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Maxon 80 Series Maintenance Manual

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M-04-08
APRIL 2004

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Summary of Contents for Maxon 80 Series

  • Page 1 M-04-08 APRIL 2004...
  • Page 3 MAXON agrees to replace any components which are found to be defective during the first 2 years of service, and will reimburse for labor based on MAXON’s Liftgate Warranty Flat Rate Schedule.

  • Page 4: Table Of Contents

    REPLACING PLATFORM TORSION SPRING ..............17 PARTS BREAKDOWN .................. 18 80 SERIES FINAL ASSEMBLY ................... 19 80 SERIES MAIN FRAME & LIFTING FRAME ..............20 PLATFORM & FLIPOVER ASSY ..................22 GRAVITY DOWN HYDRAULIC COMPONENTS..............24 PUMP BOX ASSEMBLY (GRAVITY DOWN) ............... 25 POWER DOWN HYDRAULIC COMPONENTS ..............
  • Page 5 TABLE OF CONTENTS - Continued ELECTRICAL SYSTEM DIAGRAMS ............34 ELECTRICAL SCHEMATIC - GRAVITY DOWN ..............34 ELECTRICAL SCHEMATIC - POWER DOWN..............35 TROUBLESHOOTING .................. 36 PLATFORM WILL NOT RAISE .................... 36 PLATFORM RAISES BUT LEAKS DOWN................37 PLATFORM RAISES PARTIALLY AND STOPS ..............38 LIFTGATE WILL NOT LIFT RATED CAPACITY ..............

  • Page 6: Warnings

    • Never perform unauthorized modifications on the Liftgate. Modifications may result in early failure of the Liftgate and may create hazards for Liftgate operators and maintainers. Provide Liftgate model and serial • Use only Maxon Authorized Parts for replacement parts. number information with your parts order. Order replacement parts from: MAXON LIFT CORP.

  • Page 7: Liftgate Terminology

    7.0 gemaker 7.0 gemaker 7.0 LIFTGATE TERMINOLOGY (80 SERIES) EXTENSION PLATE CONTROL SWITCH SADDLE PUMP BOX PLATFORM OPENER MAIN FRAME PLATFORM LIFT CYLINDERS FLIPOVER PARALLEL LIFT...

  • Page 8: Service Time Chart

    SERVICE TIME CHART...

  • Page 10: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHECKLIST ! ! ! ! ! WARNING Never operate the Liftgate with parts loose or missing. Annually Visually check the entire Liftgate for excessively worn parts and broken welds, especially the Hinge Pins. See PARTS BREAKDOWN section for replacement parts. Also, do the Semi- annual and Quarterly Maintenance checks.

  • Page 11: Checking Hydraulic Fluid

    CHECKING HYDRAULIC FLUID NOTE: Use correct grade of hydraulic fluid for your location. +70 to +140 Degrees F - Grade ISO 32 +40 to +105 Degrees F - Grade ISO 15 Below + 70 Degrees F - Grade ISO 10 or MIL-H-5606 See TABLES 11-1, 11-2, &...

  • Page 12: Changing Hydraulic Fluid

    PERIODIC MAINTENANCE CHANGING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the open- ings from accidental contamination.
  • Page 13 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 14: Platform Adjustment

    PERIODIC MAINTENANCE PLATFORM ADJUSTMENT NOTE: Before doing the following procedure, make sure vehicle is parked on level ground. TIP OF FLIPOVER 1. Make sure Platform is at ground level. Unfold the Platform and Flipover. As the Platform first touches PLATFORM & SHACKLES the ground, Shackles and tip of Flipover must touch TOUCH GROUND the ground at the same time (FIG.
  • Page 15 3. Make sure Platform is still at ground level. If the tip of Flipover is not touching the ground, measure and compare distance “B” (FIG. 15-1) with TABLE 15-1 to determine how much to grind from the Platform Stops (FIG. 15-2). Grind correct TIP OF FLIPOVER amount of metal (TABLE 15-1) from...

  • Page 16: Saddle Adjustment

    SADDLE ADJUSTMENT 1. Lower Platform to ground level. 2. Remove bolts, lock nuts, and Saddle (FIG. 16-1B)from Right Hand (RH) side Mounting Plate. Repeat step for Left Hand (LH) side. MOUNTING PLATE BOLTS & LOCK NUTS PLATFORM SADDLE (REF) BOLTING SADDLE FIG.

  • Page 17: Replacing Platform Torsion Spring

    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. Fold Flipover onto Platform. HINGE HINGE PIN 2. Fold Platform. BRACKET PLATFORM TORSION...

  • Page 18: Parts Breakdown

    PARTS BREAKDOWN...

  • Page 19: 80 Series Final Assembly

    80 SERIES FINAL ASSEMBLY REFER TO HYDRAULIC COMPONENTS & PUMP BOX ASSEMBLY REFER TO MAIN FRAME & LIFTING FRAME REFER TO PLATFORM & FLIPOVER ASSEMBLY " 4 " 2 " 8 " 1 " 8 " 8 " 8...

  • Page 20: 80 Series Main Frame & Lifting Frame

    80 SERIES MAIN FRAME & LIFTING FRAME...
  • Page 21 80 SERIES MAIN FRAME & LIFTING FRAME " 8 " 1 " 8 " 4 " 8 " 2 " 8 " 8 " 6 " 4 " 8 " 2 " 2 " 4 " 2 " 4 " 4 ( "...

  • Page 22: Platform & Flipover Assy

    PLATFORM & FLIPOVER ASSY (WEDGE) " 8 " 2 " 2 " 2...
  • Page 23 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 24: Gravity Down Hydraulic Components

    GRAVITY DOWN HYDRAULIC COMPONENTS CYLINDER (REF) CYLINDER (REF) REFER TO PUMP BOX ASSEMBLY -GRAVITY DOWN " 3 " 5 " 3 " 5 " 8 " 1 " 4 " 0 " 8 " 7 " 4 " 5 " 4 "...

  • Page 25: Pump Box Assembly (Gravity Down)

    PUMP BOX ASSEMBLY (GRAVITY DOWN) (LATCH) (LATCH) CONTROL SWITCH CABLE ASSEMBLY (REF) (CATCH) (CATCH) &...

  • Page 26: Power Down Hydraulic Components

    POWER DOWN HYDRAULIC COMPONENTS REFER TO PUMP BOX ASSEMBLY -POWER DOWN " 3 " 5 " 3 " 5 " 8 " 1 " 8 " 8 " 8 " 7 " 8 " 3 " 8 " 5 " 8 "...

  • Page 27: Pump Box Assembly (Power Down)

    PUMP BOX ASSEMBLY (POWER DOWN) (LATCH) (LATCH) CONTROL SWITCH CABLE ASSEMBLY (REF) (CATCH) (CATCH) & " 8...

  • Page 28: Control Switch And Power Cable

    CONTROL SWITCH AND POWER CABLE NOTE: Use Switch to RAISE and LOWER Liftgate to make sure Switch operates as shown on the decal. BLACK POWER (FOR REFERENCE- UNIT) SEE DECALS) YELLOW WHITE GREEN WHITE & " 1 SHORT END TO VEHICLE BATTERY ! ! ! ! ! WARNING...

  • Page 29: Decals

    DECALS INSTRUCTION DECAL P/N 251838 (REFERENCE) CAPACITY DECAL P/N 264081 (REFERENCE) CAUTION DECAL P/N 263998 WARNING DECAL P/N 264081...
  • Page 30 DECALS - CONTINUED UP/DOWN DECAL P/N 264507 WARNING DECAL P/N 264081 (REFERENCE) CAUTION DECAL P/N 263998 (REFERENCE) CAPACITY DECAL (SEE TABLE 30-1) LIFT CAPACITY DECALS CAPACITY PART NO. 220382 2500 LBS. INSTRUCTION DECAL 3000 LBS. 220388 P/N 251838 4000 LBS. 220389 5000 LBS.
  • Page 31 FLUID LEVEL DECAL P/N 265330-03...

  • Page 32: Hydraulic System Diagrams

    HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC - GRAVITY DOWN HYDRAULIC CYLINDERS 4 GPM FLOW CONTROL VALVE FILL HOLE (PLUGGED) PRESSURE PORT RETURN PORT VALVE A RELIEF VALVE CHECK VALVE (SET AT 3250 PSI) PUMP MOTOR (REFERENCE) FILTER RESERVOIR DRAIN HOLE (PLUGGED)

  • Page 33: Hydraulic Schematic - Power Down

    HYDRAULIC SCHEMATIC - POWER DOWN HYDRAULIC CYLINDERS 4 GPM FLOW CONTROL VALVE FILL HOLE PORT B - LOWER (PLUGGED) (POWER DOWN) PORT A - RAISE VALVE VALVE MOTOR CHECK VALVE CHECK VALVE (REFERENCE) RELIEF VALVE RELIEF VALVE PUMP (SET AT (SET AT 1000 PSI) 3250 PSI)

  • Page 34: Electrical System Diagrams

    ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC - GRAVITY DOWN CONTROL SWITCH WHITE YELLOW WHITE GREEN BLACK CABLE ASSEMBLY SOLENOID, THERMAL VALVE A SWITCH STARTER SOLENOID CABLE WITH 200 AMP FUSE MOTOR BATTERY...

  • Page 35: Electrical Schematic - Power Down

    ELECTRICAL SCHEMATIC - POWER DOWN CABLE ASSEMBLY YELLOW WHITE BLACK GREEN WHITE THERMAL SWITCH STARTER STARTER SOLENOID, SOLENOID, SOLENOID SOLENOID VALVE A VALVE B (LOWER) (RAISE) MOTOR CABLE WITH 200 AMP FUSE BATTERY...

  • Page 36: Troubleshooting

    TROUBLESHOOTING PLATFORM WILL NOT RAISE 1. Connect voltmeter between Motor Solenoid Terminal “A” and Bracket (FIG. 36-1) to verify that battery power is getting to “A”. Recharge the battery if voltmeter indicates less than 12.6 Volts DC. CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings.

  • Page 37: Platform Raises But Leaks Down

    PLATFORM RAISES BUT LEAKS DOWN LOWERING 1. Check if Lowering Solenoid Valve is SOLENOID VALVE constantly energized. Connect volt- meter negative (-) lead to Motor MOTOR Solenoid bracket and positive (+) lead to Motor Solenoid terminal “C” (FIG. 37-1). If voltmeter reads bat- tery voltage (+12.6 Volts DC mini- mum) without pushing the toggle switch, the control circuit is operating...

  • Page 38: Platform Raises Partially And Stops

    TROUBLESHOOTING PLATFORM RAISES PARTIALLY AND STOPS CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.

  • Page 39: Liftgate Will Not Lift Rated Capacity

    LIFTGATE WILL NOT LIFT RATED CAPACITY 1. Use voltmeter to verify that the Battery shows 12.6 volts or more under load from pump motor. 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 40: Platform Raises Slowly

    TROUBLESHOOTING PLATFORM RAISES SLOWLY 1. Connect voltmeter between Motor Solenoid Terminal MOTOR SOLENOID “A” and Bracket (FIG. 40-1) to verify that battery BRACKET power is getting to “A”. Recharge the battery if (VOLTMETER voltmeter indicates less than 12.6 Volts DC. - LEAD ) CAUTION Keep dirt, water and other contaminants from enter-...

  • Page 41: Platform Will Not Lower, Lowers Too Slowly, Or Lowers Too Quickly

    PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR LOWERS TOO QUICKLY LOWERING 1. Connect voltmeter between Motor Solenoid Terminal “A” SOLENOID VALVE and Bracket (FIG. 41-1) to verify that battery power is getting to “A”. Recharge the battery if voltmeter indicates less than 12.6 Volts DC.

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