Maxon RCM-1250C, RCM-1600C AB, RCM-1250C AB, RCM-1600C Maintenance Manual

M-91-18
REV. F
DECEMBER 2012

MAINTENANCE

MANUAL

LIFT CORP.

• RCM-1250C

• RCM-1250C AB

• RCM-1600C

• RCM-1600C AB

11921 Slauson Avenue
Santa Fe Springs, CA 90607
[phone]

© MAXON Lift Corp. 2012

11921 Slauson Ave.
Santa Fe Springs, CA. 90670

LIFT CORP.

CUSTOMER SERVICE:

TELEPHONE [phone] TOLL FREE [phone]

FAX: [phone]

NOTE: For latest version of all Manuals (and replacements), download the

Manuals from Maxon’s website at www.maxonlift.com.

WARRANTY/ RMA POLICY & PROCEDURE

LIFTGATE WARRANTY

Type of Warranty: Full Parts and Labor
Term of Warranty: Standard Liftgates - 2 years from ship date or 6,000 cycles

Premium Liftgates - 2 years from ship date or 10,000 cycles
This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s specifi cations as set forth in

MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments, damage or
malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this warranty does not
cover equipment that has had unauthorized modifi cations or alterations made to the product.

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. (Copy of the Flat Rate is available at www.maxonlift.com.)

All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and labor,
MAXON’s Technical Service Department must be notifi ed and an “Authorization Number” obtained.

All claims for warranty must be received within 30 Days of the repair date, and include the following information:

1. Liftgate Model Number and Serial Number

2. The End User must be referenced on the claim

3. Detailed Description of Problem

4. Corrective Action Taken, and Date of Repair

5. Parts used for Repair, Including MAXON Part Number(s)

6. MAXON R.M.A. # and/or Authorization # if applicable (see below)

7. Person contacted at MAXON if applicable

8. Claim must show detailed information i.e. Labor rate and hours of work performed
Warranty claims can also be placed online at www.maxonlift.com. Online claims will be given priority processing.
All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s Warranty

Department within 30 days of repair date.
All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior written

approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with original
invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized returns will be

refused and will become the responsibility of the returnee.

Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in plain
view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned parts
are subject to no credit and returned back to the customer. Defective parts requested for return must be returned within 30 days of the claim date for
consideration to:

10321 Greenleaf Ave., Santa Fe Springs, CA 90670

MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income due to
downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.

MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.
All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not returned

in new condition will be subject to an additional reworking charge, which will be based upon the labor and material cost required to return the Liftgate or
component to new condition.

PURCHASE PART WARRANTY

Term of Warranty: 1 Year from Date of Purchase.
Type of Warranty: Part replacement only. MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts

and original invoice.
All warranty replacements parts will be sent out via ground freight. If a rush shipment is requested, all freight charges will be billed to the requesting
party.___

MAXON Lift Corp.

Attn: RMA#__

TABLE OF CONTENTS

WARNINGS ........................................................................................................................... 6

SAFETY INSTRUCTIONS ....................................................................................................6

PERIODIC MAINTENANCE .................................................................................................. 8

PERIODIC MAINTENANCE CHECKLIST ............................................................................. 8

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

CHECKING HYDRAULIC FLUID ..........................................................................................9

CHANGING HYDRAULIC FLUID .........................................................................................11

CLEAN AND LUBRICATE COLUMNS ................................................................................13

ADJUST DRIVE CHAINS .................................................................................................... 14

PARTS BREAKDOWN .......................................................................................................16

RCM-1250C.........................................................................................................................16

RCM-1250C AB ...................................................................................................................20

RCM-1600C.........................................................................................................................24

RCM-1600C AB ...................................................................................................................28

PLATFORM & RAMP ASSEMBLY ....................................................................................... 32

PUMP ASSEMBLY 12 VOLT (GRAVITY DOWN) ................................................................36

PUMP ASSEMBLY 24 VOLT (GRAVITY DOWN) ................................................................38

HYDRAULIC COMPONENTS ............................................................................................. 40

PUMP BOX ASSEMBLY ......................................................................................................42

CONTROL SWITCH ............................................................................................................ 43

DECALS ..............................................................................................................................44

DRIVE CHAIN SYSTEM DIAGRAM .................................................................................... 45

4

HYDRAULIC SYSTEM DIAGRAM ......................................................................................46

ELECTRICAL SYSTEM DIAGRAM ..................................................................................... 47

TROUBLESHOOTING ........................................................................................................ 48

PLATFORM WILL NOT RAISE, MOTOR WILL NOT RUN .................................................. 48

PLATFORM WILL NOT LOWER .........................................................................................49

PLATFORM RAISES, BUT LEAKS DOWN ......................................................................... 50

PLATFORM RAISES, BUT WILL NOT LIFT RATED CAPACITY ........................................ 50

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5

Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.

WARNINGS

• Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your

feet are clear of the Liftgate.

• Keep fi ngers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.

• Correctly stow platform when not in use. Extended platforms could create a hazard for

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

people and vehicles passing by.

• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.

• If it is necessary to stand on the platform while maintaining the Liftgate, keep your feet and any

objects clear of the inboard edge of the platform. Your feet or objects on the platform can become
trapped between the platform and the Liftgate extension plate.

• Recommended practices for welding on steel parts are contained in the current AWS (American
Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and

personal injury could result from welds that are done incorrectly.

• Recommended practices for welding on aluminum parts are contained in the current AWS
(American Welding Society) D1.2 Structural Welding Code - Aluminum. Damage to Liftgate

and/or vehicle, and personal injury could result from welds that are done incorrectly.

!

WARNING

SAFETY INSTRUCTIONS

• Read and understand the instructions in this Maintenance Manual before performing mainte-

nance on the Liftgate.

• Before operating the Liftgate, read and understand the operating instructions in Operation
Manual.

• Comply with all WARNING and instruction decals attached to the Liftgate.

• Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement
decals are available from Maxon Customer Service.

• Consider the safety and location of bystanders and location of nearby objects when operating the

Liftgate. Stand to one side of the platform while operating the Liftgate

• Do not allow untrained persons to operate the Liftgate.

• Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while

performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.

• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no fl ames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek fi rst aid. If acid gets on your
skin, immediately wash it off with soap and water.

SAFETY INSTRUCTIONS

6

• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the con­trol switch to stop the Liftgate.

• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the power unit while the platform is raised. Listen for scraping, grat­ing 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 num­ber information with your parts order. Order replacement parts from:

MAXON LIFT CORP. Customer Service

11921 Slauson Ave., Santa Fe Springs, CA 90670

Online: www.maxonlift.com
Express Parts Ordering: Phone [phone] ext. 4345
Email: Ask your Customer Service representative

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

7

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE CHECKLIST

!

WARNING

Never operate the Liftgate if parts
are loose or missing.

Annually or 5000 Cycles (whichever occurs fi rst)

Visually check the entire Liftgate for excessively worn parts and broken welds, especially

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

the Hinge Pins. See PARTS BREAKDOWN section for replacement parts. With the Cylin-
der Housing Cover removed, lubricate drive chains with red grease. Also, do the Semi-an-

nual and Quarterly Maintenance checks.

Semi-annually or 2500 Cycles (whichever occurs fi rst)

Visually check the Platform Hinge Pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly Maintenance checks.

Quarterly or 1250 Cycles (whichever occurs fi rst)

Check the Hydraulic Fluid level in the Pump Reservoir. Refer to the CHECKING HYDRAU­LIC FLUID procedure in the PERIODIC MAINTENANCE section.

If Hydraulic Fluid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure in the PERIODIC MAINTENANCE section.

Keep track of the grade of Hydraulic Fluid in the Pump Reservoir and never mix two differ­ent grades of fl uid.

Check all Hoses and Fittings for chaffi ng and fl uid leaks. Replace if necessary.
Check electrical wiring for chaffi ng and make sure wiring connections are tight and free of

corrosion.
Check that all WARNING and instruction decals are in place and legible.

Check that all roll pins are in place and protrude evenly from both sides of Hinge Pin collar.
Replace roll pins if necessary.

CAUTION

Damaged cylinder seals and contaminated hydraulic fl uid can result from paint-
ing the polished portion of the cylinder rod. To prevent damage, protect the
exposed polished portion of the cylinder rod while painting.

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

8

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.

NOTE: Use correct grade of hydraulic fl uid for your location.

+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606

See TABLES 10-1 and 10-2 for recommended brands.

NOTE: If the hydraulic fl uid in the reservoir is contaminated, do the CHANGING
HYDRAULIC FLUID procedure in this section.

1. Open and lower platform to ground level.

Unfasten latch and remove the pump cover
(FIG. 9-1) .

2. Remove threaded fi ller cap (FIG. 9-2).

Check the hydraulic fl uid level in reservoir.
hydraulic fl uid level should be 1” below the
top of fi ller hole (FIG. 9-2). If needed, add
hydraulic fl uid to fi ll the reservoir to the
level shown in FIG. 9-2.

3. Reinstall fi ller cap (FIG. 9-2).

CAUTION

PUMP COVER

REMOVING / REINSTALLING

FILLER CAP

RESERVOIR

LATCH

PUMP COVER

FIG. 9-1

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Pump Cover must be correctly secured
to prevent it from becoming a hazard.
To secure Pump Cover, fasten the rub­ber latch on the Pump Box to the re­ceiver on the Pump Box Cover.

4. Reinstall the pump cover and fasten

latch (FIG. 9-2).

1”

CHECKING FLUID LEVEL

FIG. 9-2

9

PERIODIC MAINTENANCE

CHECKING HYDRAULIC FLUID - Continued

ISO 32 HYDRAULIC OIL

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

RECOMMENDED

BRANDS

AMSOIL AWH-05
CHEVRON HIPERSYN 32
KENDALL GOLDEN MV
SHELL TELLUS S2 V32
EXXON UNIVIS N-32

MOBIL

PART NUMBER

DTE-13M, DTE-24,
HYDRAULIC OIL-13

TABLE 10-1

ISO 15 OR MIL-H-5606 HYDRAULIC OIL
RECOMMENDED

BRANDS

AMSOIL AWF-05
CHEVRON FLUID A, AW-MV -15

PART NUMBER

KENDALL GLACIAL BLU
SHELL TELLUS S2 V15
EXXON UNIVIS HVI-13
MOBIL DTE-11M
ROSEMEAD THS FLUID 17111

TABLE 10-2

10

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.

NOTE: Use correct grade of hydraulic fl uid for your location.

+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606

See TABLES 10-1 and 10-2 for recommended brands.

1. Open and lower Platform to ground

level. Remove cover from cylinder
housing. Disconnect pressure hose
from the fl ow control valve on the cyl-
inder (FIG. 11-1).

HYDRAULIC HOSE

(PRESSURE LINE)

2. Unfasten latch and remove the pump cover
(FIG. 11-2) .

NOTE: To prevent spills, drain used

hydraulic fl uid into an empty 5
gallon bucket. Hold hydraulic
hose in container until fl uid stops
fl owing. If needed, get a helper.

3. Place disconnected end of hydraulic
hose in an empty 5 gallon bucket. Set
control switch to RAISE position until the
hydraulic system starts to make cavitat­ing sounds. Release the control switch.
When fl uid stops fl owing from hydraulic
hose, re-connect hose to RAISE port on
the cylinder (FIG. 11-1). Reinstall cover
on cylinder Housing (FIG. 11-1). Move
5 gallon bucket from work area and dis­pose fl uid correctly.

FLOW CONTROL

VALVE

CYLINDER

CONNECTING / DISCONNECTING

PRESSURE LINE

FIG. 11-1

PUMP COVER

LATCH

REMOVING / REINSTALLING

PUMP COVER

FIG. 11-2

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11

PERIODIC MAINTENANCE

CHANGING HYDRAULIC FLUID - Continued

4. Remove threaded Filler Cap (FIG. 12-1).

Fill the Reservoir with correct Hydraulic
Fluid to the level shown in FIG. 12-1.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

5. Reinstall Filler Cap (FIG. 12-1).

CAUTION

Pump Cover must be correctly secured
to prevent it from becoming a hazard.
To secure Pump Cover, fasten the rub­ber latch on the Pump Box to the re­ceiver on the Pump Box Cover.

6. Reinstall the Pump Cover and fasten
latch (FIG. 11-2).

FILLER CAP

RESERVOIR

1”

CHECKING FLUID LEVEL

FIG. 12-1

12

CLEAN AND LUBRICATE COLUMNS

CAUTION

Do not apply oil or grease to the Lift Columns.

1. Thoroughly pressure wash (or steam clean)
inside surfaces of both Lift columns (FIG.
13-1) to remove oil, grease, and debris.

CAUTION

Do not store can of lubricant on truck.

2. Lubricate inside each of the two Lift col-
umns (FIG. 13-1) with silicon spray or
tefl on spray.

CLEAN & LUBRICATE

3. Repeat washing procedure if there is any

build up of solid lubricant. Re-apply recom­mended lubricants as required.

FIG. 13-1

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13

PERIODIC MAINTENANCE

ADJUST DRIVE CHAINS

NOTE: Vehicle body must be empty

(unloaded) before performing
the following adjustment.

1. Adjust drive chains as follows.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

2. Remove cover from Cylinder Hous­ing. Loosen the lock nut on each chain
adjusting rod (FIG. 14-1). Then lower
Platform to ground level.

3. Turn each chain adjusting nut (FIG.
14-1) an equal amount of clockwise

turns (alternate from chain to chain) until
hydraulic cylinder is fully compressed.
Then tighten the lock nut (FIG. 14-1)
on each chain.

ADJUSTING

RODS

LOCK NUTS

ADJUSTING

NUTS

CYLINDER

ADJUSTING DRIVE CHAIN

FIG. 14-1

4. If either of the 2 chain rods are too
long, cut off the excess as shown in
FIG. 14-1.

14

THIS PAGE INTENTIONALLY LEFT BLANK

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15

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

PARTS BREAKDOWN

RCM-1250C

REFER TO PLATFORM AND

RAMP ASSEMBLY

16