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Maxon TUK-A-WAY Series Maintenance Manual

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M-03-07
REV. E
JUNE 2014
MAINTENANCE MANUAL
72-25 & 72-30
©
2014 MAXON LIFT CORP.

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Summary of Contents for Maxon TUK-A-WAY Series

  • Page 1 M-03-07 REV. E JUNE 2014 MAINTENANCE MANUAL 72-25 & 72-30 © 2014 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

    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 ..................
  • Page 5 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) ..............

  • Page 6: Summary Of Changes: M-03-07, Revision F

    SUMMARY OF CHANGES: M-03-07, REVISION F PAGE DESCRIPTION OF CHANGE COVER Updated REV and date of release and copyright date. Added SUMMARY OF CHANGES Update warning and added decal P/N 282687-01 Added safety instructions Updated Safety Hook instruction Updated fl ow regulator (control) valve P/N 906923-01, HP hose P/N 288241-01 and 29, 35, 51, 53 description 30, 36...

  • Page 7: Warning

    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. •...

  • Page 8: 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 9: Liftgate Terminology 72-25 & 72-30

    LIFTGATE TERMINOLOGY 72-25 & 72-30 EXTENSION PLATE CONTROL CONTROL SWITCH HANDLE MAIN FRAME PARALLEL PLATFORM LIFT PUMP BOX CYLINDER LIFT FRAME RAMP FLIPOVER WEDGE FLIPOVER SPECIAL PROFILE FLIPOVER...

  • Page 10: Periodic Maintenance

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

  • Page 11: Periodic Maintenance Checklist

    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.

  • Page 12: 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 13 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. FILLER FLUID LEVEL PLATFORM POSITION “H” STOWED 2-5/8” to 3-1/8” VEHICLE BED HEIGHT 2-5/8”...

  • Page 14: 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 15 5. Bolt on the pump cover as shown in FIG. 15-1. Torque the bolts (cap screws) to 10 - 14 lbs.- in. UNBOLTING / BOLTING PUMP COVER FIG. 15-1...

  • Page 16: Platform Adjustment

    PERIODIC MAINTENANCE PLATFORM 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 TIP OF platform and fl ipover. As the platform fi rst touches FLIPOVER the ground, shackles and tip of fl...
  • Page 17 3. Make sure platform is still at ground level. If the tip of fl ipover is not touch- ing the ground, measure and compare distance “B” (FIG. 17-1) with TABLE 17-1 to determine how much to grind from the platform stops (FIG. 17-2). Grind correct amount of metal (TABLE TIP OF FLIPOVER...

  • Page 18: Replacing Platform Torsion Spring

    PERIODIC MAINTENANCE REPLACING PLATFORM TORSION SPRING 1. Manually fold fl ipover onto platform. 2. Raise Liftgate to a convenient work height to gain access and release tension on the torsion spring. ROLL PIN (REMOVED) TORSION SPRING COLLAR PLATFORM CAUTION HINGE PIN To prevent injury and equipment damage, make sure there is no tension on torsion spring before removing hinge pin.
  • Page 19 5. Drive platform hinge pin inboard to ROLL PIN correct position through the platform PLATFORM HINGE (INSTALLED) hinge bracket (FIG. 19-1). Line up BRACKET the hole in the platform hinge pin with PLATFORM the hole in the pin collar. Install the HINGE PIN roll pin through the pin collar until roll pin protrudes equally from both sides...

  • Page 20: Adjust Safety Hook (If Required)

    ADJUST SAFETY HOOK (IF REQUIRED) CHECK SAFETY HOOK FUNCTION EXTENSION PLATFORM LOOP CORRECT 1. When raising platform to stowed position, PLATE (WRONG POSITION) POSITION listen for sound of safety hook engaging platform loop. 2. When the Liftgate is stowed, see if plat- form loop is positioned above the safety hook as shown in FIG.

  • Page 21: Parts Breakdowns

    PARTS BREAKDOWNS 72-25 & 72-30 MAIN ASSEMBLY REFER TO EXTENSION PLATE ASSEMBLY REFER TO LIFT FRAME & PARALLEL ARMS REFER TO PLATFORM & FLIPOVER ASSEMBLY (RAMP FLIPOVER SHOWN) REFER TO PUMP COVER, HYDRAULIC COMPONENTS, & POWER UNITS ITEM QTY. PART NO. DESCRIPTION 221416 ROLL PIN, 3/8”...

  • Page 22: Extension Plate Assembly

    REFER TO EXTENSION PLATE ASSEMBLY 1 (6 PLACES) ITEM QTY. PART NO. DESCRIPTION 207644 RIVET , 3/16” DIA. X .402” LG. 050175 MAXON PLATE 262999 EXTENSION PLATE WELDMENT 215342 SPRING LEVER, 2-1/2” LG 215341 SAFETY HOOK WELDMENT 201606 HOOK RELEASE HANDLE, 5/8” X 52-3/4” LG 201015 FLAT, 1/4”...

  • Page 23: Lift Frame & Parallel Arms

    LIFT FRAME & PARALLEL ARMS ITEM QTY. PART NO. DESCRIPTION 260315 LIFT FRAME ASSEMBLY 260363 SELF LUBE BEARING, 1” X 1-1/2” 260368-03 PIN, 1” DIA X 3-1/2” LG 260368-04 PIN, 1” DIA X 4-1/2” LG 221416 ROLL PIN, 3/8” X 2” LG 260369 SELF LUBE BEARING, 1-1/8”...

  • Page 24: Platform & Flipover Assembly (Ramp)

    PLATFORM & FLIPOVER ASSEMBLY (RAMP) ITEM QTY. PART NO. DESCRIPTION 201629 FLIPOVER WELDMENT (RAMP) 203405-05 PIN, 1” DIA X 3-1/4” LG 221416 ROLL PIN, 3/8” X 2” LG 280369 PLATFORM WELDMENT...

  • Page 25: Platform & Flipover Assembly (Wedge)

    PLATFORM & FLIPOVER ASSEMBLY (WEDGE) ITEM QTY. PART NO. DESCRIPTION 213085 FLIPOVER WELDMENT (WEDGE) 203405-05 PIN, 1” DIA X 3-1/4” LG 221416 ROLL PIN, 3/8” X 2” LG 280369 PLATFORM WELDMENT...

  • Page 26: Platform & Flipover Assembly (Special Profile)

    PLATFORM & FLIPOVER ASSEMBLY (SPECIAL PROFILE) ITEM QTY. PART NO. DESCRIPTION 253875 ALUMINUM RAMP, 3/8” X 10” X 69” LG 900061-5 FLAT HEAD SOCKET SCREW, 3/8”-16 X 1-1/4” LG 902001-2 FLAT WASHER, 3/8” 901002 LOCK NUT, 3/8”-16 NYLON 253516 RUBBER BUMPER, 1” HEIGHT 900061-6 FLAT HEAD SOCKET SCREW, 3/8”-16 X 1-1/2”...

  • Page 27: Pump Cover & Mounting Plate Assembly (Gravity Down)

    PUMP COVER & MOUNTING PLATE ASSEMBLY (GRAVITY DOWN) (5 PLACES) (5 PLACES) MAIN FRAME (REF) 12 VDC POWER UNIT 24 VDC POWER UNIT (REF, GRAVITY DOWN) ITEM QTY. PART NO. DESCRIPTION 266406-01 PUMP ASSEMBLY, STANDARD TUK-A-WAY 266406-02 PUMP ASSEMBLY, STANDARD TUK-A-WAY (24 VOLT) 266419-01 COVER ASSY 093201-01...

  • Page 28: Pump Cover & Mounting Plate Assembly (Power Down)

    PUMP COVER & MOUNTING PLATE ASSEMBLY (POWER DOWN) (5 PLACES) (5 PLACES) MAIN FRAME (REF) 12 VDC POWER UNIT (REF, POWER DOWN) ITEM QTY. PART NO. DESCRIPTION 268180-01 PUMP ASSEMBLY, POWER DOWN TUK-A-WAY 266419-01 COVER ASSY 093201-01 GASKET, RUBBER CHANNEL, 57-1/2” LG. 261740 LABEL, OIL LEVEL 268179-01...

  • Page 29: Gravity Down Hydraulic Components

    GRAVITY DOWN HYDRAULIC COMPONENTS SEE 12 VDC POWER UNIT (GRAVITY DOWN) ITEM QTY. PART NO. DESCRIPTION 266401-01 CYLINDER, 3” DIA X 10” STROKE (72-25) 266401-02 CYLINDER, 3-1/2” DIA X 10” STROKE (72-30) 260916-03 BEARING, SELF LUBE 906722-01 ELBOW, 90 DEG O-RING, #6 M-M 906923-01 FLOW REGULATOR VALVE, 2 GPM 288241-01...

  • Page 30: Vdc Power Unit (Gravity Down)

    35 lbs.-in. Torque the nuts on #10-32 control terminals to 15 lbs.-in. CAUTION To prevent damage when installing 2-way valves, torque valve cartridge nut to 30 lbs.-in. max. NOTE: MAXON recommends using dielectric grease on all electrical connections. CONTROL SWITCH WIRING HARNESS 1A,1B (REF.
  • Page 31 ITEM QTY. PART NO. DESCRIPTION 268070-01 12 VDC POWER UNIT (GRAVITY DOWN) 290002 3-PIECE GEAR PUMP 226594 OIL SEAL KIT 290020 O-RING 268027-01 WIRE ASSEMBLY, 18 GA, #10 RING - 5/16” RING 280404 CABLE ASSEMBLY 268029-01 SOLENOID SWITCH 905152 ELBOW, 90 DEG, O-RING 280806-01 FILLER CAP 267733-11...

  • Page 32: Vdc Power Unit (Gravity Down)

    To prevent damage to plastic case starter solenoid, do not over-tighten the terminal nuts. For the 5/16” load terminals, torque nuts 35-40 lbs.-in. Torque the nuts on #10-32 control terminals 15-20 lbs.-in. NOTE: MAXON recommends using dielectric grease on all electrical connections. CONTROL SWITCH...
  • Page 33 ITEM QTY. PART NO. DESCRIPTION 280610-24 24 VDC POWER UNIT (GRAVITY DOWN) 290065 3-PIECE GEAR PUMP 280566-01 WIRE ASSEMBLY, 16 GA, GREEN 280404 CABLE ASSEMBLY 281571-01 MOTOR STARTER SOLENOID, 24 VOLT DC 905152 90 DEG ELBOW 280806-01 FILLER CAP 280589-01 RESERVOIR 908017-01 DRAIN PLUG...
  • Page 34 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 35: Power Down Hydraulic Components

    POWER DOWN HYDRAULIC COMPONENTS SEE 12 VDC POWER UNIT (POWER DOWN) ITEM QTY. PART NO. DESCRIPTION 266401-01 CYLINDER, 3” DIA X 10” STROKE (72-25) 266401-02 CYLINDER, 3-1/2” DIA X 10” STROKE (72-30) 260916-03 BEARING, SELF LUBE 906722-01 ELBOW, 90 DEG, O-RING, #6 M-M 906923-01 FLOW REGULATOR VALVE, 2 GPM 288241-01...

  • Page 36: Vdc Power Unit (Power Down)

    35 lbs.-in. Torque the nuts on #10-32 control terminals to 15 lbs.-in. CAUTION To prevent damage when installing 2-way valves, torque valve cartridge nut to 30 lbs.-in. max. NOTE: MAXON recommends using dielectric grease on all electrical connections. CONTROL SWITCH WIRING HARNESS (REF. CONTROL SWITCH...
  • Page 37 ITEM PART NO. DESCRIPTION 268181-01 12 VDC POWER UNIT (POWER DOWN) 268176-01 MOTOR, 12 VDC 268029-01 SWITCH, SOLENOID 906821-01 2P2W VALVE & COIL ASSEMBLY, 4 WAY, DOUBLE SPADE 906822-01 2P2W VALVE 290045 COIL, DOUBLE SPADE, 2 WAY 290046 VALVE ASSEMBLY, 4 WAY, DOUBLE SPADE 290047 VALVE CARTRIDGE, 4 WAY 290048...

  • Page 38: Decals

    DECALS CAPACITY DECAL CAPACITY DECAL P/N 220382 P/N 220388 UP/DOWN DECAL P/N 264507 STOW WARNING DECAL P/N 282847-02 WARNING DECAL (2 PLACES, LH SIDE NOT SHOWN) P/N 265736-03 DECAL SHEET P/N 282522-01 INSTRUCTION DECAL FIG. 38-1 P/N 251867-05...
  • Page 39 DECAL SHEET P/N 282522-01 FIG. 39-1 WARNING DECAL P/N 282847-02 FIG. 39-2...

  • Page 40: 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. NOTE: MAXON recommends using dielectric grease on all electrical connections. BLACK WHITE POWER (FOR REFERENCE- BLACK UNIT)

  • Page 41: Hydraulic System Diagrams

    HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC (GRAVITY DOWN) HYDRAULIC CYLINDER 2 GPM FLOW CONTROL VALVE RETURN PORT FILLER HOLE (PLUGGED) (PLUGGED) PRESSURE PORT VENT PORT VALVE A RELIEF VALVE CHECK VALVE (SET AT 3250 PSI) AUX. HAND PUMP PORT (PLUGGED) PUMP MOTOR (REFERENCE) FILTER...

  • Page 42: Hydraulic Schematic (Power Down)

    HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDER 2 GPM FLOW CONTROL VALVE PORT B - LOWER PORT A - RAISE (POWER DOWN) VALVE A RELIEF VALVE 2 (SET AT 1100 PSI) VALVE E RELIEF VALVE 1 (SET AT 3200 PSI) AUX. HAND PUMP PORT (PLUGGED) MOTOR...

  • Page 43: Electrical System Diagrams

    ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC (GRAVITY DOWN) CONTROL SWITCH WHITE GREEN BLACK WHITE GREEN BLACK CABLE ASSEMBLY THERMAL SWITCH SOLENOID, (IN MOTOR VALVE A CASING) STARTER SOLENOID CABLE WITH 175 AMP FUSE MOTOR BATTERY FIG. 43-1...

  • Page 44: Electrical Schematic (Power Down)

    ELECTRICAL SCHEMATIC (POWER DOWN) BLACK (DOWN) (UP) WHITE CONTROL SWITCH BLACK WHITE GREEN GREEN CABLE ASSEMBLY THERMAL SOLENOID, SOLENOID, SWITCH VALVE E VALVE A (IN MOTOR CASING) STARTER SOLENOID GREEN CABLE WITH 175 AMP FUSE BATTERY FIG. 44-1...

  • Page 45: Troubleshooting

    TROUBLESHOOTING PLATFORM WILL NOT RAISE 1. Use voltmeter to verify power is being supplied to solenoid terminal “B” (FIG. 45-1). Recharge the battery if there is less than 12.6 volts. CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl...

  • Page 46: Platform Raises But Leaks Down

    PLATFORM RAISES BUT LEAKS DOWN 1. Check if solenoid valves are constantly energized by touch- COIL ing a screwdriver to the top nut of the solenoid (FIG. 46- 1). Try pulling the screwdriver away from the solenoid. If the solenoid nut attracts the screwdriver (magnetically) without pushing the toggle switch, the control circuit is operating incorrectly.

  • Page 47: 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 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.

  • Page 48: Liftgate Will Not Lift Rated Capacity

    LIFTGATE WILL NOT LIFT RATED CAPACITY 1. Use voltmeter to verify the battery shows 12.6 volts or more under load from pump mo- tor. 2. Check for structural damage and lack of lubrication. Replace worn parts. CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl...

  • Page 49: Platform Raises Slowly

    TROUBLESHOOTING PLATFORM RAISES SLOWLY 1. Use voltmeter to verify power is being supplied to solenoid terminal “B”. Recharge the battery if volt- TERMINAL meter indicates less than 12.6 volts (FIG. 49-1). “B” BATTERY (+) CAUTION Keep dirt, water and other contaminants from entering the hydraulic system.

  • Page 50: Platform Will Not Lower, Lowers Too Slowly Or Too Quickly

    7. Check if fl ow control valve (FIG. 50-3) is FLOW (REF) CONTROL pointing to the direction of controlled fl uid VALVE fl ow (toward pump). If arrow appears to be pointed in the wrong direction, call MAXON Technical Service. FIG. 50-3...

This manual is also suitable for:

Tuk-a-way 72-25Tuk-a-way 72-30

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