Maxon TUK-A-WAY, TUK-A-WAY 72-25, TUK-A-WAY 72-30 Maintenance Manual

M-03-07
REV. E
JUNE 2014

MAINTENANCE MANUAL

72-25 & 72-30

© 2014 MAXON LIFT CORP.

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 Avenue, 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

SUMMARY OF CHANGES: M-03-07, REVISION F ............................................................. 6

WARNING ....................................................................................................................... ...... 7

SAFETY INSTRUCTIONS ....................................................................................................8

LIFTGATE TERMINOLOGY 72-25 & 72-30 .......................................................................... 9

PERIODIC MAINTENANCE ................................................................................................ 10

PERIODIC MAINTENANCE CHECKS ................................................................................ 10

PERIODIC MAINTENANCE CHECKLIST ............................................................................11

CHECKING HYDRAULIC FLUID ........................................................................................12

CHANGING HYDRAULIC FLUID ........................................................................................ 14

PLA TFORM ADJUSTMENT ................................................................................................16

REPLACING PLATFORM TORSION SPRING ................................................................... 18

ADJUST SAFETY HOOK (IF REQUIRED) ........................................................................20

PARTS BREAKDOWNS .....................................................................................................21

72-25 & 72-30 MAIN ASSEMBLY ........................................................................................ 21

EXTENSION PLATE ASSEMBLY ........................................................................................ 22

LIFT FRAME & PARALLEL ARMS ......................................................................................23

PLATFORM & FLIPOVER ASSEMBLY (RAMP) .................................................................24

PLATFORM & FLIPOVER ASSEMBLY (WEDGE) .............................................................. 25

PLATFORM & FLIPOVER ASSEMBLY (SPECIAL PROFILE) ............................................ 26

PUMP COVER & MOUNTING PLATE ASSEMBLY (GRAVITY DOWN) ............................. 27

PUMP COVER & MOUNTING PLATE ASSEMBLY (POWER DOWN) ...............................28

GRAVITY DOWN HYDRAULIC COMPONENTS ................................................................29

12 VDC POWER UNIT (GRAVITY DOWN) ......................................................................... 30

24 VDC POWER UNIT (GRAVITY DOWN) ......................................................................... 32

POWER DOWN HYDRAULIC COMPONENTS .................................................................. 35

12 VDC POWER UNIT (POWER DOWN) ........................................................................... 36

DECALS ..............................................................................................................................38

CONTROL SWITCH AND POWER CABLE ........................................................................40

HYDRAULIC SYSTEM DIAGRAMS ................................................................................... 41

HYDRAULIC SCHEMATIC (GRAVITY DOWN) ................................................................... 41

HYDRAULIC SCHEMATIC (POWER DOWN) ....................................................................42

ELECTRICAL SYSTEM DIAGRAMS .................................................................................43

ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 43

ELECTRICAL SCHEMATIC (POWER DOWN) ...................................................................44

TROUBLESHOOTING ........................................................................................................ 45

PLATFORM WILL NOT RAISE ............................................................................................45

PLATFORM RAISES BUT LEAKS DOWN .......................................................................... 46

PLATFORM RAISES PARTIALLY AND STOPS .................................................................. 47

LIFTGATE WILL NOT LIFT RATED CAPACITY .................................................................. 48

PLATFORM RAISES SLOWLY ...........................................................................................49

PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY ................ 50

SUMMARY OF CHANGES: M-03-07, REVISION F

PAGE DESCRIPTION OF CHANGE

COVER Updated REV and date of release and copyright date.

6 Added SUMMARY OF CHANGES
7 Update warning and added decal P/N 282687-01

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

8 Added safety instructions

20 Updated Safety Hook instruction

29, 35, 51, 53

30, 36 Clarifi ed torque specs for electrical connections on started solenoid

38-39

Updated fl ow regulator (control) valve P/N 906923-01, HP hose P/N 288241-01 and
description

Replaced WARNING decal P/N 264081 with decal sheet P/N 282522-01.
Inserted new page for Decal Sheet 282522-01 & Warning Decal 282847-02, added
decal 282687-01

6

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

WARNING

!

WARNING

WARNING

• 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
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.

• Welding on galvanized parts gives off especially hazardous fumes. Comply with WARNING decal
on the galvanized part (

adequate ventilation, and wear suitable respirator.

FIG. 7-1). To minimize hazard remove galvanizing from weld area, provide

FIG. 7-1

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

7

SAFETY INSTRUCTIONS

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

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

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.

• 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

8

LIFTGATE TERMINOLOGY

72-25 & 72-30

EXTENSION

PLATE

CONTROL

SWITCH

MAIN FRAME

PARALLEL

ARM

PLATFORM

CONTROL

HANDLE

LIFT

CYLINDER

LIFT FRAME

RAMP FLIPOVER

WEDGE FLIPOVER

SPECIAL PROFILE

FLIPOVER

PUMP BOX

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

9

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE CHECKS

!

WARNING

Never operate the Liftgate with parts loose or missing.

NOTE: Make sure vehicle is parked on level ground while perform-

ing the maintenance checks.

Quarterly or 1250 Cycles (whichever occurs fi rst)

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

Check the hydraulic fl uid level in the pump reservoir. Refer to the CHECKING HYDRAULIC
FLUID procedure in the PERIODIC MAINTENANCE section.

If hydraulic fl uid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure in the PERIODIC MAINTENANCE section.

Keep track of the grade of hydraulic fl uid in the pump reservoir and never mix two different
grades of fl uid.

Check all hoses and fi ttings for chafi ng and fl uid leaks. Tighten loose fi ttings or replace
parts as required.

Check electrical wiring for chafi ng and make sure wiring connections are tight and free of
corrosion. Use dielectric grease to protect electrical connections.

Check that all WARNING and instruction decals are in place. Also, make sure decals are
legible and decals are clean and undamaged.

Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.

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

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 or 1250 Cycles main-

tenance checks.

10

PERIODIC MAINTENANCE CHECKLIST

NOTE: Make sure vehicle is parked on level ground while performing the maintenance

checks.

Quarterly or 1250 Cycles (whichever occurs fi rst)

Check the level and condition of the hydraulic fl uid.

Visually check all hoses for chafi ng and fl uid leaks. Tighten loose fi ttings or replace
parts as required.

Check electrical wiring for chafi ng and make sure wiring connections are tight and free
of corrosion. Use dielectric grease to protect electrical connections.

Check that all WARNING and instruction decals are in place. Also, make sure decals
are legible, clean and undamaged.

Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.

CAUTION

Damaged cylinder seals and contaminated hydraulic fl uid can result from
painting 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 Liftgate or if the Lift­gate is dirty, clean it off. Touch up the paint where bare metal is showing.

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

Visually check the platform hinge pins for excessive wear and broken welds.

Do the Quarterly or 1250 Cycles Checks on this checklist.

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

11

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.

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

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 13-2 and 13-3 for recommended brands.

1. Unbolt & remove pump cover (FIG. 12-1).

NOTE: If the hydraulic fl uid in the

reservoir is contaminated, do
the CHANGING HYDRAULIC

FLUID procedure in this section.

NOTE: If you have a power down

power unit, skip instructions

2 & 3.

2. For gravity down power unit, check the

hydraulic fl uid level “H” in reservoir (FIG.
12-2 and TABLE 12-1). If needed, add

fl uid to the reservoir as follows.

PLATFORM POSITION

STOWED 1-7/8” to 2-3/8”

FLUID LEVEL

“H”

POWER UNIT

(REF)

CAP SCREWS

(5 PLACES)

FLAT WASHERS

(5 PLACES)

PUMP COVER

UNBOLTING / BOLTING PUMP COVER

FIG. 12-1

VEHICLE BED HEIGHT 1-7/8” to 2-3/8”
ON THE GROUND 3-1/2” to 4”

GRAVITY DOWN FLUID LEVEL

TABLE 12-1

3. Pull out (no threads) fi ller cap (FIG. 12-2).

Fill the reservoir with hydraulic fl uid to level
“H” shown in FIG. 12-2 and TABLE 12-1.
Reinstall fi ller cap (FIG. 12-2)

RESERVOIR

“H”

FILLER CAP

GRAVITY DOWN POWER UNIT

FIG. 12-2

12

4. For power down power unit, check the hydraulic

fl uid level “H” in reservoir (FIG. 13-1 and TABLE
13-1). If needed, add fl uid to the reservoir as fol-

lows.

PLATFORM POSITION

STOWED 2-5/8” to 3-1/8”
VEHICLE BED HEIGHT 2-5/8” to 3-1/8”

FLUID LEVEL

“H”

FILLER

CAP

ON THE GROUND 2-3/8” to 2-7/8”

POWER DOWN FLUID LEVEL

TABLE 13-1

5. Pull out (no threads) fi ller cap (FIG.
13-1). Fill the reservoir with hydraulic
fl uid to level “H” shown in FIG. 13-1
and TABLE 13-1. Reinstall fi ller cap
(FIG. 13-1).

6. Bolt on the pump cover (FIG. 12-1).

Torque the bolts (cap screws) to

10 - 14 lbs.- in.

RESERVOIR

POWER DOWN POWER UNIT

FIG. 13-1

ISO 32 HYDRAULIC OIL

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 13-2

“H”

ISO 15 OR MIL-H-5606 HYDRAULIC OIL
RECOMMENDED

BRANDS

AMSOIL AWF-05
CHEVRON FLUID A, AW-MV -15
KENDALL GLACIAL BLU
SHELL TELLUS S2 V15
EXXON UNIVIS HVI-13
MOBIL DTE-11M
ROSEMEAD THS FLUID 17111

PART NUMBER

TABLE 13-3

13

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

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.

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

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 13-2 and 13-3 for recommended brands.

GRAVITY DOWN LIFTGATES

1. Remove the pump cover (FIG. 15-1). Place emp-

ty 5 gallon bucket under drain plug (FIG. 14-1).

2. Lower platform to ground. Pull out (no
threads) drain plug (FIG. 14-1). Drain hydraulic

fl uid from system. Reinstall drain plug.

3. Pull out (no threads) fi ller cap (FIG. 14-1) and
refi ll reservoir with hydraulic fl uid to level shown in

FIG. 14-1. Reinstall fi ller cap (FIG. 14-1).

4. Bolt on the pump cover as shown in FIG. 15-1

Torque the bolts (cap screws) to 10 - 14 lbs.- in.

POWER DOWN LIFTGATES

1. Remove the pump cover (FIG. 15-1). Place emp-

ty 5 gallon bucket under drain plug (FIG. 14-1).

RESERVOIR

3-1/2” - 4”

DRAIN

PLUG

FILLER CAP

LIFTGATE SHOWN WITH GRAVITY

DOWN PUMP & MOTOR

FIG. 14-1

2. Open and raise platform to vehicle bed height. Pull

out (no threads) drain plug (FIG. 14-1). Drain hy­draulic fl uid.

3. Disconnect the motor power cable (FIG. 14-

2) from starter solenoid. Lower the platform

while draining the remaining hydraulic fl uid from
system. Reinstall drain plug. Reconnect the
motor power cable to starter solenoid.

4. Pull out (no threads) fi ller cap (FIG. 14-1) and
refi ll reservoir with hydraulic fl uid to level shown
in FIG. 14-1. Reinstall fi ller cap (FIG. 14-1).

14

STARTER

SOLENOID

MOTOR

POWER

CABLE

POWER DOWN PUMP

FIG. 14-2

5. Bolt on the pump cover as shown in
FIG. 15-1. Torque the bolts (cap
screws) to 10 - 14 lbs.- in.

POWER UNIT

(REF)

CAP SCREWS

(5 PLACES)

FLAT WASHERS

(5 PLACES)

PUMP COVER

UNBOLTING / BOLTING PUMP COVER

FIG. 15-1

15

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PERIODIC MAINTENANCE

PLA TFORM ADJUSTMENT

NOTE: Before doing the following procedure,

make sure vehicle is parked on level
ground.

1. Make sure platform is at ground level. Unfold the
platform and fl ipover. As the platform fi rst touches
the ground, shackles and tip of fl ipover must touch
the ground at the same time (FIG. 16-1). If the

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

shackles and the tip of fl ipover touch the ground
at the same time, raise platform to bed height.
Outboard edge on top of fl ipover should be above
bed level (FIG. 16-2). If indications are correct in
both cases (FIGS. 16-1 & 16-2), Liftgate is in­stalled correctly and no adjustment is needed. If
indications are incorrect, continue to instruction 2.

NOTE: If tip of fl ipover touches fi rst (FIG.
16-3), do instruction 2. If the shackle

touches fi rst (FIG. 17-1), skip instruc-
tion 2 and do 3.

2. Make sure platform is still at ground level. If
the shackle is not touching the ground, mea­sure and compare distance “A” (FIG. 16-3)
with TABLE 16-1 to determine the correct
shim. Make shims as needed (FIG. 16-5).
Weld shim as shown in FIG. 16-4.

RAISE TIP OF

FLIPOVER

THIS DISTANCE “A”

7/8” 1/16” 1/16”
1-3/4” 1/8” 1/8”
2-5/8” 3/16” 3/16”
3-1/2” 1/4” 1/4”

REQUIRED SHIM

THICKNESS

WELD SIZE “W”

TIP OF

FLIPOVER

FLIPOVER & SHACKLES

TOUCH GROUND

FIG. 16-1

OUTBOARD

EDGE

LEVEL LINE

FLIPOVER EDGE ABOVE

BED LEVEL

FIG. 16-2

“A”

(TABLE 16-1)

SHACKLES DO NOT TOUCH

GROUND

FIG. 16-3

EXISTING STOP

TABLE 16-1

1-1/2”

2-1/4”

SHIM (1/16”, 1/8”, 3/16”, or 1/4”)

MADE FROM STEEL FLAT

FIG. 16-5

NEW SHIM

“W”

TABLE 16-1

SHACKLE

WELDING SHIMS (CURBSIDE SHOWN)

FIG. 16-4

16