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Maxon MXT-25 Maintenance Manual

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M-20-11
REV.A
DECEMBER 2020
© 2020 MAXON Lift Corp.

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  • Page 1 M-20-11 REV.A DECEMBER 2020 © 2020 MAXON Lift Corp.
  • Page 3 MAXON agrees to replace any components which are found to be defective during the fi rst 2 years of service, and will reimburse for labor based on MAXON’s Liftgate Warranty Flat Rate Schedule.

  • Page 4: Table Of Contents

    CHECKING HYDRAULIC FLUID ..................14 CHANGING HYDRAULIC FLUID ..................16 REPLACING PLATFORM TORSION SPRING ..............18 DECALS: MXT-25 & MXT-33 ....................24 DECALS & PLATES ......................26 SYSTEM DIAGRAMS ......................28 PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) ........28 HYDRAULIC SCHEMATIC (GRAVITY DOWN) ..............
  • Page 5 HYDRAULIC SCHEMATIC WITH MAX ECU MODULE (POWER DOWN) ......38 ELECTRICAL SCHEMATIC WITH MAX ECU MODULE (POWER DOWN) ....... 39 ELECTRICAL VALUES & TORQUE SPECIFICATIONS ............. 40 TROUBLESHOOTING ......................42 MOTOR WILL NOT RUN ....................42 PLATFORM WILL NOT RAISE, BUT MOTOR RUNS ............43 PLATFORM RAISES BUT LEAKS DOWN ................

  • Page 6: Summary Of Changes: M-20-11, Revision A

    SUMMARY OF CHANGES: M-20-11, REVISION A PAGE DESCRIPTION OF CHANGE COVER Updated REV. and date of release. 10, 13, 18, 22, Mounting plates and platform opener changed. 23, 58 Updated platform adjustment procedure dimensions to be 1/2” to 2” maximum level 22, 23 above bed height.
  • Page 7 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 8: Warnings

    Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining Liftgates. See Operation Manual for operating safety requirements. WARNING Installing and maintaining a liftgate can expose you to chemicals, including lead, which are knowto the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, install and maintain liftgate in a well-ventilated area and wear proper Per- sonal protective equipment (PPE).

  • Page 9: Safety Instructions

    Listen for scraping, grat- ing and binding noises and correct the problem before continuing to operate Liftgate. • Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial num- ber information with your parts order. Order replacement parts from: MAXON LIFT CORP.

  • Page 10: Liftgate Terminology

    LIFTGATE TERMINOLOGY EXTENSION PLATE CONTROL SWITCH MAIN FRAME LIFT CYLINDER LIFT ARM PLATFORM PUMP ASSEMBLY (COVER IS BUMPER SHOWN) PLATFORM OPENER TORSION WEDGE SPRING FLIPOVER PARALLEL...

  • Page 11: Periodic Maintenance

    Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it off. Touch up the paint where bare metal is showing. MAXON recommends using aluminum primer touchup paint.

  • Page 12: Periodic Maintenance Checklist

    PERIODIC MAINTENANCE CHECKLIST NOTE: Make sure vehicle is parked on level ground while performing maintenance checks. Quarterly or 1250 Cycles (whichever occurs fi rst) Check the level and condition of the hydraulic fl uid. Visually check all hoses and fi ttings for chafi ng and fl uid leaks. Tighten loose fi ttings or replace parts as required.
  • Page 13 Refer to the PERIODIC MAINTENANCE CHECKS and PERIODIC MAINTENANCE CHECKLIST for the recommended grease and maintenance interval. LH CYLINDER, LIFT ARM & PARALLEL ARM RH CYLINDER, LIFT ARM & PARALLEL ARM MXT-25 & MXT-33 LUBRICATION DIAGRAM FIG. 13-1...

  • Page 14: Checking Hydraulic Fluid

    PERIODIC MAINTENANCE CHECKING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydrau- lic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
  • Page 15 ISO 32 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER ROSEMEAD ROSEMEAD MV150 EXXONMOBIL MOBIL DTE 10 EXCEL 32 EXXONMOBIL UNIVIS N-32, DTE-24 CHEVRON CHEVRON AV MV32 CHEVRON HIPERSYN 32 U.S. PRESTIGE PRESTIGE AW HVI 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 TABLE 15-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED BRANDS...

  • Page 16: Changing Hydraulic Fluid

    PERIODIC MAINTENANCE CHANGING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydrau- lic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
  • Page 17 3. Lower the platform all the way to the ground while draining the remaining hydraulic fl uid. 4. Reinstall drain plug (FIG. 14-2). 5. Remove fi ller cap (FIG. 14-2). Add 1 gallon of hydraulic fl uid to reservoir. Re-install fi ller cap. 6.

  • Page 18: Replacing Platform Torsion Spring

    PERIODIC MAINTENANCE REPLACING PLATFORM TORSION SPRING NOTE: The following procedure shows how to replace torsion spring on RH side of platform. Use this procedure for replacing torsion spring on the LH side. 1. If platform is on the ground, manually fold fl...
  • Page 19 CAUTION Incorrect selection of torsion spring bracket holes can result in unnecessary strain or injury to operator. Selecting the correct bracket hole will reduce the force needed for operator to unfold and fold the platform. 5. Install the new torsion spring and bushing as shown in (FIGS.
  • Page 20 REPLACING PLATFORM TORSION SPRING - Continued 6. Drive platform hinge pin inboard to correct position through the platform hinge bracket ( FIG. 20-1). Line up the hole in the platform hinge pin with the hole in the pin collar. Install the roll pin through the pin collar until roll pin protrudes equally from both sides of the collar (FIG.
  • Page 21 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 22 PERIODIC MAINTENANCE PLATFORM ADJUSTMENT NOTE: Before doing the following procedures, make sure vehicle is parked on level ground. 1. With the platform and fl ipover unfolded, raise platform to bed level (FIG. 22-1). Measure how much the outboard edge of platform rises above fl...
  • Page 23 2. If the tip of the platform is less than 1/2” above fl oor level (FIG. 23-1), turn both RH and LH platform adjust- ment bolts clockwise until the platform tip is 1/2” to 2” above fl oor level (FIGS. 23-1 and 23-2). EXTENSION PLATE (REF) VEHICLE...

  • Page 24: Decals: Mxt-25 & Mxt-33

    DECALS: MXT-25 & MXT-33 NOTE: Preferred decal layout is shown. Decals on the Liftgate are attached at the factory. If vehicle does not permit this layout, decals in the manual and decal kit must be applied so that they are easily visible when approaching vehicle to operate Liftgate.
  • Page 25 DECAL SHEET P/N 282522-01 FIG. 25-1 MODEL DECAL P/N CAPACITY MXT-25 220382 2500 POUNDS [1134 KG] MXT-33 220388-02 3300 POUNDS [1500 KG] CAPACITY DECALS TABLE 25-1...

  • Page 26: Decals & Plates

    DECALS & PLATES QR CODE DECAL 299348-09 SERIAL PLATE (REF) MAXON NAME PLATE P/N 280004-01 FIG. 26-1A FIG. 26-1...
  • Page 27 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 28: System Diagrams

    SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) “C1” DIRECTION OF CONTROLLED FLOW STARTER MOTOR SOLENOID “S1” VALVE JUNCTION BLOCK GRAVITY DOWN POWER UNIT FIG. 28-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE LOCK MOTOR...

  • Page 29: Hydraulic Schematic (Gravity Down)

    HYDRAULIC SCHEMATIC (GRAVITY DOWN) FIG. 29-1...

  • Page 30: Electrical Schematic (Gravity Down)

    SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC (GRAVITY DOWN) FIG. 30-1...

  • Page 31: Pump & Motor Solenoid Operation (Power Down)

    PUMP & MOTOR SOLENOID OPERATION (POWER DOWN) “C2” “C1” DIRECTION OF CONTROLLED FLOW OFF TIME DELAY MODULE STARTER SOLENOID MOTOR “S1” VALVE POWER DOWN MODULE POWER DOWN POWER UNIT FIG. 31-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION...

  • Page 32: Hydraulic Schematic (Power Down)

    SYSTEM DIAGRAMS - Continued HYDRAULIC SCHEMATIC (POWER DOWN) VALVE “S1” FIG. 32-1...

  • Page 33: Electrical Schematic (Power Down)

    ELECTRICAL SCHEMATIC (POWER DOWN) FIG. 33-1...

  • Page 34: Pump & Motor Solenoid Operation With Max Ecu Module

    SYSTEM DIAGRAMS - Continued PUMP & MOTOR SOLENOID OPERATION WITH MAX ECU MODULE (GRAVITY DOWN) “C1” DIRECTION OF CONTROLLED FLOW STARTER MOTOR SOLENOID “S1” VALVE MAX ECU MODULE GRAVITY DOWN POWER UNIT WITH MAX ECU MODULE FIG. 34-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE...

  • Page 35: Hydraulic Schematic With Max Ecu Module (Gravity Down)

    HYDRAULIC SCHEMATIC WITH MAX ECU MODULE (GRAVITY DOWN) FIG. 35-1...

  • Page 36: Electrical Schematic With Max Ecu Module (Gravity Down)

    SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC WITH MAX ECU MODULE (GRAVITY DOWN) FIG. 36-1...

  • Page 37: Pump & Motor Solenoid Operation With Max Ecu Module

    PUMP & MOTOR SOLENOID OPERATION WITH MAX ECU MODULE (POWER DOWN) “C2” “C1” DIRECTION OF CONTROLLED FLOW STARTER SOLENOID MOTOR “S1” VALVE MAX ECU MODULE OFF TIME DELAY MODULE POWER DOWN POWER UNIT FIG. 37-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE...

  • Page 38: Hydraulic Schematic With Max Ecu Module (Power Down)

    SYSTEM DIAGRAMS - Continued HYDRAULIC SCHEMATIC WITH MAX ECU MODULE (POWER DOWN) VALVE “S1” FIG. 38-1...

  • Page 39: Electrical Schematic With Max Ecu Module (Power Down)

    ELECTRICAL SCHEMATIC WITH MAX ECU MODULE (POWER DOWN) FIG. 39-1...

  • Page 40: Electrical Values & Torque Specifications

    ELECTRICAL VALUES & TORQUE SPECIFICATIONS Solenoid Switch 5.4Ω @70ºF. ±15% 20.1Ω @70ºF. ±15% Coil resistance: 2.2A 1.2A Ampere: Coil terminal torque: 10-15 lb-in max. Contact terminal torque: 30-35 lb-in max. Solenoid Valve (S1) 6.2Ω @ 70ºF. ±15% 35.8Ω @ 70ºF. ±15% Coil resistance: 1.6A 0.67A...
  • Page 41 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 42: Troubleshooting

    TROUBLESHOOTING MOTOR WILL NOT RUN 1. Connect voltmeter between solenoid switch terminal “B” and ground wires connection on pump (FIG. 42-1). Verify that full bat- tery voltage is at “B.” Recharge the batteries if voltmeter indicates less than 12.6 volts DC, or 25.2 volts DC for a 24 volt system. 2.

  • Page 43: Platform Will Not Raise, But Motor Runs

    PLATFORM WILL NOT RAISE, BUT MOTOR RUNS 1. Do the CHECKING HYDRAULIC FLUID procedure in this manual. If necessary, add hydraulic fl uid. 2. Check for the following. (Refer to ELECTRICAL SCHEMATIC.) • Ground connections are clean and tight at batteries and pump. Clean and/or tighten if necessary.

  • Page 44: Platform Raises But Leaks Down

    PLATFORM RAISES BUT LEAKS DOWN 1. Check if the “S1” (lowering) solenoid valve is constantly energized. Connect voltmeter negative (-) lead to ground (-) VOLTMETER (-) connection on pump and posi- LEAD) tive (+) lead to (+) terminal on the “S1” (lowering) solenoid SOLENOID GROUND (-) WIRE valve (FIGS.
  • Page 45 CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean COIL up contaminants that can get in the open- ings. Also, protect the openings from acci- VALVE dental contamination during maintenance.

  • Page 46: Platform Raises Partially And Stops

    PLATFORM RAISES PARTIALLY AND STOPS 1. Lower the opened platform to the ground. Do the RESERVOIR (PUMP OIL FILTER INSIDE) CHECKING HYDRAULIC FLUID procedure in this manual. If necessary, add hydraulic fl uid. 2. Use voltmeter to verify the battery voltage, under load from pump motor, is a minimum 10.5 volts DC, or 21 volts DC for a 24 volt system, .

  • Page 47: Liftgate Will Not Lift Rated Capacity

    LIFTGATE WILL NOT LIFT RATED CAPACITY 1. Use voltmeter to verify the battery voltage, under load from pump motor, is a minimum 10.5 volts DC, or 21 volts DC for a 24 volt DC system, 2. Check for structural damage or lack of lubrication. Replace worn parts. CAUTION Keep dirt, water and other contaminants from entering the hydraulic system.
  • Page 48 LIFTGATE WILL NOT LIFT RATED CAPACITY - Continued 4. With platform on the ground, remove cover for access to relief valve (FIGS. 48-1, 48-1A, 48-2 and 48-2A). Hold the control switch in the “RAISE” position. Adjust the relief valve until the gauge reads 2750 PSI (FIGS.

  • Page 49: Platform Raises Slowly

    PLATFORM RAISES SLOWLY 1. Connect voltmeter between solenoid switch terminal “B” and ground (-) wires connection on pump (FIG. GROUND (-) WIRES 49-1). Verify that there is a minimum of 12.6 volts DC, CONNECTION or 24.8 volts DC for 24 volt system, at “B.” Recharge the battery if voltmeter indicates less than 12.6 volts DC, or 25.2 volts DC for 24 volt system.
  • Page 50 PLATFORM RAISES SLOWLY - Continued CAUTION To prevent damage to fl ow control valve, do not disassemble the valve. 3. Remove fl ow control valve (FIGS. 50-1, 50-1A, 50-2 and 50-2A). Ensure the fl ow control valve operates with a smooth spring-loaded action.
  • Page 51 4. Verify the pump motor is grounded to vehicle frame. 5. Check for leaking hoses and fi ttings. Tighten or replace as required. 6. Check for structural damage and poor lubrication. Replace worn parts. 7. Check pump oil fi lter in the reservoir (FIGS. 51-1 and 51-2). Clean or replace fi...

  • Page 52: Platform Will Not Lower, Lowers Too Slowly, Or Too Quickly

    PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY 1. Connect voltmeter (+) lead to motor solenoid terminal “B” and the (-) lead to the ground wires connection on pump (FIG. 52-1). Verify that full battery voltage is at “B.”...
  • Page 53 CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the open- COIL ings. Also, protect the openings from acci- dental contamination during maintenance.

  • Page 54: Platform Begins To Lower On Lh Side, But Will Not Lower On Rh Side

    PLATFORM BEGINS TO LOWER ON LH SIDE, BUT WILL NOT LOWER ON RH SIDE 1. Check for battery voltage at the hydraulic lock CONNECTOR COIL as follows. Disconnect wiring harness from coil on the lock valve (FIG. 54-1). Then, connect voltmeter (+) and (-) leads to connector con- tacts 1 and 2 on the wiring harness (FIG.
  • Page 55 CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance. 3.
  • Page 56 PLATFORM BEGINS TO LOWER ON LH SIDE, BUT WILL NOT LOWER ON RH SIDE - Continued 5. Disconnect green wire from the “S1” LOCK VALVE WIRING HARNESS (lowering) solenoid valve (FIG. 56-1). Do (REF) resistance checks on the lock valve wir- GREEN ing harness as follows.
  • Page 57 7. Reconnect lock valve wiring harness CONNECTOR (FIG. 57-1). COIL WIRING HARNESS RECONNECTING LOCK VALVE WIRING HARNESS FIG. 57-1 8. Bolt on the pump cover as shown in FIG. 57-2. Torque the 5/16”-18 cover bolts from 10 to 14 lb-in. BOLTING ON PUMP COVER FIG.

  • Page 58: Platform Will Not Tilt Down To The Ground

    PLATFORM WILL NOT TILT DOWN TO THE GROUND NOTE: If the Liftgate is not damaged, the 1800 psi (lowering) pressure relief valve in the pump may need to be adjusted as follows. 1. Lower the platform until shackles touch the ground (FIG.
  • Page 59 3. With platform on the ground, remove cover for access to relief CAUTION valve (FIGS. 59-1, 59-1A, 59-2 and 59-2A). Hold the control switch in the “RAISE” position. Adjust the relief valve until the gauge reads 2750 PSI (FIGS. 59-1, 59-1A, 59-2 and 59-2A). Check if pump relief valve is dirty.
  • Page 60 PLATFORM WILL NOT TILT DOWN TO THE GROUND - Continued CAUTION Pump cover must be correctly secured to prevent it from becoming a hazard. To secure pump cover, the long side of the holder fl ats must butt against pump cover as shown in the illustration. 4.

This manual is also suitable for:

Mxt-33

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