Maxon TE-20 Manuale utente

M-12-04

REV. F

SEPTEMBER 2015

TE-20 & 72-150

INSTALLATION MANUAL

To nd 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 Maintenance Manual in the PRODUCT DOCU-

MENTATION window.

TABLE OF CONTENTS

SUMMARY OF CHANGES: M-12-04, REVISION F ............................................................. 4

WARNINGS........................................................................................................................... 5

SAFETY INSTRUCTIONS .................................................................................................... 6

NOTICE................................................................................................................................. 6

72-150 & TE-20 LIFTGATE COMPONENTS ........................................................................ 7

PARTS BOX FOR 72-150 GRAVITY DOWN (96” WIDE, PAINTED FINISH) ....................... 8

PARTS BOX FOR 72-150 & TE-20 GRAVITY DOWN

(96” WIDE, GALVANIZED FINISH, 12 VOLT & 24 VOLT)..................................................... 9

PARTS BOX FOR 72-150 POWER DOWN

(96” WIDE, PAINTED FINISH) ............................................................................................ 10

PARTS BOX FOR 72-150 & TE-20 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 PLATE TO VEHICLE .................................... 20

WELD GALVANIZED EXTENSION PLATE TO VEHICLE................................... 22

WELD INSTALLATION BRACKETS.................................................................... 23

STEP 2 - WELD LIFTGATE TO VEHICLE ......................................................................... 24

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED). 27

STEP 4 - RUN POWER CABLE.......................................................................................... 35

STEP 5 - CONNECT POWER CABLE................................................................................ 37

STEP 6 - CONNECT GROUND CABLE (RECOMMENDED) ............................................. 39

STEP 7 - INSTALL CONTROL SWITCH ............................................................................. 40

STEP 8 - ADD HYDRAULIC FLUID .................................................................................... 43

STEP 9 - CONNECT POWER CABLE TO BATTERY......................................................... 45

STEP 10 - REMOVE LOCKING ANGLE AND CHECK FOR INTERFERENCE.................. 46

STEP 11 - BOLT PLATFORM OPENER TO LIFTGATE...................................................... 51

STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED) .................................................... 54

STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE ..................................................... 57

STEP 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

HYDRAULIC SYSTEM DIAGRAMS................................................................................... 64

HYDRAULIC SCHEMATIC (GRAVITY DOWN)................................................................... 64

HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 65

ELECTRICAL SYSTEM DIAGRAMS ................................................................................. 66

ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 66

ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 67

OPTIONS ........................................................................................................................... 68

OPTIONAL LIFTGATE COMPONENTS.............................................................................. 68

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

SUMMARY OF CHANGES: M-12-04, REVISION F

PAGE DESCRIPTION OF CHANGE

COVER Updated REV and date of release.

6Added note to installers to ensure that trucks and trailers are equipped with grab

handles if needed.

44 Removed AMSOIL from the table of recommended hydraulic oil.

68 Removed LVTS options from the OPTIONS table.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

FIG. 5-1

•Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your

feet are clear of the Liftgate.

• Keep ngers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform

edges) when operating the Liftgate.

•Make sure vehicle battery power is disconnected while installing Liftgate. Connect vehicle

battery power to the Liftgate only when installation is complete or as required in the installation

instructions.

Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing

Liftgates. See Operation Manual for operating safety requirements.

•If it is necessary to stand on the platform while operating 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.

• Never perform unauthorized modications on the Liftgate. Modications may result in early failure

of the Liftgate and may create hazards for Liftgate operators and maintainers.

• Correctly stow platform when not in use. Extended platforms could create a hazard for

people and vehicles passing by.

•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 can result from welds that are done incorrectly.

WARNING

WARNINGS

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

on the galvanized part (FIG. 5-1). To minimize hazard remove galvanizing from weld area, provide

adequate ventilation, and wear suitable respirator.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

NOTICE NOTICE

•Maxon Lift is responsible for the instructions to correctly install MAXON Liftgates on

trucks or trailers only.

•Liftgate installers, not Maxon Lift, are responsible for reviewing and complying with all

applicable Federal, State, and Local regulations pertaining to the trailer or truck.

SAFETY INSTRUCTIONS

•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

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.

•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.

•Do not allow untrained persons to operate the Liftgate.

•Be careful working by an automotive type battery. Make sure the work area is well ventilated and

there are no 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 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 con-

trol switch to stop the Liftgate.

•Read and understand the instructions in this Installation Manual before installing Liftgate.

•Before operating the Liftgate, read and understand the operating instructions in Operation

Manual.

•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 and lowered. Listen for

scraping, grating and binding noises and correct the problem before continuing to operate Liftgate.

•Installers of the liftgate should ensure that all trucks and trailers are equipped with grab

handles as needed.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

72-150 & TE-20 LIFTGATE COMPONENTS

72-150 & TE-20 COMPONENTS

FIG. 7-1

WELD-ON EXTENSION PLATE

(PAINTED)

BOLT-ON EXTENSION PLATE

(GALVANIZED OR PAINTED)

OPENER

PARTS BOX

NOTE: Make sure you have all components and parts before you start installing Lift-

gate. Compare parts in the 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 [email protected]

Prevent injuries and equipment damage. Before cutting the shipping straps

from the Liftgate, put Liftgate on level ground that will support at least 1500

pounds. Be careful lifting and moving components (such as extension plate)

after shipping straps are removed.

CAUTION

BOLT-ON STEP

(GALVANIZED

OR PAINTED)

BOLT-ON STEP

(GALVANIZED

OR PAINTED)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

PARTS BOX FOR 72-150 GRAVITY DOWN

(96” WIDE, PAINTED FINISH)

TABLE 8-1

ITEM QTY. PART NUMBER DESCRIPTION

REF 1 269661-01 PARTS BOX, 72-150 GRAVITY DOWN (PAINTED)

14 030458 SCREW TAPPING #10 X 1/2” LG.

27 050079 CLIP, FRAME

31 055011 RUBBER HANDLE

41 203417 RENTAL LOCK BRACKET, 6-1/2" LG.

51 203570 INNER BRACKET, 1" LG. (USE WITH RENTAL LOCK)

61 125674 CLAMP, JIFFY #130

710 205780 TIE, PLASTIC, 7" LG.

88 206864 TIE, PLASTIC, 12-14" LG.

93 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 1 M-12-04 MANUAL, INSTALLATION 72-150/TE-20

13B 1 M-12-05 MANUAL, OPERATION 72-150/TE-20

13C -

REFER TO DECAL

PAGES IN THIS

MANUAL

DECALS

14 1 267959-01 MOLDED SWITCH ASSY

15 2 900057-5 SCREW, SELF TAPPING, #10-24 X 1” LG.

16 1 906497-02 LUG, 2GA, COPPER

NOTE: To nd 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 button. Open the Maintenance Manual in the PRODUCT DOCU-

MENTATION window.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

PARTS BOX FOR 72-150 & TE-20 GRAVITY DOWN

(96” WIDE, GALVANIZED FINISH, 12 VOLT & 24 VOLT)

ITEM QTY. PART NUMBER DESCRIPTION

REF 1269642-01 PARTS BOX, 72-150 GRAVITY DOWN (GALVANIZED)

269642-03 PARTS BOX, TE-20 GRAVITY DOWN (GALVANIZED)

14 030458 SCREW TAPPING #10 X 1/2” LG.

27 050079 CLIP, FRAME

31 125674 CLAMP, JIFFY #130

410 205780 TIE, PLASTIC, 7" LG.

52 206864 TIE, PLASTIC, 12-14" LG.

63 214663 CLAMP, #8 RUBBER LOOM

72 251333 SHIM, 1/8" X 2" X 2" LG.

81 264422 CABLE ASSY, 175 AMPS, 38’ LG.

91269641-01 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 M-12-05 MANUAL, OPERATION 72-150/TE-20

9C -

REFER TO DECAL

PAGES IN THIS

MANUAL

DECALS

10 1 267959-01 MOLDED SWITCH ASSY

11 2 900057-5 SCREW, SELF TAPPING, #10-24 X 1” LG.

12 1 906497-02 LUG, 2GA, COPPER

TABLE 9-1

NOTE: To nd 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 button. Open the Maintenance Manual in the PRODUCT DOCU-

MENTATION window.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

PARTS BOX FOR 72-150 POWER DOWN

(96” WIDE, PAINTED FINISH)

TABLE 10-1

ITEM QTY. PART NUMBER DESCRIPTION

REF 1 269661-03 PARTS BOX, 72-150 GRAVITY DOWN (PAINTED)

14 030458 SCREW TAPPING #10 X 1/2” LG.

27 050079 CLIP, FRAME

31 055011 RUBBER HANDLE

41 203417 RENTAL LOCK BRACKET, 6-1/2" LG.

51 203570 INNER BRACKET, 1" LG. (USE WITH RENTAL LOCK)

61 125674 CLAMP, JIFFY #130

710 205780 TIE, PLASTIC, 7" LG.

88 206864 TIE, PLASTIC, 12-14" LG.

93 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 1 M-12-04 MANUAL, INSTALLATION 72-150/TE-20

13B 1 M-12-05 MANUAL, OPERATION 72-150/TE-20

13C -

REFER TO DECAL

PAGES IN THIS

MANUAL

DECALS

14 1 264951-04 MOLDED SWITCH & CABLE ASSEMBLY

15 2 900057-5 SCREW, SELF TAPPING, #10-24 X 1” LG.

16 1 906497-02 LUG, 2GA, COPPER

NOTE: To nd 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 button. Open the Maintenance Manual in the PRODUCT DOCU-

MENTATION window.

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