Maxon TUK-A-WAY 80-3LM Installation Manual Download Page 27

Page: 27 / 36

11921

Slauson

Ave.

Santa

Springs,

CA.

90670

(800)

227-41

(888)

771-7713

PAGE 27

SADDLE MOUNTING INSTRUCTIONS

SADDLE

WELDMENT

PLATFORM OPENER

EXTENSION PLATE

FOLDED

PLATFORM

.25

TYP

After mounting the

Platform Openers,

straddle the Saddle

Weldments over the

Platform Openers as

shown.

Store the Platform in the folded position.

Position the Saddle Weldments so that

the Platform touches nothing but the

Plastic Pads on the inner surface of the

saddle weldment.

NOTE:

Open & close

SADDLE

WELDMENT

Platform to ensure the Saddle Weldment is positioned correctly for the

stowing procedure. Rotate Saddle Weldment as required to achieve this.

Cut off any excess plate and weld Saddle to the Platform Openers.

PLATFORM

OPENER

CUT

EXCESS

PLATE

(TYP.)

Summary of Contents for TUK-A-WAY 80-3LM

Page 1: ...g 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 m...

Page 2: ...rs 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 consid...

Page 3: ...OWN 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 20 HYD HOSE ROUTING POWER DOWN PAGE 22 DECALS 80 SERIES P...

Page 4: ...th our Engineering 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 o...

Page 5: ...e Springs CA 90670 800 227 4116 FAX 888 771 7713 PAGE 5 Approx 24 Ref Only CLEARANCE DIMENSIONS 14 55 Max Bed Height 46 Min Bed Height 2 6 3 4 L o c k A n g l e I n s i d e 12 21 Ref Locking Angle Cyl...

Page 6: ...Springs CA 90670 800 227 4116 FAX 888 771 7713 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 V...

Page 7: ...1 7713 PAGE 7 EXTENSION PLATE WELDING 2 WELDS EQUALLY SPACED TYP WELD ALL AROUND TYP THESE WELDS ARE OVER THE RECTANGULAR TUBE LOCATED UNDER THE FLOORPLATE 2 WELDS 4 WELDS 4 WELDS 2 WELDS NOTE THE 2 W...

Page 8: ...IN 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...

Page 9: ...PENING 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...

Page 10: ...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...

Page 11: ...to the Main Frame install the Electrical System as shown on the following pages Four 4 2 Long Welds Typ both Mount Plates 5 16 Weld all around Inside Outside of Both Plates Mount Plate NOTE Keep Max S...

Page 12: ...witch Channel with holes on top and resting on the Extension Plate Leave a minimum of 1 2 clearance for cable at bottom or drill 1 2 Dia access hole through the Corner Post near the lower edge of Swit...

Page 13: ...re modification of the switch channel Drill a 1 2 Dia ac cess hole through the street side Corner Post just above the light With the Channel holes on top cut the Channel length as required 2 Min and w...

Page 14: ...sure proper wiring to match the UP DOWN Decal 250876 Switch Boot Seal 226889 Switch 250916 01 Switch Harness Assembly 051076 105 Harness Looking at Switch from the Platform the Wht Wire must be on the...

Page 15: ...nt Fuse Kit P N 264422 200AMP Replacement Fuse Kit P N 264687 Short End to Vehicle Battery Cable Assembly Extension Cable Assembly Long End to Motor Solenoid Do not attach cable to battery until liftg...

Page 16: ...ngs CA 90670 800 227 4116 FAX 888 771 7713 PAGE 16 WIRE CONNECTIONS GRAVITY DOWN POWER TO WHT BLK UP DOWN 1234567890123 1234567890123 1234567890123 1234567890123 1234567890123 1234567890123 TOGGLE SWI...

Page 17: ...S ASY 250876 SWITCH BOOT SEAL 252527 01 HARNESS 030029 SCREWS RED BLK GRN WHT LOOKING AT SWITCH FROM THE PLATFORM THE RED WIRE MUST BE ON THE LEFT OR DOOR SIDE 224845 03 JUMPER CORNER POST 251868 CHAN...

Page 18: ...nt Fuse Kit P N 264422 200AMP Replacement Fuse Kit P N 264687 Short End to Vehicle Battery Cable Assembly Extension Cable Assembly Long End to Motor Solenoid Do not attach cable to battery until liftg...

Page 19: ...6 FAX 888 771 7713 PAGE 19 WIRE CONNECTIONS POWER DOWN TOGGLE SWITCH TO BATTERY Black Ground Wire Red Green White POWER TO WHT RED WHT BLK UP DOWN 12345678901234567 12345678901234567 12345678901234567...

Page 20: ...253352 Flow Control Valve 3 8 NPT 224370 14 Hose Plastic 1 4 x 25 Lg 202386 Fitting 1 4 x 1 4 To Upper Tee To Lower Tee 226948 24 Hose Asy H P 3 8 x 29 Lg 040395 Elbow 3 8 NPT x 8 JIC 224370 12 Hose...

Page 21: ...01 Hose Asy H P 3 8 x 27 Lg 260144 Connector JIC 8 x 3 8 NPT 253715 01 Hose Asy H P 3 8 x 27 Lg 227001 01 Pipe Thd d 22 Lg 227001 03 Pipe Thd d 42 Lg 227003 Tee 3 8 F 228151 Swivel 3 8 Str 224370 12...

Page 22: ...PT 050207 Elbow Swivel 260490 Needle Valve 3 8 NPT 227382 Adaptor 1 4 NPT x 3 8 NPT 226948 24 Hose Asy H P 3 8 x 29 Lg 227004 Elbow 3 8 NPT M F 030283 Nipple 3 8 NPT x 1 1 2 LG To Upper Tee To Lower T...

Page 23: ...E 23 HYD HOSE ROUTING POWER DOWN 253715 02 Hose Asy H P 3 8 x 31 Lg 253715 01 Hose Asy H P 3 8 x 27 Lg 260144 Connector JIC 8 x 3 8 NPT 226948 24 Hose Asy H P 3 8 x 29 Lg 227001 09 Pipe Thd d 23 3 4 L...

Page 24: ...o not use the Lift until these problems have been corrected Do not overload the Lift The load limit is based on evenly distrib uted cargo over the entire Platform surface If you are using a pallet jac...

Page 25: ...an emer gency repair Heat Shrink tubing is provided and must be installed at each end fitting CRIMPING For Trucks route the cable along the chassis frame flange Use caution when routing through or aro...

Page 26: ...m vertical 2 Position the Opener on top of the Mainframe Weldment and slide the Opener to where it butts up against the folded Platform Tack weld into position FLIPOVER PLATFORM PLATFORM OPENER MAINFR...

Page 27: ...Openers as shown 2 Store the Platform in the folded position Position the Saddle Weldments so that the Platform touches nothing but the Plastic Pads on the inner surface of the saddle weldment NOTE O...

Page 28: ...PAGE 28 SUGGESTED REAR LIGHT INSTALLATION NOTE All lighting fixtures must be installed in accordance with all applicable state and federal laws Platform Opener Rear Lights NOTE Light and Fixtures must...

Page 29: ...Platform Remove the Floorjack chain C clamp and Hoist Raise and Lower the Platform several times to assure proper alignment of the Unit If alignment is correct complete the welding of the Mounting Pl...

Page 30: ...e Extension Plate or vehicle bed There should be no sag in the Platform as pictured below YES NO No Sag Sag Weld Shims to here Lower the Platform to the ground so that the Shackles and Platform tip re...

Page 31: ...in to the inside wall of the Extension Plate Tube leaving only enough slack to enable the Hook to be removed and reattached ADD SHIM PLATE 264731 4 7 16 PLATFORM ADJUSTMENT If Platform tip does not to...

Page 32: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 PAGE 32 80 3 80 4 ACCESSORIES SECTION...

Page 33: ...oles in the Angle are facing toward the rear of the vehicle Weld the Dock Bumper Support Angles to the bottom of the Dock Bumper Angles and the Mainframe Assembly 1 2 Grind off sharp corners Typ Dock...

Page 34: ...X 888 771 7713 PAGE 34 BUMPER INSTALLATION OPTIONAL 1 2 3 4 5 ITEM QTY PART NUMBER DESCRIPTION 1 4 030083 BOLT 1 2 20 x 2 GR8 ZINC 2 4 030323 NUT 1 2 20 ZINC 3 4 030566 WASHER FLAT 1 2 ZINC 4 4 030567...

Page 35: ...from battery post and between batteries and lift gate solenoid See Fig 1 2 TRAILER MOUNT Install Circuit Breaker no more than 24 from battery post and between batteries and lift gate solenoid See Fig...

Page 36: ...mpressed air or shop towel Apply the Liquid Sealant Compound PLS 2 to the external threads of the Male Connector Assemble the fitting and torque it to the prescribed value Check for leakage If leakage...

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