Maxon TUK-A-WAY 80-3LM User manual

11921 Slauson Avenue.
Santa Fe Springs, CA. 90670
[phone]
80-3LM,
80-4LM
INSTALLATION
MANUAL
C MAXON Lift Corp. 2000
NOTE:
If the the liftgate being installed
is equipped with an underride
device, no additional or special
installation procedures are
required. Be certain, however,
that the understructure of the
trailer to which the liftgate will be
mounted can withstand equal to
or greater forces then is required
by the underride device, as
outlined in FMVSS223.
LIFT CORP.
M-99-47
REV. B
MAR. 2000

LIFT CORP.
11921 Slauson Ave.
Santa Fe Springs, CA. 906 0
CUSTOMER SERVICE:
(562) 464-00
[phone]
FAX: [phone]
TECHNICAL SERVICE:
(800) 8-MAXTEK (862- 835)
WARRANTY POLICY & PROCEDURE
NEW LIFTGATE WARRANTY
Term of Warranty: 2 Years from Date of In Service
Type of Warranty: Full Parts and Labor
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
Labor Schedule. (Call MAXON Customer Service for a copy).
All claims for warranty must be received within 30 Days of the repair date, and include the
following information:
1. Liftgate Model Number
2. Liftgate Serial Number
3. Description of Problem
4. Corrective Action Taken, and Date of Repair.
5. Parts used for Repair, Including MAXON Part Number(s).
6. MAXON R.G.A. # and/or Authorization # if applicable (see below).
7. Person contacted at MAXON if applicable.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase Type of Warranty: Part Replacement and
Replacement Labor.
MAXON will guarantee all returned genuine replacement parts upon receipt, and inspection
of parts and invoice. All Warranty repairs must be performed by an authorized MAXON warranty
station.
For major repairs, MAXONs Warranty Department must be notified, and an Authorization
Number received. Major repairs would generally be considered repairs made to the structural
assembly of the liftgate and/or repairs not outlined in the MAXON Liftgate Waranty Flat Rate
Schedule.
Major components (i.e. hydraulic pumps, cylinders, valves, or failed structural parts) must
be returned, freight pre paid, prior to the claim being processed. To ensure timely processing of
these warranty claims, an R.G.A. (Returned Goods Authorization) number must be obtained from
MAXONs Warranty Department prior to the return of any defective part. Defective Parts must be
returned within 60 days of the claim date for consideration to:
Warra ty Dapartme t, MAXON Lift Corp.
5920 Alameda St., Hu ti gto Park, CA. 90255
MAXONs warranty policy does not include the reimbursement for travel time; towing;
vehicle rental; service calls; fabrication of parts which are available from MAXON; oil; defects due to
misuse or abuse; loss of income due to downtime.
MAXONs Flat Rate Labor Schedule times takes into consideration time required for
diagnosis of problem.
Warranty and Technical Information is available by calling MAXONs Customer Service
Department.
NOTE: Check with Customer Service Department for
updated versions of Manuals on an annual basis.

Table of Contents
INTRODUCTION............................................................................................. PAGE 4
CLEARANCE DIMENSIONS .......................................................................... PAGE 5
TRUCK FRAME CUT-OUT ............................................................................. PAGE 6
EXTENSION PLATE WELDING ..................................................................... PAGE 7
FLIPOVER INSTALLATION ............................................................................ PAGE 8
OPENING PLATFORM ................................................................................... PAGE 9
WELD LIFTGATE TO VEHICLE ................................................................... PAGE 1
CONTROL SWITCH CHANNEL INSTALLATION ......................................... PAGE 12
CONTROL SWITCH GRAVITY DOWN ........................................................ PAGE 14
FUSED POWER CABLE............................................................................... PAGE 15
WIRE CONNECTIONS GRAVITY DOWN .................................................... PAGE 16
CONTROL SWITCH, POWER DOWN ......................................................... PAGE 17
FUSED POWER CABLE............................................................................... PAGE 18
WIRE CONNECTIONS, POWER DOWN ..................................................... PAGE 19
HYD. HOSE ROUTING, GRAVITY DOWN ................................................... PAGE 2
HYD. HOSE ROUTING, POWER DOWN ..................................................... PAGE 22
DECALS, 8 SERIES .................................................................................... PAGE 24
POWER CABLE INFORMATION .................................................................. PAGE 25
PLATFORM OPENER ................................................................................... PAGE 26
SADDLE MOUNTING INSTRUCTIONS ....................................................... PAGE 27
SUGGESTED REAR LIGHT INSTALLATION ............................................... PAGE 28
FINAL ADJUSTMENTS ................................................................................. PAGE 29
PLATFORM ADJUSTMENT .......................................................................... PAGE 3
HOOK INSTALLATION ................................................................................. PAGE 31
ACCESSORIES SECTION ......................................PAGE 32
DOCK BUMPER ANGLES ............................................................................ PAGE 33
BUMPER INSTALLATION ............................................................................. PAGE 34
CIRCUIT BREAKER INSTALLATION ........................................................... PAGE 35

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FA [phone]
PAGE 4
INTRODUCTION
This publication contains the information required to install the 0-3LM, 0-4LM. If
there is any doubt regarding the suitability of these lifts being installed on its intended
vehicle, or any portion of these instructions that you do not understand, please contact the
MAXON Customer Service Department for consultation.
Unauthorized modification to this equipment may cause premature failure or create
hazards in its use that are not foreseen at the time of installation. These kinds of changes
should be discussed with our ngineering Department before being undertaken.
Before you start!
The dimension of the open liftgate Platform length must be added to the
body length when considering proper weight distribution on the truck chassis.
In other words, be mindful of the possibility that a loaded liftgate could raise
the front wheels off of the ground.
1. When installing Taillight Systems, consult the Chassis or Trailer
manufacturers instructions for splicing into the vehicles lighting circuit.
2. CONSPICUITY DECALS: Federal Motor Vehicle Safety Standards call
out for the placement of retro-reflective sheeting, or reflex reflectors on all
vehicles prior to their being delivered. These decals or reflectors are not
supplied with the lift gate. Refer to the standard for details.
CAUTION!
When all else fails, read the
instructions.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FA [phone]
PAGE 5
Approx. 24
(Ref. Only)
CLEARANCE DIMENSIONS
14
55 Max. Bed Height
46 Min. Bed Height
26-3/4
Lock Angle
Inside
12-21
Ref.
Locking Angle
Cyl. Mount
Pin
Cyl. Mount
Pin

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FA [phone]
PAGE 6
TRUCK FRAME CUT-OUT
4-1/2
19
12
TOP OF VEHICLE FLOOR
80-3LM, 80-4LM
W/48-54 PLATFORM
80-3LM, & 80-4LM
W/60 PLATFORM
VEHICLE
FRAME
4-1/2
21
13
TOP OF VEHICLE FLOOR
VEHICLE
FRAME

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FA [phone]
PAGE 7
EXTENSION PLATE WELDING
2 WELDS
EQUALLY SPACED (TYP.)
WELD ALL AROU D
(TYP.)
THESE WELDS ARE OVER THE RECTA GULAR
TUBE LOCATED U DER THE FLOORPLATE.
2 WELDS
4 WELDS
4 WELDS
2 WELDS
NOTE: THE 2 WELDS
ARE EQUALLY SPACED
BETWEE THE 4
WELDS.
VIEW FROM BELOW VEHICLE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FA [phone]
PAGE 8
FLIPOVER INSTALLATION
ITEM QTY. PART NUMBER DESCRIPTION
1 2 262258 PIN, HINGE WELDMENT
2 4 902020-1 WASHER, FLAT NYLON 1.317x .765x .062 THK.
3 2 905033-1 ROLLPIN, 1/4" DIA. x 1-1/4" LONG
4 2 260917-04 BEARING, FIBERGLIDE, 3/4"I.D. x 1/2" LONG
If not already assembled. Attach the Flipover Section to the Platform per
the illustration below. This will be repeated on the other side.
1
2
3
4
FLIPOVER SECTION
PLATFORM
2
NOTE: Top surface of Platform & Flipover must
be even. If not, first check that all pins and
bearings are in the hinge holes. Add shims to this
area if needed. Typical for both sides of platform.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FA [phone]
PAGE 9
OPENING PLATFORM
The Locking Angles on 80-3LM, & 80-4LM
are located inside the Lifting Arms (Shown).
Keep Feet Clear when Unfolding the Platform.
WARNING!
Do not remove the Locking Angle until
instructed to do so in this manual.
Platform
Locking Angle
Unfold
Flipover
Unfold Platform
Flipover

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FA [phone]
PAGE 10
WELD LIFTGATE TO VEHICLE
Place a C Clamp on
each side of the Platform as
shown to prevent the Hoist
Chain from slipping off of the
Platform. Tack weld two (2)
temporary support straps to
the Extension Plate to align
the Platform. Place chain en-
tirely around the Platform, then
hoist and jack the unit into
position. The rear edge of the
Platform must be flush with the
Extension Plate. The Hinge Pins must be 90° to the vehicle bed.
Floor Jack
Hinge Pins
Support Straps Hoist
90°
The rear edge of the Platform must be level with and flush against the
Extension Plate. The edges of the Platform should be equally spaced inboard
from the ends of the Extension Plate. Tack weld the two (2) temporary Exten-
sion Plate support straps to the Extension Plate.
Support Strap
Platform
Rear Edge of
Platform
Tack Weld to
Extension Plate,
close to the Edge.
(Typ.)
Equal Spaces
Extension Plate
Weld, see
following
page.
Approx. 1
Overhang
(Typ)