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Magliner LiftPlus Maintenance Manual

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

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Summary of Contents for Magliner LiftPlus

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

  • Page 2: Table Of Contents

    LiftPlus ® 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...

  • Page 3: Liftplus Toolkit

    LiftPlus ® LiftPlus Toolkit • Standard Allen wrench set • #1, #2 Phillips head screwdrivers • Large flat head screwdriver • Micro flat head screwdriver • Standard socket wrench set • Metric socket wrench set • Standard combination wrench set •...

  • Page 4: Safety Instructions

    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.

  • Page 5: Removing Covers

    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. Battery Cover Fold the LiftPlus; pull latch tab on top of the cover and slide down. Item Qty.

  • Page 6: Disconnecting/Connecting Battery

    Remove connectors off the positive and negative terminals. Unfold and lock the LiftPlus. 2. Disconnecting the battery. Fold the LiftPlus. Slide the connectors onto the positive and negative terminals. Install the battery cover; unfold and lock the LiftPlus. LIFT DRIVE SYSTEM Item Qty. Part Number...

  • Page 7: 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.

  • Page 8: Motor Assembly

    LiftPlus ® LIFT DRIVE SYSTEM (CONT.) M, N K, L Item Qty. Part Number Motor Assembly Part No.: 48” models - 534100 Complete motor assembly includes: 60” models - 534100-60 A Motor - 12V DC 63024 72” models - 534100-72...
  • Page 9 3/16” MAGNETIC HEX DRIVER OR ALLEN WRENCH TOOLS NEEDED: 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.

  • Page 10: Pulleys 1, 2-3

    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.

  • Page 11: Motor Brake Pad

    MOTOR BRAKE PAD TOOLS NEEDED: NEEDLE-NOSE VISE-GRIPS OR PLIERS Removal: 1. Turn off the LiftPlus and disconnect the battery. 2. Remove the motor cover. 3. Grip the motor brake pad with a pair of needle nose vise-grips or pliers. 4. Hold the motor brake lever firmly against the motor mount with one hand.
  • Page 12 LiftPlus ® LIFT DRIVE SYSTEM (CONT.) Item Qty. Part Number Lift screw - 48” 531102 Lift screw - 60” 531105 Lift screw - 72” 531107 Item Qty. Part Number A Spring pin - 3/16” dia. x 1-5/8” long 81167 B Spring pin - 3/16” dia. x 1” long...

  • Page 13: Lower Lift Screw Collar And Assembly

    6. Check to be sure that the guide has not slid out of the bottom of the column. If it has it must be slid back and held in place by hand to avoid damage while folding the LiftPlus. 7. Fold the LiftPlus 8.

  • Page 14: Lift Screw Thrust Bearing

    6. Using a 1-2 lb hammer deliver gentle blows to the pin until it begins to enter the hole in the Lift screw. 7. Continue to drive the pin until the top of the pin is level with the lift screw collar 8. Install Pulley 4 Install the lift screw assembly onto the LiftPlus. GUIDE...
  • Page 15 LiftPlus ® Quick change latch assembly - 536034 Item Qty. Part Number A Nut, trolley drive 531705 B Trolley assembly 531700 C Rear roller 531709 D Axle for rear roller 22146 E Front roller 531708 F E-ring - 3/8” 221012...

  • Page 16: Trolley Assembly

    8. Check to be sure that the guide has not slid out of the bottom of the column. If it has it must be slid back and held in place by hand to avoid damage while folding the LiftPlus. 9. Fold the LiftPlus 10.

  • Page 17: Front Rollers

    1. Slide the caster shells around the caster plate as shown. Slide the M10 screw through both shells and secure with the washer and lock nut. 2. Slide the caster shells into the LiftPlus arm and secure with 2” long screw and lock nut. 1-800-MAGLINE (624-5463)
  • Page 18 A Brake caliper, RH 532100R B Brake caliper, LH 532100L Part of cable assembly Item Qty. Part Number C Wheel assembly 532310 D E-ring - 1/2” 221009 E E-ring - 5/16” 221010 Quantities listed are per side of the LiftPlus. 1-800-MAGLINE (624-5463)

  • Page 19: Disengaging/Engaging Brake Cable Ends

    LiftPlus ® DISENGAGING/ENGAGING THE BRAKE CABLE ENDS TOOLS NEEDED: VISE-GRIPS Disengage: 1. Grip the adjustable cable crimps with a pair of vise-grips. 2. Loosen the setscrew using a hex driver or allen wrench. 3. Remove the adjustable cable crimps from the cable 4.

  • Page 20: Adjusting The Brakes, Caliper

    LiftPlus ® 9. Slide the rear wheel assembly off the axle. 10. Slide the inner brake pad and brake pad spacers off the mounts. Installation: 1. Place blocking under the chassis on the side you are working. 2. Slide the inner brake pad and brake pad spacers onto the mounts.
  • Page 21 LiftPlus ® Adjusting the Brake Calipers The brake calipers can be adjusted using a 3/16” hex screwdriver. The brake caliper screws are accessed between the wheel spokes on either side. 1. Adjust the brake cable mount to its highest position as described in the preceding section (Adjusting the Brake Cable Tension).

  • Page 22: Replacing Battery

    5. Inspect the Battery for cracks, leaks, and corrosion. If you find cracks, leakage or corrosion on the battery: a. Contact Customer Service to order a replacement battery - do not operate the LiftPlus until repairs are made. b. Wear acid-resistant gloves and chemical goggles. Do not let leakage contact your skin.
  • Page 23 TOOLS NEEDED: LARGE FLAT SCREWDRIVER Removal: 1. Turn off the LiftPlus and remove the battery 2. Remove the battery box by pushing up from below. It may be necessary to pry at the upper lip with a large flat-blade screwdriver.

  • Page 24: Lower Limit Switch

    6. Fasten the lower limit switch to the column using the two screws. NOTE: Do not over tighten the screws. 7. Install the battery box and the battery. 8. Unfold and lock the LiftPlus. 1-800-MAGLINE (624-5463)

  • Page 25: Upper Limit Switch

    LiftPlus ® UPPER LIMIT SWITCH TOOLS NEEDED: #1 PHILLIPS SCREWDRIVER, BLUE THREAD LOCKER Removal: 1. Turn power switch off and remove the battery. 2. Remove the top cover. 3. Remove the screws fastening the upper limit switch using a #1 Phillips driver.

  • Page 26: Power Switch; Up/Down Switch

    TOOLS NEEDED: LARGE FLAT SCREWDRIVER (removal only) Removal: 1. Turn power switch off and disconnect the battery, leaving the LiftPlus folded. 2. Remove the brake cover. 3. Reach one finger around the wires connecting to the power switch and pull them gently toward you.

  • Page 27: Charging Input; Remote Control Input

    2. Remove the brake cover. Unplug the power jack wiring harness from the control board. 3. Remove the lock nut from the front side of the power jack connector. 4. Remove the harness from the LiftPlus by pulling through the back of the electrical mount plate. Installation: 1.

  • Page 28: Control Board Diagram

    LiftPlus ® Control Board Diagram Caution: Disconnect the battery before making any replacements to the wiring harnesses or control board. When connecting wire terminals, make sure the locking tabs on all wires and the board are facing each other. Locking tab on...
  • Page 29 LiftPlus ® Control Board Diagram - Top Wiring harnesses are connected to the top side of the control board as shown below. Motor wire extensions (60” and 72” units): Motor wires (part of motor) 60” units - (black, red) • Positive lead extension - 534417 Upper limit switch •...

  • Page 30: Maintenance

    LiftPlus ® Maintenance Inspection Area Procedure/Normal Condition Frequency Keep clean and dry. Replace any cracked or missing Outside Surfaces Daily covers. Fasteners Daily Tighten any loose hardware. Battery Charging Daily Green charging light should turn on when charging. Rear Wheels Daily Inspect wheels and tires for wear and cracks.

  • Page 31: Troubleshooting Guide

    LiftPlus ® Lubrication Points Troubleshooting Guide Problem Solution(s) The lift does not respond, and does 1. Is the power switch turned on? not make any noise when the lift 2. Has the circuit breaker tripped? switch is activated. 3. Check the battery connections.

  • Page 32: Advanced Troubleshooting Guide

    • After charging, check voltage across battery terminals: • Under 12V - replace battery • 12 to 12.6V - Normal • Place a load on the LiftPlus and run up and down a few cycles. If voltage drops from 12V, you should replace the battery. Figure 1...
  • Page 33 • If the switches are operating correctly, then determine whether the terminals on top of the control board are getting power to the motor. • Remove the top covers from the LiftPlus. Remove the Multi-Meter from the battery and reconnect the battery. Change the range on the Multi-Meter to volts.
  • Page 34 • Lubricate the lift screw; see pages 13-14 for instructions. Diagnostic Instructions: 1. Remove the motor cover from the LiftPlus. Check the wire connections to the upper and lower switches and the board. Fix any loose connections; replace any damaged wiring.
  • Page 35 LiftPlus ® Part Accessories Number Work bench (includes platform, vice clamps, vice handle and back bar) 536020 Quick change adapter (for use with 536020 work bench only) 536026 Arbor - 24” long x 1.66” diameter 536039 Adjustable boom with chain/hook assembly (requires arbor...
  • Page 36 LiftPlus ® Part Parts Number Limit switch (used for upper and lower) 62067 Lock washer for circuit breaker 80799 Motor assembly - high speed (includes motor, mounting bracket, solenoid 534101 and brake) Motor assembly - standard speed (includes motor, mounting bracket,...
  • Page 37 LiftPlus ® 1-800-MAGLINE (624-5463)
  • Page 38 LiftPlus ® 1-800-MAGLINE (624-5463)
  • Page 39 LiftPlus ® 1-800-MAGLINE (624-5463)
  • Page 40 LiftPlus ® Form # B9384 © Copyright 2017-2019, Magline, Inc. REV 10/19 U.S. Patent: www.magliner.com/patents 1-800-MAGLINE (624-5463)

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