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LIFT-A-LOFT APX16 Maintenance Manual

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LIFT-A-LOFT
MANUAL NUMBER APX16092602
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APX16-1036S thru APX16-1037S
LIFT-A-LOFT CORPORATION
9501 SOUTH CENTER ROAD MUNCIE, IN 47302-9443
EFFECTIVITY: 09/26/02
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Maintenance
REV 00
P.O. BOX 2645 MUNCIE, IN 47307-0645
Phone Number (765) 288-3691
Fax Number (765) 284-1023
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  • Page 1 LIFT-A-LOFT APX16 - G ASOLINE MANUAL NUMBER APX16092602 EFFECTIVITY: 09/26/02 Maintenance 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 (765) 288-3691 Fax Number (765) 284-1023...

  • Page 2: Table Of Contents

    LIFT-A-LOFT APX16 - G ASOLINE 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 ..........
  • Page 3 LIFT-A-LOFT APX16 - G ASOLINE 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 ..............
  • Page 4 LIFT-A-LOFT APX16 - G ASOLINE 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.

  • Page 5: Section Page

    LIFT-A-LOFT APX16 - G ASOLINE 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.
  • Page 6 LIFT-A-LOFT APX16 - G ASOLINE 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.
  • Page 7 LIFT-A-LOFT APX16 - G ASOLINE THIS PAGE LEFT BLANK CHAPTER 2 CONTENTS 09-26-02...

  • Page 8: 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.

  • Page 9: Scissor Framework Access

    LIFT-A-LOFT APX16 - G ASOLINE 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.
  • Page 10 LIFT-A-LOFT APX16 - G ASOLINE GREASE & OIL CHART – Figure 1 Point of Lubrication Capacity/ Type Amount Gasoline Engine Crankcase 7 quarts* Use Motorcraft oil or equivalent that meets (6.6 L) Ford spec. ESE-M2C153-E and API category SG or SH. 10W-30 viscosity for temps -10 to 90 F.
  • Page 11 LIFT-A-LOFT APX16 - G ASOLINE SPREADER (Opt.)Oiler System (Opt.) Compressor APX16 Lube/Service Points Figure 2 CHAPTER 2 SECTION 1 Page 4 09-26-02...
  • Page 12 LIFT-A-LOFT APX16 - G ASOLINE REAR FRONT CHAPTER 2 APX16 Lube/Service Points SECTION 1 Page 5 09-26-02...

  • Page 13: Engine

    The frequency of engine lubrication has engine). Add new filter and replace plug. been proposed by Lift-A-Loft. See Add oil and begin checking level on Preventative Maintenance Schedule Ch 5 in the Engine Operator’s Manual for other dipstick.
  • Page 14 LIFT-A-LOFT APX16 - G ASOLINE ITEM FREQUENCY ENGINE (CONT.) CARBURETOR AREA: Spray carburetor Every 300 hours or (3) months 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.

  • Page 15: Battery

    LIFT-A-LOFT APX16 - G ASOLINE ITEM FREQUENCY BATTERY Every 300 hours or every 3 months 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.

  • Page 16: Brakes

    LIFT-A-LOFT APX16 - G ASOLINE ITEM FREQUENCY BRAKES Check brake fluid level. Check for leaks. Daily inspection These vehicles have no pad wear Every 300 hours or every 3 months indicators. Use flashlight to check thickness of brake pads through sight SEE PAGE 3 FOR hole (or at ends of caliper).

  • Page 17: Controls

    LIFT-A-LOFT APX16 - G ASOLINE ITEM FREQUENCY CONTROLS Watch for vehicle control malfunction. Daily inspection Cycle check all controls to ensure they Daily inspection operate freely and without restriction. Check Emergency Controls. TRANSMISSION Daily inspection Check fluid level. Check security of linkage fasteners.
  • Page 18 LIFT-A-LOFT APX16 - G ASOLINE ITEM FREQUENCY HYDRAULIC SYSTEM (Cont.) RETURN LINE FILTER: Remove and Annually replace with correct filter element. SUCTION LINE STRAINER: Clean Annually Strainer. HYDRAULIC FLUID: Drain, (Via Annually SEE PAGE 3 FOR reservoir drain plug) flush and fill LUBRICANTS reservoir.

  • Page 19: Stabilizers

    Through normal use, certain portions of Periodically as needed the unit may need touch-up painting. Paint, in one gallon cans, and in aerosol spray cans, is available from Lift-A-Loft Corporation. PLATFORM GUARD RAILS & PLATES See that guard rails are properly Every 100 hours or every month installed.

  • Page 20: (Opt) Oiler Filter System

    LIFT-A-LOFT APX16 - G ASOLINE ITEM FREQUENCY (Opt.) OILER FILTER SYSTEM (oiler) DESICCANT FILTER: (Located on top of Daily inspection reservoir behind seat.) Unscrew and Desiccant material will change from replace with new Des-Case DC3. blue to pink. Time will vary according to humidity at your location.

  • Page 21: Maintenance Records

    LIFT-A-LOFT APX16 - G ASOLINE MAINTENANCE RECORD Model______________________ Date in Service___________________________ Unit Serial Number___________________________ LUBE/SERVICE ACTIVITY Performed See Lube/ Service Chart for details 1 ENGINE OIL – Check 1 ENGINE AIR FILTER – Check 1 RADIATOR – Check level in overflow tank 5 STEERING FLUID LEVEL –...
  • Page 22 LIFT-A-LOFT APX16 - G ASOLINE MAINTENANCE RECORD Model______________________ Date in Service___________________________ Unit Serial Number___________________________ LUBE/SERVICE ACTIVITY LUBE/ SERVICE INTERVAL See Lube/ Service Chart for details Months or Operating Hours 14a FILLER-BREATHER – Cap in place. 14c HYDRAULIC FLUID LEVEL Check level of fluid.
  • Page 23 LIFT-A-LOFT APX16 - G ASOLINE MAINTENANCE RECORD Model______________________ Date in Service___________________________ Unit Serial Number___________________________ LUBE/SERVICE ACTIVITY Performed See Lube/ Service Chart for details 15 SCISSOR MOUNTING CLEVISES – Check for cracked welds or damage and retaining hardware is in place.
  • Page 24 LIFT-A-LOFT APX16 - G ASOLINE MAINTENANCE RECORD Model______________________ Date in Service___________________________ Unit Serial Number___________________________ LUBE/SERVICE ACTIVITY Performed See Lube/ Service Chart for details 1 CARBURETOR AREA – Clean w/ spray cleaner 1 ENGINE BELTS - Check & dress fan &...
  • Page 25 LIFT-A-LOFT APX16 - G ASOLINE MAINTENANCE RECORD Model______________________ Date in Service___________________________ Unit Serial Number___________________________ LUBE/SERVICE ACTIVITY Performed See Lube/ Service Chart for details 1 ENGINE FUEL FILTERS - Replace 1 ENGINE AIR FILTER - Replace 1 ENGINE BOLTS - Check torque settings 1 ENGINE COOLANT –...
  • Page 26 LIFT-A-LOFT APX16 - G ASOLINE MAINTENANCE RECORD Model______________________ Date in Service___________________________ Unit Serial Number___________________________ LUBE/SERVICE ACTIVITY LUBE/ SERVICE INTERVAL See Lube/ Service Table for details Months or Operating Hours 10 11 12 19 PAINT & APPEARANCE 21 DESICCANT FILTER (Behind cab) –...
  • Page 27 LIFT-A-LOFT APX16 - G ASOLINE THIS PAGE LEFT BLANK CHAPTER 2 SECTION 1 09-26-02...

  • Page 28: Troubleshooting

    LIFT-A-LOFT APX16 - G ASOLINE TROUBLESHOOTING 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.
  • Page 29 LIFT-A-LOFT APX16 - G ASOLINE DEVICE ACTIVATION CHART UPPER LOWER CONTROLS CONTROLS X – DEVICE ACTIVATED A – PLATFORM SPEED LOWER SOLENOID (SOFT LOWER) IS ENERGIZED ONLY WHEN PLATFORM IS NEAR THE END OF IT’S DOWNWARD TRAVEL IGNITION POWER RELAY...
  • Page 30 LIFT-A-LOFT APX16 - G ASOLINE Limit Switches and Their Location (ESL25) 8 ft LIMIT SWITCH – PLATFORM TRAVERSE Will not permit platform to traverse out unless platform is raised beyond 8 ft. (ESL24) SOFT LOWERING LIMIT SWITCH – Activate the soft lowering system the final few inches of travel.
  • Page 31 LIFT-A-LOFT APX16 - G ASOLINE TROUBLESHOOTING CHART SYMPTOM CAUSE REMEDY 1. ENGINE WILL NOT Starter Motor Failure If a firm "rap" to the starter START housing (while the key is in → “Start “ position) activates Won’t crank starter, then the armature is...
  • Page 32 LIFT-A-LOFT APX16 - G ASOLINE SYMPTOM CAUSE REMEDY → Plugged fuel filter. Replace filter. Will crank Choke misadjusted. Inspect & adjust per Holley Tune-up kit specifications. Faulty fuel pump. Replace. Distributor related failure. Inspect the Rotor, and Cap for cracks or water. Inspect for burnt cap tips.
  • Page 33 LIFT-A-LOFT APX16 - G ASOLINE SYMPTOM CAUSE REMEDY 3. NO STEERING Steering mechanism (i.e. tie Inspect and remove FUNCTION rod) obstructed or obstruction. Replace → damaged. damaged parts. Pump is running Clogged Filter or Filler- Change filter; Clean cap; breather cap,.
  • Page 34 LIFT-A-LOFT APX16 - G ASOLINE SYMPTOM CAUSE REMEDY 4. TRANSMISSION SLOW Improper oil level; Refer to Chapter 5, OR ROUGH INITIAL Contaminated oil; Clutch/ ENGAGEMENT Band problems; Filter clogged. 5. SLOW TO STOP Broken or collapsed brake Inspect and replace lines.
  • Page 35 LIFT-A-LOFT APX16 - G ASOLINE SYMPTOM CAUSE REMEDY 6. LOSS OF ALL Engine/pump failure. Check engine/pump. CONTROLS and/or PUMP/MOTOR FUNCTION Repair/replace pump. SPEED IS REDUCED Hydraulic line failure. Replace hydraulic lines. Hydraulic fluid level low. Fill reservoir with approved fluid.
  • Page 36 LIFT-A-LOFT APX16 - G ASOLINE SYMPTOM CAUSE REMEDY 7. UNIT CONTINUES T0 Control button malfunction. Remove, clean, and test. RESPOND TO A Replace if necessary. MOMENTARY ACTUATION OF A CONTROL BUTTON Directional valve will not Remove, clean valve, return to center position due replace seals if necessary.
  • Page 37 LIFT-A-LOFT APX16 - G ASOLINE SYMPTOM CAUSE REMEDY 9. PLATFORM WILL NOT Obstruction in scissor Raise platform slightly and LOWER assembly or under platform. remove obstruction. WARNING: Do not work under platform without scissor spreader in place. "Lower" valve on main...
  • Page 38 LIFT-A-LOFT APX16 - G ASOLINE SYMPTOM CAUSE REMEDY 11. (Opt.) COMPRESSOR Intake air filter is dirty. Replace. WILL NOT OPERATE Seals in motor/pump are Replace. Consider worn. replacing motor or pump. Switch has failed. Check and replace. Pressure control valve is Readjust.
  • Page 39 LIFT-A-LOFT APX16 - G ASOLINE THIS PAGE LEFT BLANK CHAPTER 2 SECTION 2 09-26-02...

  • Page 40: General

    LIFT-A-LOFT APX16 - G ASOLINE 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.
  • Page 41 LIFT-A-LOFT APX16 - G ASOLINE SAE GRADE SAE GRADE SAE GRADE SAE GRADE GRADE BOLT 1 OR 2 MARKING MINIMUM MEDIUM BEST INTERMEDIATE DEFINITION COMMERCIAL COMMERCIAL COMMERCIAL QUALITY QUALITY QUALITY QUALITY MEDIUM MEDIUM MEDIUM LOW CARBON CARBON CARBON MATERIAL CARBON...

  • Page 42: Engine/Transmission Carriage

    LIFT-A-LOFT APX16 - G ASOLINE 2. ENGINE/TRANSMISSION CARRIAGE: (Total task time - 45 min. average) Removal: (Task time - 15 minutes average) Electrical Connections Disconnect the negative terminal from the battery and alternator bracket. Disconnect the positive terminal from the starter motor and alternator.
  • Page 43 LIFT-A-LOFT APX16 - G ASOLINE Disconnect the radiator coolant hoses and the transmission coolant lines. Support the transmission coolant lines so that they do not catch during removal of the engine carriage assembly. Mechanical Connections From Inside the Cab Disconnect the throttle and choke cables from the carburetor and remove them from their mounting brackets.
  • Page 44 LIFT-A-LOFT APX16 - G ASOLINE Raise the engine up enough to ensure that the bell housing and oil pan bolts do not catch on the APX frame cross members. Make sure that the transmission coolant lines to not catch during removal.
  • Page 45 LIFT-A-LOFT APX16 - G ASOLINE 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...

  • Page 46: Cylinder Seals

    LIFT-A-LOFT APX16 - G ASOLINE 3. STEERING CYLINDER: Removal: Disconnect battery. 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.

  • Page 47: Radiator

    LIFT-A-LOFT APX16 - G ASOLINE 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.

  • Page 48: Seat

    LIFT-A-LOFT APX16 - G ASOLINE Check oil level after warming up the engine and add as needed. 6. SEAT : Removal: Remove the four nuts on the underside of the wheel well below the seat. Lift the seat vertically to remove.

  • Page 49: Driveshaft

    LIFT-A-LOFT APX16 - G ASOLINE 9. DRIVESHAFT: Removal: Fig 2 Remove the four bolts (1) securing the driveshaft (2) to the axle companion flange. Do not allow the parking brake disk (3) to fall. Insert cardboard wedges between the pads of the parking brake to prevent loss of the pads.

  • Page 50: Shifter

    LIFT-A-LOFT APX16 - G ASOLINE (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.

  • Page 51: Accelerator Cable And Pedal

    Installation: Reverse the above procedure as it applies to each component. 14. STEERING AXLE: Removal: Elevate the APX16 by supporting either its frame rails or the front and rear bumpers. Remove both front wheels. CHAPTER 2 SECTION 3...

  • Page 52: Steering Column

    LIFT-A-LOFT APX16 - G ASOLINE Disconnect the brake lines from the frame mounted bulkheads. Disconnect both hydraulic hoses from the steering cylinder. Remove the bolts securing the shocks to the front axle. Support the front axle. Remove the bolts passing through the front leaf spring eyes.

  • Page 53: Master Cylinder/Booster Assembly

    LIFT-A-LOFT APX16 - G ASOLINE 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. Remove the nuts from the studs on the front side of the dash (Fig 6 Item 1) and remove the steering pump.

  • Page 54: Brake Pedal

    LIFT-A-LOFT APX16 - G ASOLINE From inside the driver’s side front compartment, tilt the master cylinder/booster assembly upward and slide forward to remove. Installation: Reverse the above procedure. Be sure to bleed the reservoir and each brake caliper. (See Ch 3, Sect 4) Check for leaks and re-bleed as necessary.

  • Page 55: Alternator/Voltage Regulator

    LIFT-A-LOFT APX16 - G ASOLINE Loosen the jam nut on the cable at its mount to remove the parking brake cable. The nut nearest the end of the cable may have to be completely undone in order to allow the cable to slip out of the mount.
  • Page 56 LIFT-A-LOFT APX16 - G ASOLINE Installation: Reverse the above procedure. Be sure to properly install all electrical connections. Refer to the electrical prints if necessary. 20. GAUGES: OIL TEMPERATURE, OIL PRESSURE, FUEL, VOLT, & HOUR METER: Removal: Remove the two thumb screws from the dash panel and lower it.

  • Page 57: Gauges

    LIFT-A-LOFT APX16 - G ASOLINE 22. LIGHTS: HEAD LIGHTS, BRAKE, TURN, DRIVING, BACK-UP: Removal: 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.

  • Page 58: Scissor Cylinders

    LIFT-A-LOFT APX16 - G ASOLINE Installation: Reverse the above procedure. 24. 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.)
  • Page 59 LIFT-A-LOFT APX16 - G ASOLINE (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.

  • Page 60: Stabilizer Cylinder

    LIFT-A-LOFT APX16 - G ASOLINE STABILIZER CYLINDERS: Removal: (1) Raise entire truck 12” to give clearance (use jacks; lifts; or ramps.) WARNING: Vehicle must be fully supported before working under unit. (2) Disconnect hydraulic lines at ends of cylinder. (Inner access panel on upper section of stabilizer housing.) (Plug hoses and ports.)

  • Page 61: Hydraulic Valves - General

    LIFT-A-LOFT APX16 - G ASOLINE (8) Remove vehicle from supports. 26. 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.

  • Page 62: Compressor (Opt.)

    LIFT-A-LOFT APX16 - G ASOLINE (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.
  • Page 63 LIFT-A-LOFT APX16 - G ASOLINE (2) Remove compressor cover to locate hydraulic motor/compressor assembly. (3) Remove bolt (left side outboard) holding slide out tray. (4) Loosen hydraulic motor mount hold down bolts and loosen adjusting bolts (Fig 11) allowing motor to slide toward compressor to loosen belt.
  • Page 64 LIFT-A-LOFT APX16 - G ASOLINE (8) Turn on hydraulic motor and check for hydraulic oil leaks and ease of operation. (9) Check and refill hydraulic fluid level as needed. 29. (Opt.) COMPRESSOR: Removal: (1) Locate hydraulic motor/compressor on passenger side behind cab.

  • Page 65: Brake Pads - Rear

    LIFT-A-LOFT APX16 - G ASOLINE (2) Remove cover over tray and remove bolt holding tray in closed position. Slide tray out. (3) Remove all hydraulic oil and/or turbine oil lines and mark location for re- assembly. (4) Unbolt oil pump or motor from APX16 unit and remove.
  • Page 66 LIFT-A-LOFT APX16 - G ASOLINE CAUTION: Do not allow caliper to hang by the brake line or brake line damage may occur. Support the caliper or wire to frame. (5) Compress holding spring (Item 3) allowing old brake pads to be pulled free.

  • Page 67: Brake Pads - Front

    LIFT-A-LOFT APX16 - G ASOLINE (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"...
  • Page 68 LIFT-A-LOFT APX16 - G ASOLINE (3) Rotate top of caliper out of holding bracket and pull from brake rotor. (4) Use wire to fasten calipers to frame. CAUTION: Do not allow caliper to hang from brake line or damage to brake line may occur (5) Remove old brake pads (pads are clipped into position.) Notice how pads are...
  • Page 69 LIFT-A-LOFT APX16 - G ASOLINE Replace brake fluid in master cylinder with new fluid from a fresh can. Do not allow master cylinder to become empty. Break in new pads by using brakes gently until friction material has taken a "set"...

  • Page 70: Repair

    REPAIR 1. GENERAL: This section contains general instructions for repair of components in the APX16. 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.

  • Page 71: Electrical Components

    LIFT-A-LOFT APX16 - G ASOLINE 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.).
  • Page 72 LIFT-A-LOFT APX16 - G ASOLINE Contact Insertion Grasp the contact-wire Hold the connector with the Push the contact straight into the assembly between the rear grommet facing you. connector grommet until a positive thumb and forefinger on stop is felt. The retaining fingers in...

  • Page 73: Brake Booster

    LIFT-A-LOFT APX16 - G ASOLINE 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: Drain fluid from unit before disassembling.
  • Page 74 LIFT-A-LOFT APX16 - G ASOLINE Remove spring (19), shim(s) (18) and valve stem (17) from housing (16). Be (12) aware of the number of shim(s) (18) removed for re-assembly purposes. Assembly: NOTE: Use only hydraulic oil in power assist section.
  • Page 75 LIFT-A-LOFT APX16 - G ASOLINE Install end plug (3) on piston (8). (13) Install retainer (14) over piston (12) and install spring (15) over retainer (14). (14) Install entire internal parts assembly (22) into housing (16) bore. Use a spanner (15) wrench to torque end plug to 30-40 lbs-ft (40-55 Nm).
  • Page 76 LIFT-A-LOFT APX16 - G ASOLINE Re-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. Clean all parts thoroughly before assembling. Install new retaining ring (28) in flange end of housing (23).
  • Page 77 LIFT-A-LOFT APX16 - G ASOLINE Install new O-rings (26) on new adapters (27). Install new springs (24), new (14) valves (25), and new adapters (27) in housing. Torque adapters 45-50 lbs-ft (61- 68 Nm). 7. BRAKE BLEEDING PROCEDURES – PRESSURE BLEEDING: Master cylinder must be mounted to power assist section.
  • Page 78 LIFT-A-LOFT APX16 - G ASOLINE 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. Actuate master cylinder piston with a smooth object, large enough to hold the small internal piston from coming out.

  • Page 79: Other Components

    LIFT-A-LOFT APX16 - G ASOLINE 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.) Chapter 4 –...

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