Service Manual
Contents
1. 52 0 TENSION PINK BOUE 5 nit eR NM 5 2 10 IDLE SHAFT 52 HU BENRINGS eese eet scettr ice e Ne doeet erret E 5 2 12 FIXED SPROCKET SHAFT ASSEMBLY ccccccccccccsssscssscccccsssssscsccsccessesscssssscescssssssssssssecsesssssessscessesssssassess 6 DISMANTLING AND 2 1 1 asses e seta snas aee e 12 6 1 DISMANTLING 12 6 2 REASSEMBLING THE LYCOLOADER 2 2 00000 0 0 0 0000 1020000 16 7 CHECK LIST FOR GENERAL SERY ICE cereo ee eee nenne eterna nasse tete tasas ases e seta snas aes e 20 A ER Ee eei 20 7Z 22INSPECTION PROCEDUBE aee re I Une GI EN 20 8 SPAREPARTS FITTING Ue NER ERN ue 21 81 DRIVE END CORNER BLOCK KE eR Aeterna e ed eere dut ed festes dale eei eei 21 8 2 HANDLE ASSEMBLY i Te ete t teet he coe bete o ER itia ee PERO YES 21 8 3 BRAKE CLUTCH ASSEMBLY2. 21 8 4 TENSION LINK ASSEMBLY eee eee eene enne 22 S S LATCH REPATR KIT eee RR ER P CREDE ERE EC RENE RR ee 22 8 6 CABLE CHAIN ASSEMBLBDY needed red e EC Eee tee 23 SS EASTENBR KETE tior ors etal E RUE rM Uti 23 8S RUBBER KIT Rl ae act og 23 8 9 PULLEY REPAIR KIT Re dede 25 9 TEST PROCEDURE AFTER 1 1 sese sean 26 10 DOCUMENTATION 50 50 26 11 APPENDIX PART NUMBER 1 sesenta nass ses eese tasa asses e seen 27 IT PEATEORM ASSEMBEYX euet aac pere n a 27 TENSION EINK nennen retra ee RAT dt tod Mom M eke 27 IE OESTE ementi e AOL LI A T Em 28 L14IDEER SIDE CORNER BEOGK tecti to estre RE IC teo e eoe Bs esc ege 28 11 5 DRIVESIDECORNBER BLEOGK 3 ete hec e Re EC E e ERO T EET EE TER 29 1126 BRAKE ASSEMBIGY toda iua ie eM 29 11 7 DRIVE SIDE END BLOCK ASSEMB
3. Brake Pad 12 months Fixed Sprocket Shaft amp Nuts 12 months Clutch Assembly 12 months Steel Cables 12 months Pulleys 12 months Platform Screws 12 months Starlock Washers on Latch Handle 12 months Tension Link Bolt 12 months Idle Shaft Circlip 12 months Locking Block Grub Screws 12 months Table 4 Maintenance Schedules 7 3 INSPECTION PROCEDURE The following step should be carried out to service the LycoLoader Dismantling the LycoLoader Steps 1105 Dismantling the LycoLoader Step 9 Dismantling the LycoLoader Steps 111017 X Inspect brake nuts fixed sprocket shaft brake pads and clutch assemblies for wear see parts specifications for details Re lubricate the fixed sprocket shaft with nickel anti seize and place 10 grams of APXT grease in drive shaft end if required Inspect cables for wear see parts specifications for details Inspect pulleys for wear see parts specifications for details Reassembling the LycoLoader Steps 17 to 24 Reassembling the LycoLoader Step 26 X Ensure all grub screws are tightened see parts specifications for details Reassembling the LycoLoader Step 29 Dismantling the LycoLoader Step 6 Dismantling the LycoLoader Steps 18 to 20 X Inspect the circlip on idle shaft see parts specifications for details Inspect cables for wear see par
4. LH DIECAST 313 ALUM T Section Right Hand 100107 T SECTION RH DIECAST 313 ALUM Plastic Handle 100044 HANDLE PLASTIC Side Member Left Hand 100048 RHS 50 8x50 8x2 0 x 590 LONG Side Member Right Hand 100049 RHS 50 8x50 8x2 0 x 590 LONG Rear Member 100050 RHS 50 8 50 8 2 0 x 1600 LONG Platform Screws 100051 SCREW PLATFORM RETAINING Tray Bracket 100055 TRAY BRACKET DIECAST 313 ALUM Latch Handle 100063 LATCH CATCH HANDLE Table 3 Spare Parts List 5 2 PARTS SPECIFICATIONS 5 2 1 GRUB SCREWS The Grub Screws located in the Locking Block should be tightened to a torque of 25 30 Nm 5 2 2 PLATFORM SCREWS The screws joining the T Sections to the Platform should be tightened to torque of 30 35 Nm 5 2 3 BRAKE NUTS The Brake Nuts should be flat and free from any defects such as scratches cracks or scores 5 2 4 BRAKE PADS The Brake Pads should conform to the specifications listed below as well as showing no signs of cracking or deformation Outside Diameter 42 mm MINIMUM Inside Diameter 13 0 mm MAXIMUM Thickness 4 5 mm MINIMUM HINT If brake pads have a glazed appearance it is possible that they may have been over heated at some stage This can result in brake noise The glazed surface can be simply removed with a medium to course grade sandpaper such as grade 120 grit 5 2 5 CLUTCH ASSEMBLY The Clutch Assembl
5. corner block Slide the idle shaft through the sprocket and then through the idle side corner block see Figure 6 Place the circlip onto the front of the idle shaft ensuring the bearing is in place see Figure 6 Take up the slack by pulling lightly on the short cables at both ends of the RHS Ensure the circlip groove is clean and free of grit Take care not to over stretch the circlip 10 Feed the long cable on the idle side through the idle side RHS 11 Slide the idle side RHS onto the idle side corner block 12 Re attach the cable onto the pulley and then connect the pulley to the idle side end block so that the cable is captive between pulley and the end block see Figure 5 13 Slide the idle side end block back into the idle side RHS see Figure 5 Take up the slack by lightly pulling the cable 14 If installing new brake pads smear a light coating of grease on the brake pads 1 2 shots 1 2 grams of grease is enough for both wipe off excess with rag 15 On the drive side lubricate the threaded section of the fixed sprocket shaft with Nickel Anti Seize Replace the back brake pad sliding it onto the fixed sprocket shaft see Figure 4 16 Replace the clutch assembly sliding it onto the fixed sprocket shaft Note the clutch must rotate clockwise inside the clutch housing see Figure 4 17 Replace the second brake pad sliding it onto the fixed sprocket shaft see Figure 4 18 Place approximately 10 grams of gr
6. seta setas tasto seta stessa ansa 8 TABLE 2 SPARE PART 9 TABLE 3 SPARE PARTS 10 TABLE 4 MAINTENANCE SCHEDULES seta sets sensns sens essen netu ne 20 1 GENERAL LAYOUT Figure 1 General Layout of the LycoLoader 2 OPERATION The LycoLoader is a lifting aid designed to be fitted to flat tray vehicles It is a manually operated lifting device designed to lift a maximum safe working load SWL of 300kg 66015 The device operates using a brake and clutch mechanism 3 TROUBLESHOOTING GUIDE The following table matches symptoms with probable causes to aid in resolving the fault at hand This is not intended to be an exhaustive list but more as a guide to the best starting point for service SYMPTOM Customer complaint After some period of trouble free use Latches not holding firm Latches have been stretched from misuse forcing M Tray brackets are not rigidly fixed to the tray PROBABLE CAUSE REFER TO SECTION 8 5 Cables frayed or broken Cables are worn or damaged and are due to be changed this is required every 2 years or 2000 cycles or when damage has occurred Section 8 6 Brake not working slipping Clutch assembly is defective and needs to be replaced Section 8 3 Brake Noise Unit has been operated continuously with high load and
7. the smooth side of the washer facing the tray bracket 6 7 Remove the rubber buffer from the T section 8 Replace rubber buffer with new rubber buffer securing with Loctite 480 adhesive 9 Fold front section of platform 10 Store platform in stowed position reattach latches on both sides 86 CABLE CHAIN ASSEMBLY Disassemble the LycoLoader as described in section 6 1 Replace all of the parts provided in the Cable Chain Assembly kit and reassemble the LycoLoader as per Section 6 2 8 7 FASTENER KIT Remove existing fasteners and replace with new fasteners X Ensure the fasteners are replaced in the same orientation as they were removed 8 8 RUBBER KIT 1 Release the latch handle on both sides 2 Unfold the platform 3 Lower the platform to the ground SOS cU d 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Remove the four 4 cable buttons from the T section Unscrew eight 8 platform screws and remove T section from platform Unscrew two 2 platform screws from platform cap and remove repeat for both sides Remove insulating clips from platform caps and T section Remove canoe clips from platform Remove edge rubber from front platform Remove rubber buffers from T section 11 Remove hinge rubber Note the optimum angle for removing the hinge rubber is 60 between the two platform sections Replace hinge rubber keeping the two platfor
8. LY 30 11 8 IDLER SIDE END BLOCK ASSEMBLY 4 eee eene ee eene e 30 11 9 MISCELLANEOUS 5 oie IINE eld Ot REO n RR 31 LycoLoader Service Manual Issue 3 September 5 2008 Page 3 LIST OF ILLUSTRATIONS FIGURE 1 GENERAL LAYOUT OF THE LYCOLOADER 6 FIGURE 2 GRUB SCREW 8 2 20 seen 12 FIGURE 3 END BLOCK DISASSEMBLY DRIVE 6 2 000 000 13 FIGURE 4 BRAKE CLUTCH DISASSEMBLY 2200200 200 2 0 2 13 FIGURE 5 END BLOCK DISASSEMBLY IDLE SIDE 14 FIGURE 6 IDLE SHAFT 14 FIGURE 7 FIXED SPROCKET SHAFT DISASSEMBLY 0200 4 0 1020 netus etn setas tassa seta sn 15 FIGURE 8 CABLE PLACEMENT ON IDLE SIDE CORNER 16 FIGURE 9 CABLE ARRANGEMENT 17 FIGURE 10 LINK ASSEMBLY REPLACEMENT eene eee eene tenen ntn setas tassa seta sistens esos enne 22 FIGURE 11 LATCH 23 LIST OF TABLES TABLE 1 TROUBLE SHOOTING TABLE eee netu netu
9. Manual Important Please read safety and Warranty Information Prior to Installing the LycoLoader on your Vehicle Date 1 July 2009 Manufactured by Healy Group P L 11 12 Northumberland Rd Caringbah NSW 2229 Ph 02 9525 5522 Fax 02 9525 5513 email service lycoloader com au WWW lycoloader com au H BUILT BY HEALYGROUP TABLE OF CONTENTS 1 GENERAT LAYOUT a OUR VE Re 0 FR TV FEE E seeded en SE ine So UPS 5 pg Twv 7 3 TROUBLESHOOTING GUID 7 4 TOOLS REQUIRED FOR SERVICING sscssssssssssssssssssscssccssssscssssssnsssssscssnsssesssssnassesssssnassessssssascesssssssceess 8 5 SPARE PARTS LIST ue aw exa eoe EUR TOS aee usen vao e dE eeu 9 3 Ie ea ien MU Mee 9 5 2 PARTS SPECIFICATIONS 10 527 GRUB dee tiit A rats SO 5 2 2 PLATFORM 5 532 NUTS teet tiep eee ee e reve S 2 PADS Ne RN RUN NM S CEUICHJASSEMBEY snnt eire 3250 SEBEL CA BEES DED TOPULEEYS roue uit oe EAS Neth M uot ea ae e cid AE pee DE ke fee 520 SVAR OCK WASHERS
10. at high temperature Replace clutch assembly and brake pads Sections 5 2 4 and 8 3 When the handle is turned nothing happens The handle has broken Either the chain or fixed sprocket assembly has failed New handle required Section 8 2 Inspect as per Section 7 2 Broken Handle Overloading or misuse of LycoLoader New handle required Section 8 2 Platform Drops to Ground Suddenly Brake nut seized to fixed sprocket shaft Apply anti seize to fixed sprocket shaft Refer Section Fault with new unit or not working when assembled after service work Platform moves in jerks Cables overlapped or twisted most commonly around the drive shaft 6 1 and 6 2 as required NB if the cable is only twisted around the drive shaft then it is not necessary to remove the frame from the vehicle Platform sits unevenly M Cables overlapped or twisted M 6 1 6 2 as required Platform only winds part way down M Cables overlapped M 6 1 6 2 as required Handle is difficult to turn M Too much load M Reduce load to a maximum of 300 kg Handle locks when turning in the clockwise direction Clutch mechanism is in the wrong way Section 8 3 Platform creeps down uan Clutch mechanism is in the wrong way Section 8 3 M No brake pads M Section 8 3 Table 1 Trouble Shooting Table 4 TOOLS REQUIRED FOR SERVICING The follo
11. ately 10kg first Follow all operating instructions from the LycoLoader Operators Manual Lower the platform to the ground apply the load and raise the platform Stop several times on the way up to make sure the brake is working the platform should immediately come to a stop when your hand is removed Lower the platform pausing several times to ensure the break is working Pay attention to any unusual noises or inconsistencies in the force to turn the handle The LycoLoader has some characteristic noises that are consistent with the sound of cables sliding chains meshing with sprockets and the sliding noise of the brake when the platform is going down These sounds should be audible but not unpleasant or disturbing Repeat this process with loads of approximately 50 100 200 and 300kg Never use the LycoLoader to lift people or unstable loads As a precaution keep clear of the area below the LycoLoader whilst load testing reassembled units If there are any problems first refer to Section 3 Trouble Shooting Guide If difficulties continue contact Lyco Parts and Service Division 2 02 9525 5522 02 9525 5513 10 DOCUMENTATION Sign and stamp all of the relevant documentation Relevant details are to be recorded to validate customer warranty claims APPENDIX PART NUMBER INFORMATION 10 1 PLATFORM ASSEMBLY Anchor Clip Part of Kit PZQ87A1009 m Fixed Platform 06646 Ru
12. bber 100068 Buffer Platform Screw 100051 10 2 TENSION LINK Platform Cap 100111 Xmas Tree Clip 100058 Rubber Hinge 100038 Or Part of Kit 104262 Hinged Platform Po adi 100081 ecl Edge Rubber 100052 Or part of Kit 104262 Tension Link Fasteners Part of Kit 104282 Nut Nyloc M10 Tray Bracket 100055 Bracket Only T Section 100108 LH shown 100107 RH not shown Bolt M10 x 50mm 100043 Tension Link 10 3 LATCH Latch and Cam Part of Kit 102139 Starlock Washer 100067 Part of Kit 102139 Latch plate 100064 Latch Handle Ceo 100063 10 4 IDLER SIDE CORNER BLOCK Corner Block 100110 Circlip 100029 Shaft 100033 nud 2001 iM b Sprocket 100054 100029 Bearing 100023 10 5 DRIVE SIDE CORNER BLOCK Corner Block 100110 Fixed Sprocket Assembly 100005 Chain Guide 100027 Chain amp Cable Assembly Part of Kit 100008 10 6 BRAKE ASSEMBLY di d Bearing 100023 Or Part of Kit 104261 Drive Nut 100036 Or Part of Kit 104261 Brake Pads a
13. ease in the drive shaft on the brake nut end and screw the drive shaft onto the fixed sprocket shaft see Figure 4 19 Feed the long cable on the drive side through the drive side RHS 20 Slide the RHS over the corner block ensuring the locking block is inserted correctly and the cable is aligned correctly and not twisted around the drive shaft 2 Re attach the cable onto the pulley and then connect the pulley to drive side end block so that the cable is captive between pulley and the end block see Figure 3 22 23 24 25 26 27 28 29 30 3T 32 33 Slide the end block back into the RHS see Figure 3 Tighten the grub screws in the back locking block see parts specifications for details Tighten the grub screws in the side locking block see parts specifications for details Replace the corner block caps on both corner blocks Apply a film of adhesive such as Loctite 454 to secure the caps Re attach the frame to the tray brackets ensure the tray brackets are secured to the tray Re connect drive side tension link to drive side T bolt Re connect idle side tension link to idle side T bolt Re attach cable buttons to T section Wind the platform fully up Fold front section of platform Store platform in stowed position fasten latches on both sides Complete the test procedure described in Section 9 7 CHECK LIST FOR GENERAL SERVICE 71 ITEMS FOR INSPECTION Item to Inspect Inspection Interval
14. ecessary to lock the fixed sprocket shaft to loosen the drive nut Corner Block 3 Fixed Sprocket Shaft Chain Guide Figure 7 Fixed Sprocket Shaft Disassembly Remove the chain guide from the corner block see Figure 7 Remove the fixed sprocket shaft from the drive side corner block see Figure 7 Remove the chain from the fixed sprocket shaft 6 2 REASSEMBLING THE LYCOLOADER 1 Place the chain around the fixed sprocket shaft see Figure 7 X The cable should be arranged so that turning the LycoLoader handle in a clockwise direction will result in the platform being raised 2 Slide the fixed sprocket shaft into the drive side corner block see Figure 7 Fit the loose bearing over the threaded end of the fixed sprocket 3 Screw the drive nut onto the fixed sprocket shaft see Figure 4 and tighten by hand until the nut is flush with the bearing and the bearing is inside its housing in the casting Long Cable Short Cable Long Cable Short Cable Figure 8 Cable Placement on idle side corner block Figure 9 Cable Arrangement 4 Wrap the top cables around the pulleys and place the pulleys on the drive side corner block see Figure 8 and Figure 9 X Ensure the long cable and pulley are placed on the top boss Ensure the short cable and pulley are placed on the fro
15. ink Bolt Nut and Washers Side Panel Bolts and Washers Tray Bracket Bolt Nut amp Washer Star lock Washer Rubber Kit Variable 104262 Hinge Rubber End Block Bush Inner Edge Rubber Tray Bracket Bush End Block Bush Outer Rubber Buffer Anchor Clips Xmas Tree Clips Pulley Repair Kit 60 minutes Table 2 Spare Part Kits PZQ87A1010 Pulley Bearing Circlip NIAID NB time is estimated based on trade person with LycoLoader experience 5 2 SPARE PARTS The following parts are supplied as Spares for the LycoLoader LYCO PART No CONTENTS Bearings 100023 BEARING 6001 2RS Platform Cap 100111 CAP PLATFORM DIECAST 313 ALUM Chain Guide 100027 CHAIN GUIDE SINTERED Circlip for Idler Shaft 100029 CIRCLIP 12mm EXTERNAL Corner Block 100110 CORNER BLOCK DIECAST 313 ALUM Fixed Platform 106646 EXTRUSION ALUM 1448mm LONG Hinged Platform 100081 EXTRUSION ALUM 1434mm LONG Idler Shaft 100033 SHAFT 12mm CHROME x 200mm LONG Drive Shaft Nut 100036 NUT DRIVE NUT SINTERED STAINLESS Rubber Hinge 100038 HINGE RUBBER Drive Side End Block 100012 END BLOCK ASSEMBLY INCLUDING Assembly TBOLT AND BUSHES Idler Side End Block 100010 END BLOCK ASSEMBLY INCLUDING Assembly TBOLT AND PLUG Corner Block Cap 100112 CAP CORNER BLOCK DIECAST ALUM T Section Left Hand 100108 T SECTION
16. lubricated with either Anti Seize prior to reinstalling The bearing should run smoothly and the bearing seals should be intact The sprocket should not be excessively worn 6 DISMANTLING AND REASSEMBLING 6 1 DISMANTLING THE LYCOLOADER 1 Release the latch handle on both sides Unfold the platform Lower the platform to the ground Remove the four 4 cable buttons from the T section Remove the drive side tension link from the end block T bolt Remove the idle side tension link from the end block T bolt Remove frame from tray brackets it will be necessary to unbolt one tray bracket Insert a flat head screw driver in corner block cap and gently prise off caps from both corner blocks Grub Screws x 4 No Figure 2 Grub Screw Locations 9 Loosen the side grub screws in the side locking block see Figure 2 10 Loosen the back grub screws in the back locking block see Figure 2 Drive Side RHS Pulley End Block Figure 3 End Block Disassembly Drive Side 11 Slide the drive side end block out of the drive side RHS see Figure 3 12 Remove the pulley and cable from the drive side end block see Figure 3 13 Slide the drive side RHS off the drive side corner block Fixed Sprocket Shaft Drive Nut Bearing Brake Pad Clutch Assembly Drive Shaft Assembly 14 Figure 4 B
17. ms at the optimum angle HINT lubricate the rubber with water before sliding it into the platform sections Replace canoe clips in the back platform section Replace platform caps See parts specifications for screw torque s Replace edge rubber HINT lubricate the rubber with water before pressing in Replace all insulating clips two 2 on each platform cap and two 2 on each T section Replace rubber buffers securing with Loctite 480 adhesive Remove frame from tray brackets Remove tray bracket bushes Replace tray bracket bushes Re attach frame to tray brackets NOTE tray bracket bolts should be tightened to a torque of 25 30 Nm Remove the drive side tension link from the end block T bolt Slide the drive side end block out of the drive side RHS Remove the pulley and cable from the end block Remove the End Block Bush and Handle Guide Bush from the end block Press the two new bushes into the end block Re attach the cable onto the pulley and end block Slide the end block back into the RHS Re attach tension link to T bolt Re attach cable buttons to T section 89 PULLEY REPAIR KIT Disassemble the LycoLoader as described in section 6 1 Replace all of the parts provided in the Pulley Repair Kit and reassemble the LycoLoader as per Section 6 2 9 TEST PROCEDURE AFTER SERVICING After the servicing of the LycoLoader is complete it should be load tested to ensure it is operating correctly Try a load of approxim
18. nd Clutch Assembly Part of Kit 10 7 DRIVE SIDE END BLOCK ASSEMBLY Side Member Left Hand Rear Member Not 100048 i i shown 100050 Drive Side End Block Assembly 100012 These parts assembled Chain Cable Assembly 100008 Pulley Bearing Assembly Part of Kit 100008 S gt Cable amp ends Assembly 102121 Pulley 104479 10 8 IDLER SIDE END BLOCK ASSEMBLY Bearing 104479 Side Member Right Hand 100049 Pulley Bearing Assembly Part of Kit 100008 T I ma Chain amp Cable Assembly 100008 Cable amp ends Assembly Rear Member Not shown 100050 Idler Side End Block 102121 Assembly These parts assembled 109 MISCELLANEOUS Handle Grip M Handle Assembly LL Handle Corner Block 100112 Tray Bracket Bush NU di 100057 Locking Block 100004
19. nt boss Ensure the cables are not twisted around each other or the chain 5 Insert the chain guide into the corner block see Figure 7 6 Slide the cables and chain down the back RHS HINT You can feed a broom handle or similar through the back RHS and attach the chain and cable so as to ensure they do not get twisted when they are pulled through the RHS section 7 Slide the back RHS section over the drive side corner block X Ensure the locking block is inserted and that the chain guide is in place before the RHS is pushed fully onto the corner block Insert the sprocket into the chain at the idle end see Figure 6 8 Wrap the top cables around the pulleys and place the pulleys on the idle side corner block see Figure 8 and Figure 9 X Ensure the long cable and pulley are placed on the top boss Ensure the short cable and pulley are placed on the front boss Ensure the cables are not twisted around each other or the chain TWISTED OR OVERLAPPING CABLES CAN RESULT IN SEVERE CABLE DAMAGE LEADING TO FREEFALL OF THE PLATFORM IT IS CRITICAL THAT THIS IS CHECKED ON ASSEMBLY THIS FAULT MAY NOT BE IMMEDIATELY APPARENT WHEN LOAD TESTING THE LYCOLOADER AFTER ASSEMBLY 9 Slide the idle side corner block into the back RHS section holding the sprocket so it does not slide into the RHS Ensure the chain and cables not twisted tangled X Ensure the rear idle shaft bearing is in place before inserting the
20. procket shaft is not damaged Using the new components reassemble the LycoLoader by following Section 6 2 steps 17 to 24 step 26 step 29 and steps 31 to 34 Follow the procedure in Section 9 to test the LycoLoader 84 TENSION LINK ASSEMBLY Release the latch handle on both sides Unfold the Platform of the LycoLoader Remove the Tension Link from the end block T bolt Undo the 10mm bolt from the top of the drive side tension link Remove the damaged link and discard Insert the bolt through the new link the 10mm zinc plated washer the tray bracket and the 10mm zinc plated washer see Figure 10 Replace the 10mm nyloc nut Tighten until firm ensuring the link is still free to rotate 8 9 Reconnect the tension link to the T bolt Fold front section of platform 10 Store platform in stowed position reattach latches on both sides 8 5 5 qe 9 M10 Washer Bolt M10 x 50mm M10 Nyloc Nut N Figure 10 Link Assembly Replacement LATCH REPAIR KIT Release the latch handle on both sides Unfold the platform Remove the latch handle latch and cam washer from the tray bracket Discard the latch and cam washer Starlock Washer Latch Handle Figure 11 Latch Assembly 5 Insert the latch handle through the latch cam washer and then the tray bracket see Figure 11 Replace the starlock washer with
21. rake Clutch Disassembly 15 Unscrew the drive shaft assembly from the fixed sprocket shaft see Figure 4 16 Remove the front brake pad see Figure 4 17 Remove the Clutch Housing see Figure 4 18 Remove the back brake pad see Figure 4 End Block Pulley Figure 5 End Block Disassembly Idle Side 19 Slide the idle side end block out of the idle side RHS see Figure 5 20 Remove the pulley and cable from the idle side end block see Figure 5 2 Slide the idle side RHS off the idle side corner block Circlip Bearing Bearing Sprocket Idler Shaft Circlip Figure 6 Idle Shaft Disassembly 22 23 24 25 26 27 28 29 30 31 32 33 Remove the circlip from the idle shaft end block side see Figure 6 Slide the idle shaft out of the corner block see Figure 6 Slide the idle side corner block out of the back RHS section Remove the cables from the pulleys on the idle side corner block Remove the idle side sprocket from the chain Slide the drive side corner block out of the back RHS completely removing the chain and cables from the back RHS Remove the locking block from the drive side corner block Remove the cable from the pulleys on the drive side corner block Unscrew the drive nut from the fixed sprocket shaft refer to Figure 4 It may be n
22. ts specifications for details Inspect pulleys for wear see parts specifications for details Reassembling the LycoLoader Steps 13 to 16 Reassembling the LycoLoader Step 30 X Check Platform screws 98 see parts specifications for details Reassembling the LycoLoader Steps 31 to 32 Check tension link bolts see parts specifications for details Check starlock washers catch handles see parts specifications for details Check T bolts on end blocks see parts specifications for details Reassembling the LycoLoader Step 34 8 SPARE PARTS FITTING 81 DRIVE END CORNER BLOCK KIT Disassemble the LycoLoader as described in section 6 1 Replace all of the parts provided in the Drive End Corner Block Kit and reassemble the LycoLoader as per Section 6 2 8 2 HANDLE ASSEMBLY The Handle Assembly is a simple swap over x Ensure the Batch Number and client details are documented before the handle 15 replaced HINT If the old handle was broken and the handle tip is stuck in the drive socket use a magnet to remove the broken section Discard both parts of the broken handle X NEVER ATTEMPT TO REPAIR A BROKEN HANDLE Broken handles indicate that there is something wrong with the LycoLoader or the way it is being used 83 BRAKE CLUTCH ASSEMBLY Follow dismantling Section 6 1 steps 1 to 5 step 9 and steps 11 to 17 Check that the thread on the fixed s
23. wing tools may be required for servicing of the LycoLoader Hammer Circlip Pliers 4mm Allen Key 5mm Allen Key Flat Screw Driver approx 6mm Needle Nose Pliers Socket Set including 19mm 18mm 16mm 14mm 13mm Sockets Ring Spanner Set including 19mm 18mm 16mm 14mm Spanners Loctite 454 adhesive or equivalent instant adhesive gel Loctite 771 Anti Seize or equivalent nickel based anti seize Castrol T Grease or equivalent lithium complex grease S SPARE PARTS LIST 51 SPARE PARTS KIT The following Parts are supplied as Kits for the LycoLoader ITEM amp ESTIMATE N E Drive End Corner Block Kit 60 minutes PART No 104261 CONTENTS Corner Block Drive Nut Idler Shaft Fixed Sprocket Assembly Bearing Sprocket Locking Blocks c w Grub Screw Circlip NINI Handle Assembly 0 minutes LL Handle Handle Assembly Brake Clutch Assembly 15 minutes 104260 Brake Pad Clutch Assembly Tension Link Assembly 10 minutes 100043 Tension Link Assembly Latch Repair Kit 15 minutes 102139 Latch Cam Washer Star Lock Washer Rubber Buffer Cable Chain Assembly 60 minutes 100008 Chain amp Cable Assembly Idle Sprocket Circlip Pulley Bearing Assembly Fastener Kit Variable 104282 Top L
24. y should rotate in one direction only The Clutch surfaces should be smooth and free from defects such as scratches cracks or scores The Clutch surface should be flat 5 2 6 STEEL CABLES The Steel Cables should have no broken strands including the point at which it is swaged into the end button 5 27 PULLEYS The pulleys should have a minimum groove diameter of 32 0 mm 5 2 8 STARLOCK WASHERS The Starlock Washers should be pressed onto the shaft of the latch handle The washer should sit flat against the tray bracket The handle should be free to rotate 5 2 9 TENSION LINK BOLT The tension link bolt should not show excessive wear on the shank The nyloc nut should be done up firm while still allowing the tension link to rotate freely 5 2 10 IDLE SHAFT CIRCLIP The Idle Shaft Circlip should be correctly seated into the groove on the idle shaft It should not be over stretched over stretching will result in reduced clamping force 5 2 11 BEARINGS The bearings should be free to rotate with no gritty feeling The seals of the bearings should be in good condition 5 2 12 FIXED SPROCKET SHAFT ASSEMBLY The thread of the fixed sprocket shaft shall be free of grit It should be free of damage or excessive wear that is a reduced diameter of the thread peaks in the region where the drive nuts operate The nut should run smoothly on the shaft The start of the thread should not be damaged The thread should be
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