8106-010 Internal Tooth Lockwasher 10
8 8120377 Nut .38 5
9 8120388 Flatwasher 4
10 3717 Pump enclosure asm - Includes items 11 thru 15 1
11 5758 Rubber T-handle asm 2
12 8110-006 Screw #6-32 x .50 8
13 8107-006 Flatwasher #6 8
14 8106-006 Lockwasher #6 8
15 8103-017 Nut #6 8
16 4422860 Pushbutton 1
17 31445 Toggle switch asm 1
18 4938-001 45° Elbow MAORB-FJS 1
19 8111-005 Screw #10 x .75 2
20 4318-002 Ground Cable #2 x 2' 1
21 8104-006 Screw .31 x 1 1
22 4318-001 Cable asm - 2 Ga. x 2 ft 1
23 4301770 Circuit breaker - 150A 1
24 4350 Cable lug 1
25 4319-002 Heat shrink 1
26 4300030 Battery cable -2 Ga. x 25 ft 1
27 5701260 Cable retainer 12
28 4932-001 MJ-MJ-MAORB Tee 1
29 4951-005 Hose 60.00 2
30 4951-015 Hose 51.00 2
31 4941-001 MJ-MORB Straight 2
32 4936-001 MAORB-MAORB 90° 2
33 4948-006 Flow Control 1.0 GPM 2
34 4930-001 MJ-MAORB 90° 2
35 31477 Cylinder 3.5 Bore x 8 Stroke 2
36 5024 Pin 2
37 5708-001 Spring pin 2
38 5009 Pin 2
39 5781008 Retaining ring 2
40 5763 Grommet 4
41 4953-001 Branch tree MJ-MJ-MJ 1
42 5700100 Tie Strap 32.00 1

18.
4404 PUMP PARTS
Item Part Number Description Qty./Model
1 4423520 Motor 8111 1
2 4439 Pump and Reservoir Only 1
3 4420410 Breather Cap 1
4 4480 Buss Bar 1
5 4421520 Bearing 1
6 4421530 Seal 1
7 8109-012 Screw .25 x .75 2
8 4421420 Bracket 1
9 4468 Solenoid 1
10 4421600 O-Ring 2
11 4452 Solenoid Coil Only 2
12 4445 Solenold Valve Asm (lower) 1
13 4438 Solenoid Valve Asm (raise) 1
14 4457 Reservoir Ø4.50 x 12.00 1
15 4421660 Self Tap Screw #10 x .38 6

19.
SNUBBER KIT 172
Item Description Part Number Qty.
Kit 172 Snubber Kit Includes Items 1 to 6 3735330 1
1 Snubber 5702290 2
2 Mounting Angle 2019033 2
3 Locknut .31-18 9413447 2
4 Flat Washer .31 8120386 4
5 Base Plate 23049-001 2
6 Screw .31-18 8180091 2

20.
TROUBLESHOOTING GUIDE
LRST40EST
Test Equipment: 1. 0-5000 psi pressure gauge
2. DC voltmeter/ohm meter
3. DC amp meter
4. standard mechanics tools
Note: Please refer to the electrical diagrams and hose connection drawings in the liftgate’s owners manual when
troubleshooting. This guide is only for standard Thieman liftgates. Special liftgates with options other than those
in the owner’s manual will require special diagrams for troubleshooting. Read and understand this entire guide
completely before doing any troubleshooting. Certain listed problems may be related to other problems listed so
a comprehensive knowledge is required before proceeding.
1. Problem - Pump motor will not run in the raise or lower mode
Causes
a. Tripped circuit breaker
b. Blown 20A fuse
c. Improper battery cable
connection or improper
ground connection
d. Defective or
undercharged
battery(ies)
e. Defective or improperly
wired raise switch
f. Defective or improperly
wired lower switch
g. Defective or improperly
wired solenoid start
switch
h. Defective pump motor
Correction
Reset the circuit breaker located within 2ft of the liftgate supply battery(ies).
Replace 20A fuse(s). Each control cord should have a 20A in-line fuse on the
black wire, where it connects to the 2ga battery cable at the motor start solenoid.
The “at rest” voltage for the batteries without the engine running and under no
load should be at least 12.5V, and this voltage should be seen on the heavy 2ga.
battery cable, where it connects to the large terminal of the motor start solenoid.
The minimum voltage between the motor stud and ground is 10V at maximum
conditions, with pump motor, batteries, and cables under max. load. If the
voltage is dropping below 10V under max. load, bad connections may be acting
like resistors and causing larger voltage drops than expected. Check voltage
drops with system under load at different locations between the liftgate and
battery source, to locate bad connections along the battery cable. Trace ground
cable connections also to locate improper connection(s) along the ground path.
Make sure the ground cable is installed going from the 5/16 tapped hole in the
aluminum pump base marked GND to the liftgate mounting plate (scrape paint
to bare metal for good ground). The ground cable from the batteries to the
frame must be a heavy 2ga cable that is connected to bare metal on the frame.
Replace any damaged cables and repair any bad connections.
If proper voltage is not present, load test batteries and replace any defective
batteries. The battery(ies) on the vehicle should be that which has a minimum
180 amp reserve capacity.
Check for voltage on the black wire at the control switch. If no voltage is
present the black wire from the motor start solenoid is loose or broken and
needs repaired. If voltage is present then check for voltage at the white wire on
the switch with the switch in the "UP" position. If no voltage is present, replace
the switch.
If the pump motor runs in the "UP" position but will not run in the "DOWN"
position, then check for voltage on the white wire at the switch with the switch
in the "DOWN" position. If no voltage is present replace the switch.
Check for voltage on the white wire at the motor start switch when the switch is
activated either "UP" or "DOWN". If no voltage exists the white wire is loose or
broken between the switch and the motor start solenoid. Check that the purple
ground wire on the start solenoid is connected properly and there are no bad
connections. If there is voltage on the white wire and the coil does not energize
or if there is no voltage on the motor side of the solenoid or a large voltage drop
present across the large terminals of the motor start solenoid then replace the
motor start solenoid.
With the switch activated in the "UP" or "DOWN" position and the motor start
solenoid is activated, check for voltage at the motor terminal. If voltage is
present and the motor is not running, replace the motor.