Maxon 72-150 Installation Manual Download Page 1

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M-12-04

REV. F

SEPTEMBER 2015

TE-20 & 72-150

INSTALLATION MANUAL

2015 MAXON LIFT CORP.

To find

maintenance & parts

information for your

TE-20 & 72-150 Liftgate

go to

www.maxonlift.com

. Click the

PRODUCTS,

TUK-A-WAY and TE-20

72-150

buttons. Open the

Maintenance Manual

in the

PRODUCT DOCU-

MENTATION

window.

Summary of Contents for 72-150

Page 1: ...ATION MANUAL 2015 MAXON LIFT CORP To find maintenance parts information for your TE 20 72 150 Liftgate go to www maxonlift com Click the PRODUCTS TUK A WAY and TE 20 or 72 150 buttons Open the Mainten...

Page 2: ...0 POWER DOWN 96 WIDE GALVANIZED FINISH 11 VEHICLE REQUIREMENTS 12 PLATFORM WITH RAMP FLIPOVER 14 STEP 1 INSTALL EXTENSION PLATES 16 WELD PAINTED EXTENSION PLATE TO VEHICLE 17 BOLT GALVANIZED EXTENSION...

Page 3: ...P 14 ADJUST SAFETY HOOK IF REQUIRED 58 STEP 15 WELD ON LOCK BRACKET IF EQUIPPED 59 STEP 16 VEHICLE TAILLIGHT POSITIONING IF REQUIRED 60 ATTACH DECALS 61 TOUCHUP PAINTED OR GALVANIZED FINISH 63 HYDRAUL...

Page 4: ...M 12 04 REVISION F PAGE DESCRIPTION OF CHANGE COVER Updated REV and date of release 6 Added note to installers to ensure that trucks and trailers are equipped with grab handles if needed 44 Removed AM...

Page 5: ...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 Never perform unauthorized modi...

Page 6: ...ntact with battery acid may injure unprotected eyes and skin Do not allow untrained persons to operate the Liftgate Be careful working by an automotive type battery Make sure the work area is well ven...

Page 7: ...part box and each kit box with packing list closed in each box If parts and components are missing or incorrect call Maxon Customer Service Call 800 227 4116 or Send e mail to customersupport maxonli...

Page 8: ...64 TIE PLASTIC 12 14 LG 9 3 214663 CLAMP 8 RUBBER LOOM 10 1 215345 SPRING EXTENSION 2 1 2 LG 11 2 251333 SHIM 1 8 X 2 X 2 LG 12 1 264422 CABLE ASSY 175 AMPS 38 LG 13 1 269641 01 KIT MANUAL DECAL 72 15...

Page 9: ...6 3 214663 CLAMP 8 RUBBER LOOM 7 2 251333 SHIM 1 8 X 2 X 2 LG 8 1 264422 CABLE ASSY 175 AMPS 38 LG 9 1 269641 01 KIT MANUAL DECAL 72 150 269641 02 KIT MANUAL DECAL TE 20 9A 1 M 12 04 MANUAL INSTALLAT...

Page 10: ...E PLASTIC 12 14 LG 9 3 214663 CLAMP 8 RUBBER LOOM 10 1 215345 SPRING EXTENSION 2 1 2 LG 11 2 251333 SHIM 1 8 X 2 X 2 LG 12 1 264422 CABLE ASSY 175 AMPS 38 LG 13 1 269641 01 KIT MANUAL DECAL 72 150 13A...

Page 11: ...BBER LOOM 7 2 251333 SHIM 1 8 X 2 X 2 LG 8 1 264422 CABLE ASSY 175 AMPS 38 LG 9 1 269641 01 KIT MANUAL DECAL 72 150 269641 02 KIT MANUAL DECAL TE 20 9A 1 M 12 04 MANUAL INSTALLATION 72 150 TE 20 9B 1...

Page 12: ...Do not install this Liftgate on vehicle bodies equipped with swing open doors NOTE Measure the width of the Liftgate and the width of the vehicle body before you start doing this procedure Ensure the...

Page 13: ...gs CA 90670 800 227 4116 FAX 888 771 7713 13 PLATFORM WITH WEDGE FLIPOVER VEHICLE REQUIREMENTS Continued CLEARANCES FOR TE 20 72 150 HIGH BED HEIGHT ONLY FIG 13 1 54 MAX UNLOADED 44 MIN LOADED 24 1 2...

Page 14: ...RAMP FLIPOVER VEHICLE REQUIREMENTS Continued 54 MAX UNLOADED 42 MIN LOADED 24 1 8 MAX 12 1 8 MIN 22 1 2 29 11 44 MAX UNLOADED 38 MIN LOADED 16 1 2 MAX 10 1 2 MIN 24 1 4 32 9 1 2 CLEARANCES FOR TE 20...

Page 15: ...150 44 TO 54 BED HEIGHTS FIG 15 1 6 17 10 BODY CROSS MEMBERS SPACER PLATFORM CLEARANCE CUTOUT AREA WITHIN DASHED LINES BODY FRAME REAR SILL TRUCK FRAME BODY FLOOR VEHICLE FRAME CUT FOR TE 20 72 150 3...

Page 16: ...with parts bags must be used The galvanized extension plate FIG 16 2 has bolt holes so it can be bolted to vehicle body GRADE 8 bolts are required MAXON recommends getting the optional extension plat...

Page 17: ...SHOWN 1 GAP 1 GAP CAUTION To protect the original paint system a 3 wide area of paint must be removed from all sides of the weld area before welding STEP 1 INSTALL EXTENSION PLATES Continued EXTENSIO...

Page 18: ...STALL EXTENSION PLATES Continued EXTENSION SPRING PLACEMENT FIG 18 1 HOOKING EXTENSION SPRING RH SIDE VIEW FIG 18 1A EYE LOOP EXTENSION PLATE 2 Get extension spring FIG 18 1A from parts box Hook one e...

Page 19: ...FIG 19 3B FIG 19 3A 3 Make 2 support straps FIG 19 1 and 2 spacers FIG 19 2 to keep Liftgate in proper position While welding Liftgate to vehicle support straps keep platform level with extension pla...

Page 20: ...UIRED WHEN BOLTING THROUGH CORNER POST BOLT GALVANIZED EXTENSION PLATE TO VEHICLE CAUTION To preserve the corrosion resistance properties of the galvanized finish MAXON recommends bolting the galvaniz...

Page 21: ...d lock nuts until All the bolts and lock nuts are in place Top of extension plate is flush with top of rear sill STEP 1 INSTALL EXTENSION PLATES Continued EXTENSION PLATE frame bolt hex 1 2 13 x 1 3 4...

Page 22: ...le body make sure top surface of extension plate is flush with floor of vehicle body Weld the extension plate to vehicle body sill as shown in FIGS 22 1 and 22 2 WELD LENGTH SPACE 2 11 3 4 3 16 3 16 E...

Page 23: ...rs FIG 23 2 to keep Liftgate in proper position While welding Liftgate to vehicle support straps keep platform level with extension plate and spacers keep 1 4 between platform and extension plate SPAC...

Page 24: ...IPOVER LOW BED 38 46 HEIGHT FIG 24 1 WARNING Do not remove lock angle until instructed to do so in this manual NOTE Liftgates are shipped with the locking angle set up for low bed Check your lock ing...

Page 25: ...OR HORIZONTAL Floor Jack main frame PINS 2 Tack weld platform stops to shackles on LH and RH side of platform as shown in FIGS 25 1A and 25 1B NOTE To prevent misalignment when hoisting Liftgate by th...

Page 26: ...ain frame Mounting Plate WELD TO VEHICLE FRAME AND MAIN FRAME RH SIDE SHOWN FIG 26 2 2 Lg 4 PLACES Typical rh lh MOUNTING Plates 5 Clamp both mounting plates to vehicle frame Weld the mounting plates...

Page 27: ...RECOMMENDED LIFTGATE OPTIONAL BATTERY BOX INSTALLATION ON TRAILER FIG 27 1 CIRCUIT BREAKER 175 AMP FUSED CABLE TRACTOR BATTERIES TYPICAL LOCATION LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE BATT...

Page 28: ...FRAME BATTERY BOX FRAME MOUNTING BRACKETS MOUNTING BRACKETS BOLTING BRACKETS 8 PLACES FIG 28 1C FLUSH BRACKETS FOR TRAILERS 8 PLACES FIG 28 1B FLUSH BRACKETS FOR TRUCKS 8 PLACES FIG 28 2 ALIGNING BATT...

Page 29: ...olt mounting brackets to cross mem bers as shown in FIGS 29 2A and 29 2B Torque bolts and lock nuts to 85 128 lb ft NOTE If welding mounting brackets to cross members skip instruction 3 MARK AND DRILL...

Page 30: ...nded practices for welding on steel parts are contained in the cur rent AWS American Welding Society D1 1 Structural Welding Code Steel Damage to Liftgate and or vehicle and personal injury can result...

Page 31: ...ve terminal NOTE To connect charge lines refer to instructions provided with each charge line kit NOTE MAXON recommends using dielectric grease on all electrical connections Remove all rings watches a...

Page 32: ...TO VEHICLE IF EQUIPPED Continued FUSED CABLE SEE NOTE BATTERY CABLE TO COMMON GROUND FUSED CABLE TO PUMP BOX 42 LG BATTERY BOX KIT ITEM 150 AMP CIRCUIT BREAKER CABLE 12 LG CABLE 10 LG GROUND CABLE TO...

Page 33: ...VEHICLE IF EQUIPPED Continued Explosive hydrogen gas from charging batteries can accumulate in battery box if not vented from the box To prevent hydrogen gas from accumulating ensure the 3 ventilation...

Page 34: ...RAP LOCK NUT 1 4 20 2 PLACES HEX NUT 1 2 20 4 PLACES LOCK WASHER 9 16 4 PLACES FLAT WASHER 9 16 4 PLACES J BOLT ANCHOR PART OF BATTERY PLATE FLAT WASHER 1 4 4 PLACES PAN HEAD SCREW 1 4 20 X 1 LG 2 PLA...

Page 35: ...GATE RECOMMENDED LIFTGATE OPTIONAL BATTERY BOX INSTALLATION ON TRAILER FIG 35 1 175 AMP FUSED CABLE TRACTOR BATTERIES TYPICAL LOCATION LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE BATTERY BOX INS...

Page 36: ...ABLE END TERMINAL LUG TO VEHICLE BATTERY VEHICLE FRAME TRUCK FRAME SHOWN 18 24 SPACING CHARGE LINE TO PUMP BOX FRONT OF VEHICLE REAR OF VEHICLE CABLE CLIPS Never route an energized wire Make sure the...

Page 37: ...00 227 4116 FAX 888 771 7713 37 STEP 5 CONNECT POWER CABLE 1 Unbolt the pump cover as shown in FIG 37 1 UNBOLTING PUMP COVER FIG 37 1 PUMP COVER CAP SCREWS 5 PLACES FLAT WASHERS 5 PLACES POWER UNIT RE...

Page 38: ...BARE WIRE END HEAT SHRINK TUBING P N 253316 04 TYPICAL FUSED POWER CABLE WITH TERMINAL LUG INSTALLED FIG 38 2 3 Remove hex nut and lock washer from battery terminal post on the motor solenoid Connect...

Page 39: ...drill a 11 32 0 343 hole in vehicle frame for bolting the ground cable terminal lug FIG 39 2 NOTE MAXON recommends using dielectric grease on all electrical connections NOTE To ensure power unit is c...

Page 40: ...CONTROL SWITCH FIG 40 1A HOLE DRILLING TEMPLATE FIG 40 1B VEHICLE BODY VERTICAL POST CURB SIDE 18 1 3 4 7 8 2 Cut tie strap on coiled wiring harness FIG 40 2 Pull the wiring har ness through grommet o...

Page 41: ...ring harness as shown in FIG 41 2 Push extended wiring back into the hole in the verti cal post until control switch touches the post Attach control switch to vertical post with 2 self tapping screws...

Page 42: ...ith painted extension plate get the control handle grip FIG 42 1 from parts box Install the handle grip on control handle as shown in FIG 42 1 EXTENSION PLATE REF CONTROL HANDLE INSTALLING CONTROL HAN...

Page 43: ...cap drain plug and hydrau lic lines clean up contaminants that can get in the openings Also protect the openings from accidental contamination FILLER CAP RESERVOIR PUMP RESERVOIR GRAVITY DOWN POWER UN...

Page 44: ...MBER CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 V32 EXXON UNIVIS N 32 MOBIL DTE 13M DTE 24 HYDRAULIC OIL 13 ISO 15 OR MIL H 5606 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER CHEVRON FLUID A...

Page 45: ...VE BATTERY CABLE RECONNECTED BATTERY CABLES FIG 45 3 POSITIVE BATTERY TERMINAL POSITIVE BATTERY CABLE NUT NUT 2 Remove nut from positive battery terminal FIG 45 2 3 Connect fused positive cable to pos...

Page 46: ...linder pins Remove the locking angle FIG 46 1 NOTE To operate Liftgate locking angle must be removed from hydraulic cylinder REMOVING LOCKING ANGLE FIG 46 1 PLATFORM UNFOLDED LOCKING ANGLE COTTER PIN...

Page 47: ...nterference between liftgate and vehicle as platform is lowered If the platform lowers with a jerking motion bleed air from the hydraulic system by doing the following Push the control switch to the D...

Page 48: ...10 REMOVE LOCKING ANGLE AND CHECK FOR INTERFERENCE Continued LOWERING PLATFORM FIG 48 1 5 Lower platform to the ground FIG 48 1 REMOVING FLATS SPACERS PAINTED EXTENSION PLATE ONLY FIG 48 2 6 Remove t...

Page 49: ...ainst the edge of extension plate FIG 49 2 NOTE Correct any fit and interference problems before continuing with installation PLATFORM EXTENSION PLATE WITH EDGES BUTTED TOGETHER FIG 49 2 STEP 10 REMOV...

Page 50: ...ight is 1 8 maximum as shown STEP 10 REMOVE LOCKING BRACKETS CHECK FOR INTERFERENCE Continued SURFACES FLUSH EXTENSION PLATE PLATFORM DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM EXTENSION PLATE RH VIEW F...

Page 51: ...IG 51 2 STEP 11 BOLT PLATFORM OPENER TO LIFTGATE 1 Make sure platform is at ground level OPENER POSITION FOR HIGH BED HEIGHT FIG 51 1 L TABLE 51 1 44 54 BED HEIGHT PLATFORM OPENER MAIN FRAME MAIN FRAM...

Page 52: ...2 LG MAIN FRAME If there is any interference with the platform while stowing Liftgate check for damage on bottom of platform flipover and the hinge in between A damaged platform or flipover may result...

Page 53: ...ustments may be necessary To adjust opener measure vehicle bed height FIGS 53 1 and 53 2 Then move the opener as required to the matching bed height position for your Liftgate Refer to FIG 53 1 TABLE...

Page 54: ...ver As the platform first touches the ground shackles and tip of flipover must touch the ground at the same time FIG 54 1 If the shackles and the tip of flipover touch the ground at the same time rais...

Page 55: ...RM SHACKLE REF CENTERED WELDING SHIMS RH SHACKLE SHOWN FIG 55 2 SHIM 1 16 1 8 3 16 or 1 4 MADE FROM STEEL FLAT FIG 55 1 2 1 4 1 1 2 STEP 12 PLATFORM ADJUSTMENT IF REQUIRED Continued 3 Make shims as ne...

Page 56: ...d from the platform stops FIG 56 2 6 Raise the platform then lower it to the ground As the platform first touches the ground the tip of flipover and shackle should touch at the same time as shown in F...

Page 57: ...Prevent damage to hydraulic hoses Before welding next to hydraulic hoses protect the hoses with a heat resistant cover such as a welding blanket CAUTION To protect the original paint system if equippe...

Page 58: ...oned correctly FIG 58 1 Lower platform to ground level see Operation Manual 2 Adjust by bending the platform loop as shown in FIG 58 2 3 Stow the platform and check for correct safety hook position Re...

Page 59: ...ock control handle LOCK BRACKET NOTE Before positioning the locking bracket make sure safety hook is hooked correctly to platform loop see previous step FIG 59 1 3 8 16 NUT 3 8 16 BOLT INNER BRACKET F...

Page 60: ...S 60 1 60 2 60 3 FIG 60 1 TAILLIGHT POSITIONS LEFT HAND SIDE VIEW FIG 60 2 TAILLIGHT HORIZONTAL SPACING TOP VIEW FIG 60 3 7 3 4 4 TAILLIGHT 23 23 TAILLIGHTS TAILLIGHTS NOTE Positions are based on usin...

Page 61: ...CAL TE 20 ONLY P N 220387 STOW WARNING DECAL P N 282847 02 NOTE Ensure there is no residue dirt or corrosion where decals are attached If necessary clean surface before attaching decals NOTE Preferred...

Page 62: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 62 ATTACH DECALS Continued DECAL SHEET P N 282522 01 FIG 62 1...

Page 63: ...g CAUTION TOUCHUP PAINTED OR GALVANIZED FINISH If bare metal or primer is exposed on the painted portions of the Liftgate touch up the paint To maintain the protection provided by the original paint s...

Page 64: ...IC GRAVITY DOWN HYDRAULIC SYSTEM DIAGRAMS 2 GPM FLOW CONTROL VALVE VALVE A HYDRAULIC CYLINDER RELIEF VALVE SET AT 3250 PSI PUMP MOTOR REFERENCE VENT PORT RESERVOIR M PRESSURE PORT CHECK VALVE FILTER D...

Page 65: ...EMATIC POWER DOWN HYDRAULIC SYSTEM DIAGRAMS PORT B LOWER POWER DOWN PORT A RAISE RELIEF VALVE 2 SET AT 1100 PSI PUMP AUX HAND PUMP PORT PLUGGED VALVE A VALVE E HYDRAULIC CYLINDER 2 GPM FLOW CONTROL VA...

Page 66: ...88 771 7713 66 ELECTRICAL SCHEMATIC GRAVITY DOWN ELECTRICAL SYSTEM DIAGRAMS CONTROL SWITCH BATTERY MOTOR SOLENOID VALVE A STARTER SOLENOID CABLE ASSEMBLY CABLE WITH 175 AMP FUSE THERMAL SWITCH IN MOTO...

Page 67: ...67 ELECTRICAL SCHEMATIC POWER DOWN ELECTRICAL SYSTEM DIAGRAMS CABLE WITH 175 AMP FUSE BATTERY STARTER SOLENOID GREEN GREEN THERMAL SWITCH IN MOTOR CASING WHITE RED BLACK WHITE BLACK SOLENOID VALVE A...

Page 68: ...02G X X DOCK BUMPER KITS STEEL DOCK BUMBER AND STEP PAINTED VERSION ONLY 229044 X X STEEL DOCK BUMPER PAINTED VERSION ONLY 229045 X X 2 STEP DOCK BUMPER PAINTED VERSION ONLY 251416 X DUAL STEP 24 RUBB...

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