11921 Slauson Avenue.
Santa Fe Springs, CA. 90670
(800) 227-4116
MAINTENANCE
MANUAL
C MAXON Lift Corp. 2000
80-3 LM
M-97-28
REV. C
MAR. 2000
LIFT CORP.
11921 Slauson Ave.
Santa Fe Springs, CA. 90670
CUSTOMER SERVICE:
TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116
FAX: (888) 771-7713
WARRANTY POLICY & PROCEDURE
NOTE: Check with Customer Service for updated versions
of Manuals on an annual basis.
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. 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.
All warranty repairs must be performed by an authorized MAXON warranty station. For major
repairs, MAXON Customer Service must be notified and an “Authorization Number” obtained. Major
repairs would generally be considered repairs made to the structural assembly of the liftgate and/or
repairs not outlined in the MAXON Liftgate Warranty 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.M.A. (Returned Merchandise Authorization) number must be obtained from
MAXON Customer Service prior to the return of any defective part. Defective Parts must be returned
within 60 days of the claim date for consideration to:
MAXON Lift Corp.
16205 Distribution Way, Cerritos, CA 90703
Attn: RMA#__
MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle
rental, service calls, oil, batteries, defects due to misuse or abuse, or loss of income due to downtime.
Fabrication of 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.
PURCHASE PART W ARRANTY
Term of Warranty: 1 Year from Date of Purchase
Type of Warranty: Part Replacement
MAXON will guarantee all returned genuine replacement parts upon receipt and inspection of
parts and invoice.
Table of Contents
INTRODUCTION ........................................................................................................PAGE 4
WARNING .................................................................................................................. PAGE 5
PERIODIC MAINTENANCE CHECKLIST..................................................................PAGE 6
DECALS, 80 SERIES.................................................................................................PAGE 7
HYD. HOSE ROUTING, GRAVITY DOWN ................................................................PAGE 8
253171 PUMP, GRAVITY DOWN ............................................................................PAGE 10
CONTROL SWITCH GRAVITY DOWN ...................................................................PAGE 12
FUSED POWER CABLE .......................................................................................... PAGE 13
WIRE CONNECTIONS GRAVITY DOWN ...............................................................PAGE 14
HYD. HOSE ROUTING, POWER DOWN ................................................................ PAGE 15
CONTROL SWITCH, POWER DOWN .................................................................... PAGE 17
FUSED POWER CABLE .......................................................................................... PAGE 18
WIRE CONNECTIONS, POWER DOWN ................................................................PAGE 19
253170 PUMP, POWER DOWN ..............................................................................PAGE 20
80-3LM ASSEMBLY .................................................................................................PAGE 22
PUMP PRESSURE ADJUST SETTING ...................................................................PAGE 24
TROUBLESHOOTING.............................................PAGE 25
PLATFORM WILL NOT RAISE ................................................................................PAGE 26
PLATFORM RAISES BUT LEAKS DOWN ..............................................................PAGE 27
PLATFORM RAISES PARTIALLY AND STOPS ......................................................PAGE 28
LIFTGATE WILL NOT LIFT RATED CAPACITY ......................................................PAGE 29
PLATFORM RAISES SLOWLY ................................................................................PAGE 30
PUMP WILL NOT OPERATE ...................................................................................PAGE 31
PLATFORM LOWERS TOO FAST OR TOO SLOW ................................................PAGE 32
PLATFORM WILL NOT LOWER..............................................................................PAGE 33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 4
INTRODUCTION
This publication contains the information required to maintain the 80-3LM. If
there is any doubt regarding the suitability of these lifts being maintained on
it’s intended vehicle, or any portion of these instructions that you do not un-
derstand, 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 Engineering Depart-
ment before being undertaken.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 5
1. Read the Maintenance Manual and understand it thoroughly before any maintenance of
this unit is done.
2. Read the YELLOW urgent warning decal on the side of the vehicle close to the unit before
operating.
3. If decals are dirty, clean them. If decals are defaced or missing, replace them. Free replace-
ments are available from the manufacturer. See information at the end of the Warnings
4. Be aware that the safety and location of other people or objects should be considered
before operation of this unit. Stand to one side of platform while operating this unit.
5. Do not stand under, or have any foreign object under the Platform when lowering. Be sure
that the lowering of the Platform and/or Flipover will miss your feet!
6. Keep fingers, hands, arms, legs, and feet clear of moving parts when operating this unit.
7. If during your maintenance procedure, it becomes necessary to ride the platform, keep your
feet and any foreign objects clear of the rear edge of the platform. Otherwise your feet or
the foreign objects could become trapped between the edge of the platform and the vehicle
bed.
8. Inspect all Roll Pins monthly, to insure that they are not broken. Replace if broken.
9. Inspect all hydraulic hoses and fittings annually. Check for cracks and deterioration, and
replace if necessary.
10. Disconnect battery when replacing parts or servicing.
11. Do not allow children to ride, play with, or operate this unit.
12. In the event of an emergency while operating the unit, release the toggle switch and the unit
will stop immediately.
13. A properly installed Lift should operate smoothly and the only noise during the operation of
this unit should be from the Pump Unit during the raising of the Platform. Any scraping,
grating or audible indications of rough operation will need investigating. The cause will need
resolving before any further deterioration of performance occurs.
14. Use only Maxon Authorized Parts for replacement. Replacement parts should be ordered
from:
MAXON LIFT CORP. Parts Department
11921 Slauson Ave., Santa Fe Springs, Ca. 90670
Phone: (800) 227-4116
WARNING
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 6
* COLD WEATHER OPERATION
OIL SPECIFICATIONS:
Grade ISO-(32)
Gravity, API - 29.5 Degrees
Pour Point, F- (-54 Degrees)
VISCOSITY:
@ 40 Degrees C - 31.2 cSt
@100 Degrees C - 6.2 cSt
VISCOSITY INDEX - 154 VI
Flash Point, F - 325 Degrees
Visually check the complete unit for excessive wear, worn parts or broken welds.
Check all Hinge Pins for excessive wear or broken welds. For parts replacement,
see the Assembly Breakdown Drawings.
PERIODIC MAINTENANCE CHECKLIST
Check the oil in the Pump Reservoir. The oil should be Grade ISO-(32) Hydraulic
Fluid. *See below for Cold Weather operation.
Check Hoses and Fittings for scuffing and leaks. Replace if necessary.
Check the electrical wiring for worn insulation, and the terminals for corrosion and
secure fit.
Check all bolts for tightness.
Check that all Warning Decals are in place and readable.
Check that all roll pins are properly installed. Replace if necessary.
Inspect the Hook & Chain Assembly for proper operation.
Annually
Quarterly
Six Months
Visually check the Platform Hinge Pins for excessive wear or broken welds. For
parts replacement, see the Assembly Breakdown Drawings.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 7
DECALS, 80 SERIES
These Decals are located
on the rear corner post of the
vehicle, at the control position.
They should be read completely
and understood before operating
the Lift Gate. They should also be
kept clean and readable at all
times. If any decal should become
detatched from the vehicle, or
defaced, it must be replaced. Free
replacements are available from:
MAXON Lift Corp., Parts Dept.
Operating Decal
P/N 262433
Capacity
Decal
Warning Decal
P/N 260008
P/N 251838
To Tuck Unit Away after Use,
Reverse Steps 1 thru 4
Activate Toggle
Switch to Raise or
Lower Platform
Open Flipover
Open Platform
Activate Toggle
Switch to Lower
Stowed Lift Gate
This point must
touch the ground
OPERATING INSTRUCTIONS
GPT & 80-3/4 Units
Unhook Safety
Chain First.
1
2
3
4
5
6
Safety Hook Decal
P/N 263988
(Placed on both sides of
Extension Plate)
Unhook Safety Chain
Before Lowering Liftgate
P/N 263998
THE MAXIMUM CAPA CITY
OF THIS LIFT IS
WHEN THE LOAD IS
CENTERED ON THE LOAD
CARRYING PLATFORM
3000 LBS.
P/N 220388
WARNING
READ CAREFULLY
• Improper operation of this Lift can result in serious personal injury.
Do not operate unless you have been properly instructed and have
read, and are familiar with the operating instructions. If you do not
have a copy of the instructions, please obtain them from your
employer, distributor, or lessor, before you attempt to operate Lift.
• Be certain that the vehicle is properly and securely braked before
using the Lift.
• Always inspect this Lift for maintenance or damage before using it. If
there are signs of improper maintenance, damage to vital parts, or
slippery Platform surface, do 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
jack, be sure it can be maneuvered safely. Do not operate a forklift on
the Platform or travel with the platform in an open position at any time.
• Load should be placed in a stable position close to the edge of the
Platform nearest the truck. The heaviest portion of the load should
never be placed beyond the center of the Platform away from the
truck.
• Never allow yourself, a helper, or bystander to stand in a position
where a falling load could land on either of you. Also do not allow any
part of yours or your helper’s body to be placed under, within, or
around any portion of the moving liftgate, or it’s mechanisms, or in a
position that would trap them between the platform and the ground or
truck when the liftgate is operated.
• If a helper is riding the Platform with you, make sure you are both
doing so safely and that you are not in danger of coming in contact
with any moving or potentially moving obstacles. USE GOOD
COMMON SENSE. If load appears to be unsafe, do not lift or lower it.
MAXON LIFT CORP. PART NO. 264081
!
!
P/N 250993
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 8
HYD. HOSE ROUTING, GRAVITY DOWN
054036 Elbow,
Swivel
202406 Elbow, 1/4”
&
800183 Bushing, 3/8” x 1/4”
801292 Nipple
Close, 3/8 NPT
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#8JIC
224370-12
Hose Plastic
1/4”x 55”Lg.
253715-01 Hose Asy.
H.P. 3/8”x 27” Lg.
261897 3” x 10” Cylinder, 80-3
253342-01
Pump Asy. G.D.
262437
Cyl. Hose Clamp
202406 Elbow, 1/4”
&
800183 Bushing,
3/8”x 1/4”
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 9
HYD. HOSE ROUTING, GRAVITY DOWN
253715-01 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 Hose
Plastic 1/4”x 55”Lg.
224370-13 Hose
Plastic 1/4”x 75”Lg.
202376
Brass Tee, 1/4”F
224370-14 Hose,
Plastic, 1/4”x 25” Lg.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 10
253171 PUMP, GRAVITY DOWN
METIMETI
METI
METIMETI.YTQ.YTQ
.YTQ
.YTQ.YTQREBMUNTRAPREBMUNTRAP
REBMUNTRAP
REBMUNTRAPREBMUNTRAPNOITPIRCSEDNOITPIRCSED
NOITPIRCSED
NOITPIRCSEDNOITPIRCSED
11
1
1111
1
11390052390052
390052
390052390052CDSTLOV21YTUDYVAEH,ROTOMCDSTLOV21YTUDYVAEH,ROTOM
CDSTLOV21YTUDYVAEH,ROTOM
CDSTLOV21YTUDYVAEH,ROTOMCDSTLOV21YTUDYVAEH,ROTOM
22
2
2211
1
11353352353352
353352
353352353352YAW-2DIONELOS,EVLAVYAW-2DIONELOS,EVLAV
YAW-2DIONELOS,EVLAV
YAW-2DIONELOS,EVLAVYAW-2DIONELOS,EVLAV
a2*a2*
a2*
a2*a2*11
1
11495622495622
495622
495622495622EVLAVYAW-2,TIKGNIR-OEVLAVYAW-2,TIKGNIR-O
EVLAVYAW-2,TIKGNIR-O
EVLAVYAW-2,TIKGNIR-OEVLAVYAW-2,TIKGNIR-O
33
3
3311
1
11002922002922
002922
002922002922GNILPUOCGNILPUOC
GNILPUOC
GNILPUOCGNILPUOC
44
4
4411
1
11588152588152
588152
588152588152TIKEVLAVKCEHCTIKEVLAVKCEHC
TIKEVLAVKCEHC
TIKEVLAVKCEHCTIKEVLAVKCEHC
a4a4
a4
a4a411
1
11752062752062
752062
752062752062LLABLEETSLLABLEETS
LLABLEETS
LLABLEETSLLABLEETS
b4b4
b4
b4b411
1
11452062452062
452062
452062452062GNIRPSGNIRPS
GNIRPS
GNIRPSGNIRPS
c4c4
c4
c4c411
1
11852062852062
852062
852062852062GULPGULP
GULP
GULPGULP
d4d4
d4
d4d411
1
11552062552062
552062
552062552062RENIATERRENIATER
RENIATER
RENIATERRENIATER
e4e4
e4
e4e411
1
11652062652062
652062
652062652062WERCSPACDAEHTEKCOSWERCSPACDAEHTEKCOS
WERCSPACDAEHTEKCOS
WERCSPACDAEHTEKCOSWERCSPACDAEHTEKCOS
55
5
5511
1
11922062922062
922062
922062922062TIKEVLAVFEILERTIKEVLAVFEILER
TIKEVLAVFEILER
TIKEVLAVFEILERTIKEVLAVFEILER
a5a5
a5
a5a511
1
11132062132062
132062
132062132062GNIRPSGNIRPS
GNIRPS
GNIRPSGNIRPS
b5b5
b5
b5b511
1
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532062
532062532062GNIR-OGNIR-O
GNIR-O
GNIR-OGNIR-O
c5c5
c5
c5c511
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11432062432062
432062
432062432062PACEVLAVPACEVLAV
PACEVLAV
PACEVLAVPACEVLAV
d5d5
d5
d5d511
1
11232062232062
232062
232062232062WERCSGNITSUJDAWERCSGNITSUJDA
WERCSGNITSUJDA
WERCSGNITSUJDAWERCSGNITSUJDA
e5e5
e5
e5e511
1
11332062332062
332062
332062332062EDIUGGNIRPSEDIUGGNIRPS
EDIUGGNIRPS
EDIUGGNIRPSEDIUGGNIRPS
f5f5
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f5f511
1
11032062032062
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032062032062LLABLEETSLLABLEETS
LLABLEETS
LLABLEETSLLABLEETS
66
6
6611
1
11748062748062
748062
748062748062PACREHTAERB/RELLIFPACREHTAERB/RELLIF
PACREHTAERB/RELLIF
PACREHTAERB/RELLIFPACREHTAERB/RELLIF
77
7
7711
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11288152288152
288152
288152288152.TQ3,RIOVRESER.TQ3,RIOVRESER
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88
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99
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9911
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0101
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488152
488152488152GNIR-0GNIR-0
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11
111111
1
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252062
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"5YLBMESSAETALPEVIRD
"5YLBMESSAETALPEVIRD"5YLBMESSAETALPEVIRD
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072062072062HCTIWSDIONELOSHCTIWSDIONELOS
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 11
253171 PUMP, GRAVITY DOWN
4e
4d
4c
4b
4a
4
5a
5b
5c
5d
5f
5e
5
3
2
1
6
7,15
8
9
10
11
12
13
14
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 12
CONTROL SWITCH GRAVITY DOWN
Assemble Switch in Mount Bracket as shown. When mounting the
bracket to the Channel, note the location of the Wht. & Blk. wires to ensure
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 left or “Door” side.
Wht.
Grn.
Blk. ( Key Side
of Switch)
Battery Cable
Grn.
Wht.
Corner Post
251028
Channel
250993
Decal
Corner
Post
Extension Plate
Pump Unit Motor Solenoid
051076-105
Harness to Pump Unit
250993
030029
Screws
251711
Guard
1
2
3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 13
FUSED POWER CABLE
Battery Cable Assembly (32’ Std.)
(Includes Replacement 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 liftgate is
completely installed.
WARNING
STIKELBACYRETTABELBAILIAVALANOITIDDASTIKELBACYRETTABELBAILIAVALANOITIDDA
STIKELBACYRETTABELBAILIAVALANOITIDDA
STIKELBACYRETTABELBAILIAVALANOITIDDASTIKELBACYRETTABELBAILIAVALANOITIDDA
TRAPTRAP
TRAP
TRAPTRAP
REBMUN
YLBMESSAELBAC'04YLBMESSAELBAC'04
YLBMESSAELBAC'04
YLBMESSAELBAC'04YLBMESSAELBAC'04848462848462
848462
848462848462
YLBMESSAELBACNOISNETXE'01YLBMESSAELBACNOISNETXE'01
YLBMESSAELBACNOISNETXE'01
YLBMESSAELBACNOISNETXE'01YLBMESSAELBACNOISNETXE'01948462948462
948462
948462948462
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 14
WIRE CONNECTIONS GRAVITY DOWN
Toggle Switch
White
Black
Green
To Battery
(+)
Ground
Wire
POWER TO
WHT.
BLK.
UP
DOWN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 15
HYD. HOSE ROUTING, POWER DOWN
253755 Adaptor,
SAE #8 x 3/8 NPT
228151 Swivel,
3/8 NPT (M-F)
260490 Needle
Valve, 3/8 NPT
253755 Adaptor,
SAE #8 x 3/8 NPT
227003 Tee,
3/8 NPT
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 Tee
226948-09 Hose Asy.
H.P. 1/4”x 18-1/2” Lg.
040395 Elbow,
3/8 NPT x #8 JIC
253715-02 Hose Asy.
H.P. 3/8” x 31” Lg.
253715-01 Hose Asy.
H.P. 3/8”x 27” Lg.
261897 3” x 10” Cylinder, 80-3
260184
Pump Asy. P.D.
262437
Cyl. Hose Clamp
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 16
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” Lg.
227001-10 Pipe,
Thd’d. 20-3/4” Lg.
227001-03 Pipe,
Thd’d. 42” Lg.
227003 Tee, 3/8”F
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 17
CONTROL SWITCH, POWER DOWN
224849
SWITCH
252561
SWITCH &
HARNESS 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
CHANNEL
CORNER POST
EXTENSION PLATE
HARNESS TO
PUMP UNIT
250993
250993
DECAL
PUMP UNIT MOTOR
SOLENOID
BATTERY
CABLE
GRN WIRE
WHT WIRE
1
4
5
2
6
3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 18
FUSED POWER CABLE
Battery Cable Assembly (32’ Std.)
(Includes Replacement 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 liftgate is
completely installed.
WARNING
STIKELBACYRETTABELBAILIAVALANOITIDDASTIKELBACYRETTABELBAILIAVALANOITIDDA
STIKELBACYRETTABELBAILIAVALANOITIDDA
STIKELBACYRETTABELBAILIAVALANOITIDDASTIKELBACYRETTABELBAILIAVALANOITIDDA
TRAPTRAP
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REBMUN
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 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
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PAGE 20
253170 PUMP, POWER DOWN
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22
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2211
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44
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55
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5511
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88
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