Maxon TE-20, 72-150 Installation Manual

M-12-04
REV. F
SEPTEMBER 2015

INSTALLATION MANUAL

TE-20 & 72-150

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.

© 2015 MAXON LIFT CORP.

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

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

PAGE DESCRIPTION OF CHANGE

COVER Updated REV and date of release.

6

44 Removed AMSOIL from the table of recommended hydraulic oil.

68 Removed LVTS options from the OPTIONS table.

Added note to installers to ensure that trucks and trailers are equipped with grab
handles if needed.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

4

Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.

WARNINGS

• 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.

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

people and vehicles passing by.

• 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.

• 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.

• 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

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

adequate ventilation, and wear suitable respirator.

FIG. 5-1). To minimize hazard remove galvanizing from weld area, provide

FIG. 5-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

5

SAFETY INSTRUCTIONS

• 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.

• 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.

• Do not allow untrained persons to operate 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.

• 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 con­trol switch to stop the Liftgate.

SAFETY INSTRUCTIONS

• 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.

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.

• 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 [phone] FAX [phone]

6

72-150 & TE-20 LIFTGATE COMPONENTS

!

CAUTION

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.

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 [phone] or

Send e-mail to [e-mail]

WELD-ON EXTENSION PLATE

(PAINTED)

BOLT-ON STEP

(GALVANIZED

OR PAINTED)

BOLT-ON EXTENSION PLATE

(GALVANIZED OR PAINTED)

OPENER

BOLT-ON STEP

(GALVANIZED

OR PAINTED)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

PARTS BOX

72-150 & TE-20 COMPONENTS

FIG. 7-1

7

PARTS BOX FOR 72-150 GRAVITY DOWN

(96” WIDE, PAINTED FINISH)

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.

ITEM QTY. PART NUMBER DESCRIPTION

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

1 4 030458 SCREW TAPPING #10 X 1/2” LG.

2 7 050079 CLIP, FRAME

3 1 055011 RUBBER HANDLE

4 1 203417 RENTAL LOCK BRACKET, 6-1/2" LG.

5 1 203570 INNER BRACKET, 1" LG. (USE WITH RENTAL LOCK)

6 1 125674 CLAMP, JIFFY #130

7 10 205780 TIE, PLASTIC, 7" LG.

8 8 206864 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 72-150

13A 1 M-12-04 MANUAL, INSTALLATION 72-150/TE-20

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

REFER TO DECAL

13C -

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

PAGES IN THIS
MANUAL

DECALS

TABLE 8-1

8

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

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

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

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.

ITEM QTY. PART NUMBER DESCRIPTION

REF 1

1 4 030458 SCREW TAPPING #10 X 1/2” LG.

2 7 050079 CLIP, FRAME

3 1 125674 CLAMP, JIFFY #130

4 10 205780 TIE, PLASTIC, 7" LG.

5 2 206864 TIE, PLASTIC, 12-14" LG.

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

9A 1 M-12-04 MANUAL, INSTALLATION 72-150/TE-20

9B 1 M-12-05 MANUAL, OPERATION 72-150/TE-20

9C -

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

269642-01 PARTS BOX, 72-150 GRAVITY DOWN (GALVANIZED)

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

269641-01 KIT, MANUAL & DECAL 72-150

269641-02 KIT, MANUAL & DECAL TE-20

REFER TO DECAL
PAGES IN THIS
MANUAL

DECALS

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

TABLE 9-1

9

PARTS BOX FOR 72-150 POWER DOWN

(96” WIDE, PAINTED FINISH)

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.

ITEM QTY. PART NUMBER DESCRIPTION

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

1 4 030458 SCREW TAPPING #10 X 1/2” LG.

2 7 050079 CLIP, FRAME

3 1 055011 RUBBER HANDLE

4 1 203417 RENTAL LOCK BRACKET, 6-1/2" LG.

5 1 203570 INNER BRACKET, 1" LG. (USE WITH RENTAL LOCK)

6 1 125674 CLAMP, JIFFY #130

7 10 205780 TIE, PLASTIC, 7" LG.

8 8 206864 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 72-150

13A 1 M-12-04 MANUAL, INSTALLATION 72-150/TE-20

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

REFER TO DECAL

13C -

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

PAGES IN THIS
MANUAL

DECALS

TABLE 10-1

10

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

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

(96” WIDE, GALVANIZED FINISH)

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.

ITEM QTY. PART NUMBER DESCRIPTION

REF 1

1 4 030458 SCREW TAPPING, #10 X 1/2” LG.

2 7 050079 CLIP, FRAME

3 1 125674 CLAMP, JIFFY #130

4 10 205780 TIE, PLASTIC, 7" LG.

5 2 206864 TIE, PLASTIC, 12-14" LG.

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

9A 1 M-12-04 MANUAL, INSTALLATION 72-150/TE-20

9B 1 M-12-05 MANUAL, OPERATION 72-150/TE-20

9C -

10 1 264951-04 MOLDED SWITCH & CABLE ASSEMBLY

11 1 202406 BRASS ELBOW 1/4” X 1/4”

12 2 900057-5 SCREW, SELF TAPPING, #10-24 X 1” LG.

13 1 906497-02 LUG, 2GA, COPPER

269642-02 PARTS BOX, TE-20 POWER DOWN (GALVANIZED)

269642-04 PARTS BOX, 72-150 POWER DOWN (GALVANIZED)

269641-01 KIT, MANUAL & DECAL, 72-150

269641-02 KIT, MANUAL & DECAL, TE-20

REFER TO DECAL
PAGES IN THIS
MANUAL

DECALS

TABLE 11-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

11

VEHICLE REQUIREMENTS

NOTE: The maximum (unloaded) operating vehicle body bed height for the 72-150

& TE-20 Liftgates equipped with wedge ipover or ramp ipover is 54”.

The minimum height for the 72-150 & TE-20 Liftgates equipped with

wedge ipover is 44” (loaded). The minimum height for 72-150 and TE­20 Liftgates equipped with ramp ipover is 38” (loaded). Do not install

this Liftgate on vehicle bodies equipped with swing open doors.

NOTE: Make sure vehicle is parked on level ground while preparing vehicle and

installing Liftgate.

NOTE: Dimensions are provided as a reference only for tting Liftgate to vehicle

body.

NOTE: Measure the width of the Liftgate and the width of the vehicle body before

you start doing this procedure. Ensure the Liftgate is the correct width for
vehicle.

The vehicle clearance dimensions and vehicle chassis cutout dimensions, for
72-150 and TE-20 Liftgates, are shown on the pages that follow. Dimensions
are given for high bed and low bed installations.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

12

VEHICLE REQUIREMENTS - Continued

PLATFORM WITH WEDGE FLIPOVER

29”

22-1/2”

11 9/16”

54” MAX. (UNLOADED)
44” MIN. (LOADED)

24-1/2” MAX.
14-3/4” MIN.

CLEARANCES FOR TE-20 & 72-150, HIGH BED HEIGHT ONLY

FIG. 13-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

13

VEHICLE REQUIREMENTS - Continued

PLATFORM WITH RAMP FLIPOVER

29”

22-1/2”

11

54” MAX. (UNLOADED)
42” MIN. (LOADED)

24-1/8” MAX.
12-1/8” MIN.

CLEARANCES FOR TE-20 & 72-150 ON HIGH BED HEIGHT

FIG. 14-1

32”

24-1/4”

9-1/2

44” MAX. (UNLOADED)
38” MIN. (LOADED)

16-1/2” MAX.
10-1/2” MIN.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

CLEARANCES FOR TE-20 & 72-150 ON LOW BED HEIGHT

FIG. 14-2

14

VEHICLE REQUIREMENTS - Continued

REAR SILL

6”

BODY FRAME

10”

PLATFORM CLEARANCE
CUTOUT AREA

(WITHIN DASHED LINES)

BODY FLOOR

BODY CROSS MEMBERS

SPACER

TRUCK FRAME

17”

VEHICLE FRAME CUT FOR TE-20 & 72-150 (44” TO 54” BED HEIGHTS)

FIG. 15-1

REAR SILL

5-1/2”

BODY FRAME

9”

PLATFORM CLEARANCE
CUTOUT AREA

(WITHIN DASHED LINES)

BODY FLOOR

BODY CROSS MEMBERS

SPACER

TRUCK FRAME

17”

VEHICLE FRAME CUT FOR TE-20 & 72-150 (38” TO 46” BED HEIGHTS)

FIG. 15-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

15

STEP 1 - INSTALL EXTENSION PLATES

NOTE: TE-20 Liftgates may be equipped with two types of extensions plates. The

painted extension plate (FIG. 16-1) does not have bolt holes and is welded

on. Weld-on support straps and spacers (ats), provided 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 plate hardware kit listed in OP-
TIONS section. It also has holes for bolt-on installation brackets, provided
with parts bags. Refer to the following instructions for installing painted
extension plates or galvanized extension plates.

PAINTED WELD-ON EXTENSION PLATE

FIG. 16-1

GALVANIZED BOLT-ON EXTENSION PLATE

FIG. 16-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

16

STEP 1 - INSTALL EXTENSION PLATES - Continued

WELD PAINTED EXTENSION PLATE TO VEHICLE

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.

NOTE: Before welding extension plate to vehicle body, make sure:

• Inboard edge of extension plate is ush with the top of sill on vehicle body.

• Top surface of extension plate is level with the ground.

1. Center the extension

plate on vehicle body.
Weld the extension
plate to vehicle body
sill as shown in FIGS.

17-1 and 17-2

EQUALLY SPACED

BETWEEN 4” LG WELDS

EXTENSION PLATE WELDS - VIEWED FROM ABOVE

2” LG (TYP.)

1/4”

FIG. 17-1

1/4”

1/4”

1/4”

2 PLACES, MAKE 1” GAP

WHERE SHOWN

5” LG (TYP.), 4 PLACES
CENTER OVER WIDTH
OF 2 CHANNELS AND 2
TUBES (UNDER FLOOR­PLATE - SEE DASHED
LINES)

2” LG, 6 PLACES

EQUAL SPACING

(TYP.)

EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH

1/4”

1” GAP

FIG. 17-2

17

SILL

(PART OF

VEHICLE BODY)

1/4”

1/4”

1” GAP

2 PLACES, MAKE 1”

GAP WHERE SHOWN

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

STEP 1 - INSTALL EXTENSION PLATES - Continued

2. Get extension spring (FIG. 18-1A) from

parts box. Hook one end of spring in loop
(FIG. 18-1A) under extension plate (FIG.
18-1). Next, hook opposite end of spring
in eye of the safety hook (FIG. 18-1A).

EXTENSION PLATE

EXTENSION SPRING PLACEMENT

FIG. 18-1

LOOP

SAFETY

HOOK

EXTENSION

SPRING

EXTENSION

PLATE

EYE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

HOOKING EXTENSION SPRING

RH SIDE VIEW

FIG. 18-1A

18

STEP 1 - INSTALL EXTENSION PLATES - Continued

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 plate and spacers keep 1/4”
between platform and extension plate.

4. Place 2 temporary support straps (FIG. 19-3A)

on the extension plate as shown in FIG. 19-3A.
Also, put 2 temporary spacers (FIG. 19-3B) be­tween platform and extension plate as shown
in FIG. 19-3B. Weld the straps and spacers to
extension plate (FIG. 19-3B).

4”

5”

SUPPORT STRAP

(3/8” X 4” STEEL FLAT)

FIG. 19-1

1”

2-1/2”

SPACER

(1/4” X 1” STEEL FLAT)

FIG. 19-2

SUPPORT

STRAPS

1” (APPROX. - TYP.

STRAP OVERHANG)

FIG. 19-3A

1/4” SPACER

1/4” LG. TACK,

SUPPORT
STRAP TO EXTENSION

1/4”

14”

PLATE (1 WELD ONLY),

SPACER & SUPPORT
STRAP TO EXTENSION

PLATE (1 WELD ONLY)

1/2” (APPROX. - TYP.

SPACER OVERHANG)

4”

STRAP & SPACER WELDS

(TYPICAL - STRAP & SPACER AT BOTH

ENDS OF EXTENSION PLATE)

FIG. 19-3B

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

19

STEP 1 - INSTALL EXTENSION PLATES - Continued

BOLT GALVANIZED EXTENSION PLATE TO VEHICLE

CAUTION

To preserve the corrosion resistance properties of the galvanized nish,

MAXON recommends bolting the galvanized extension plate to vehicle.

NOTE: The extension plate has bolt holes so it can be bolted to vehicle body. Grade

8 bolts are required. MAXON recommends getting the optional extension

plate hardware kit listed in OPTIONS section. Vehicle body must be drilled
according to instructions. If necessary, extension plate may also be welded to
vehicle body. Do the following bolting or welding instructions.

1. Mark and drill holes into rear sill as shown in FIG. 20-1.

96”

94-1/2”

82”

19”

14”

1-1/2”

24”

34”

41”

REAR

SILL

48”

55”

62”

72”

77”

USE 19/32” DRILL

(13 PLACES)

1-1/4”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

3-1/8”

HOLE ONLY REQUIRED
WHEN BOLTING
THROUGH CORNER POST.

REAR SILL - HOLE LOCATIONS FOR 96” WIDE VEHICLE

HOLE ONLY REQUIRED
WHEN BOLTING
THROUGH CORNER POST.

FIG. 20-1

20

STEP 1 - INSTALL EXTENSION PLATES - Continued

NOTE: Do not tighten extension plate bolts and lock nuts until:

• All the bolts and lock nuts are in place.

• Top of extension plate is ush with top of rear sill.

2. Bolt extension plate to vehicle as shown in FIG. 21-1. If necessary, reposition

extension plate so top surface is ush with top surface of sill. Then, torque bolts

and lock nuts to 105 lb.-ft.

FRAME BOLT, HEX

1/2”-13 X 1 3/4” LG, GR8

(13 PLACES)

VEHICLE

BODY

EXTENSION

PLATE

TEAR DROP NUT 1/2”-13

(13 PLACES 96” EXTENSION PLATE,

15 PLACES 102” EXTENSION PLATE)

3/16”

WELD VERT. EDGE
IF NOT BOLTING

BOLTING EXTENSION PLATE (96” WIDE EXTENSION PLATE SHOWN)

IF NO CORNER POST ACCESS FOR

BOLT & NUT, WELD OUTSIDE EDGES

AS SHOWN.

WELD VERT. EDGE

IF NOT BOLTING

FIG. 21-1

21

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

3/16”

STEP 1 - INSTALL EXTENSION PLATES - Continued

WELD GALVANIZED EXTENSION PLATE TO VEHICLE

`

WARNING

!

Welding on galvanized parts gives off especially hazardous fumes. To mini-

mize hazard remove galvanizing from weld area, provide adequate ventilation,

and wear suitable respirator.

CAUTION

To preserve the corrosion resistance properties of the galvanized nish,

MAXON recommends bolting the galvanized extension plate to vehicle.

Center the extension plate on vehicle body. Before welding extension plate to vehicle

body, make sure top surface of extension plate is ush with oor of vehicle body.

Weld the extension plate to vehicle body sill as shown in FIGS. 22-1 and 22-2.

3/16”

3/16”

WELD LENGTH &

SPACE: 2” - 11 3/4”

EXTENSION

PLATE

VEHICLE

BODY

EXTENSION PLATE WELDS - VIEWED FROM ABOVE

FIG. 22-1

EXTENSION

PLATE

VEHICLE

BODY

3/16”

WELD LENGTH &

SPACE: 2” - 11 3/4”

3/16”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH

FIG. 22-2

22

STEP 1 - INSTALL EXTENSION PLATES - Continued

WELD INSTALLATION BRACKETS

`

!

WARNING

Welding on galvanized parts gives off

especially hazardous fumes. To mini­mize hazard remove galvanizing from

weld area, provide adequate ventila­tion, and wear suitable respirator.

1. Make 2 support straps (FIG. 23-1) and

2 spacers (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.

2. Place 2 temporary support straps (FIG. 23-3)

on the extension plate as shown in FIG. 23-3.
Also, put 2 temporary spacers (FIG. 23-3) be­tween platform and extension plate as shown
in FIG. 23-3. Weld the straps and spacers to
extension plate (FIG. 23-3).

SUPPORT STRAP

(3/8” X 4” STEEL FLAT)

(1/4” X 1” STEEL FLAT)

4”

FIG. 23-1

1”

SPACER

FIG. 23-2

5”

2-1/2”

SUPPORT

STRAPS

1/4” LG. TACK, SUPPORT STRAP TO

1/4”

1” (APPROX. - TYP.

STRAP OVERHANG)

14”

EXTENSION PLATE (1 WELD ONLY),

SPACER & SUPPORT STRAP TO

EXTENSION PLATE (1 WELD ONLY)

1/4” SPACER

4”

BOLTING ON INSTALLATION BRACKETS

FIG. 23-3

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

1/2”

(APPROX. - TYP.

SPACER OVERHANG)

23

STEP 2 - WELD LIFTGATE TO VEHICLE

WARNING

!

Do not remove lock angle until instructed to do so in this manual.

1. Unfold the platform as shown

in FIGS. 24-1 and 24-2.

NOTE: Liftgates are shipped with

the locking angle set up for
low bed. Check your lock­ing angle dimension (FIGS.
24-1 & 24-2) before installing
Liftgate. If locking angle is not
in correct position for your bed
height, remove and reposition
locking angle (FIGS. 24-1 &
24-2).

FLIPOVER (LOW BED, 38”- 46” HEIGHT)

LOCKING

ANGLE

UNFOLDED PLATFORM WITH RAMP

FIG. 24-1

23-1/4”

!

WARNING

Support Liftgate before removing
locking angle. To prevent possible
injury, never work in the area under
the platform.

22-3/4”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

LOCKING ANGLE

UNFOLDED PLATFORM WITH RAMP OR

WEDGE FLIPOVER, RAMP IS SHOWN

(HIGH BED, 44”- 54” HEIGHT)

FIG. 24-2

24

STEP 2 - WELD LIFTGATE TO VEHICLE - Continued

!

WARNING

To prevent injury, support Liftgate to keep it from tipping over. Stay clear of
place under the platform where Liftgate could fall on you.

CAUTION

To protect the original paint system if equipped, a 3” wide area of paint must

be removed from all sides of the weld area before welding.

NOTE: To prevent misalignment when hoisting Liftgate by the platform, each plat-

form stop must be tack welded to shackle.

2. Tack weld platform stops to shackles,

on LH and RH side of platform, as
shown in FIGS. 25-1A and 25-1B.

PLATFORM

PLATFORM

STOP

SHACKLE

3/16”

TACK WELDING

PLATFORM STOPS

FIG. 25-1B

3. Attach chain and hoist on each side of

platform at positions shown in FIG. 25-2.
(Place chain all around platform.) Hoist

the Liftgate, and then place oor jack

under main frame (FIG. 25-2). Jack the
Liftgate into position. Make sure vehicle

oor is horizontal and pins are lined up

as shown in FIG. 25-2.

FLOOR JACK

TACK

FIG. 25-1A

HOIST HERE

PINS

VERTICAL

VEHICLE FLOOR

(HORIZONTAL)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

MAIN
FRAME

FIG. 25-2

25

STEP 2 - WELD LIFTGATE TO VEHICLE - Continued

!

WARNING

Painted Liftgate is shipped from factory with mounting plates that are only tack
welded to main frame. Weld as shown in illustration before operating Liftgate.

NOTE: The mounting plates on the galvanized main frame are fully welded at the

factory, and are suitable for vehicle with 33-3/4” frame width. Do not move
the galvanized mounting plates. The following instruction only applies to
painted mounting plates.

4. Unbolt mounting plate

from main frame. Reposi­tion the mounting plate
against vehicle frame.
Tack weld as shown in
FIG. 26-1. Repeat for
second mounting plate
(reposition and tack
weld).

VEHICLE FRAME

(TYPICAL TRUCK

FRAME SHOWN)

UNBOLT TO REPOSITION
MOUNTING PLATE)

MOUNTING
PLATE

NOTE: Weld both mounting plates to

vehicle frame before welding
mounting plates to main frame.

5. Clamp both mounting

plates to vehicle frame.
Weld the mounting plates
to vehicle frame as shown
in FIG. 26-2. Remove
clamps.

2” LG. 4 PLACES

(TYPICAL - RH & LH

TACK

(TYPICAL - RH & LH

MOUNTING PLATES)

MAIN FRAME

(CUT-AWAY VIEW)

REPOSITIONING MOUNTING PLATE

VEHICLE FRAME

(TYPICAL TRUCK

FRAME SHOWN)

MOUNTING

PLATES)

1/4”

(RH SIDE SHOWN)

FIG. 26-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

1/4”

MOUNTING
PLATE

WELD TO VEHICLE FRAME AND MAIN FRAME

(RH SIDE SHOWN)

FIG. 26-2

26

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED)

RECOMMENDED CONFIGURATION

NOTE: Make sure the Liftgate power unit, and all batteries on the vehicle for the

power unit, are connected correctly to a common chassis ground.

1. Liftgate and optional

battery box are typically
installed on trailers as
shown in FIG. 27-1 and
on trucks as shown in
FIG. 27-2. See the fol­lowing page for battery
and cable connections.

LIFTGATE

LIFTGATE

POWER UNIT

FUSED CABLE

OPTIONAL

BATTERY BOX,

TYPICAL LOCATION

TRACTOR BATTERIES,

TYPICAL LOCATION

175 AMP

FUSED CABLE

175 AMP

CIRCUIT

BREAKER

RECOMMENDED LIFTGATE & OPTIONAL BATTERY BOX

INSTALLATION ON TRAILER

FIG. 27-1

TRUCK BATTERIES,

TYPICAL LOCATION

175 AMP

FUSED CABLE

175 AMP

FUSED CABLE

LIFTGATE

LIFTGATE

POWER UNIT

OPTIONAL

BATTERY BOX,

TYPICAL LOCATION

CIRCUIT

BREAKER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

RECOMMENDED LIFTGATE & BATTERY BOX

INSTALLATION ON TRUCK

FIG. 27-2

27

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

2. Select holes on top of battery box

frame to align mounting brackets

ush to cross members. Refer

to FIGS. 28-1A & 28-1B for trail­ers and FIG. 28-2 for trucks. Bolt
mounting brackets to battery box
frame as shown in FIG. 28-1C.
Torque each bolt and lock nut to

85-128 lb-ft.

TRAILER BODY

CROSS MEMBER

MOUNTING

BRACKETS

BATTERY BOX

FRAME

LOCK NUT

WASHER

MOUNTING

BRACKETS

LOCK

WASHER

CROSS

MEMBER

WASHER

CAP SCREW

BOLTING BRACKETS

(8 PLACES)

FIG. 28-1C

BATTERY BOX

FRAME

FLUSH BRACKETS

FOR TRAILERS

(8 PLACES)

FIG. 28-1B

TRUCK BODY

CROSS MEMBER

MOUNTING

BRACKETS

FLUSH BRACKETS FOR TRUCKS

ALIGNING BATTERY

BOX FRAME

(TRAILER SHOWN)

FIG. 28-1A

BATTERY BOX

FRAME

(8 PLACES)

FIG. 28-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

28

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

NOTE: If welding mounting brackets to cross members, skip instruction 3.

3. Using mounting brackets as a tem-

plate mark and drill holes through
cross members (FIG. 29-1). Bolt
mounting brackets to cross mem­bers as shown in FIGS. 29-2A and
29-2B. Torque bolts and lock nuts
to 85-128 lb-ft.

MOUNTING

BRACKETS

1/2” HOLES

MARK AND DRILL

FIG. 29-1

WASHERS

(4 PLACES)

CROSS

MEMBER

LOCK NUTS

(2 PLACES)

CAP SCREWS

(2 PLACES)

CROSS

MEMBERS

LOCK WASHERS

(2 PLACES)

MOUNTING

BRACKETS

CROSS

MEMBER

BOLTING BRACKETS

(8 PLACES)

FIG. 29-2B

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BOLTING BATTERY BOX FRAME

FIG. 29-2A

29

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

!

WARNING

Recommended 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 from welds
that are done incorrectly.

CAUTION

To prevent pump box components from being damaged by electric current

from welding, connect welder grounding cable to the part being welded.

CAUTION

Cover pump box and optional battery box with ame-resistant covering before
welding pump box frame to vehicle.

4. For galvanized frame, read

warning decal shown in FIGS.
30-1A and FIGS. 30-1B before
welding. Weld each bracket to
cross members as shown in
FIGS. 30-1A and 30-1C. Weld
top of bracket if accessible.

MEMBERS

CROSS

IF ACCESSIBLE

3/16”

WELDING BRACKETS

3/16”

(8 PLACES)

FIG. 30-1C

CROSS

MEMBERS

3/16”

BRACKET

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

WELDING GALVANIZED, WARNING DECAL

FIG. 30-1B

BOLTING PUMP & BATTERY

BOX FRAME

FIG. 30-1A

30

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

!

WARNING

Remove all rings, watches and jewelry before doing any electrical work.

NOTE: Always connect fused end of power cable to battery positive (+) 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.

5. Connect battery cables, fused cables, and ground

cables for 12 volt power as shown in FIG. 31-1 or
24 volt power as shown in FIG. 32-1.

GROUND CABLE TO PUMP

BOX OR COMMON CHASSIS

GROUND, 74” LG.

(BATTERY BOX KIT ITEM)

FUSED CABLE TO PUMP BOX

(IN PARTS BOX)

10” LG.

BLACK CABLE

10” LG.

RED CABLE

(-) BATTERY

CABLE TO

COMMON
GROUND

FUSED CABLE

(SEE NOTE)

150 AMP
CIRCUIT

BREAKER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

12” LG.

RED CABLE

12 VOLT BATTERY CONNECTIONS

FOR 12 VOLT POWER

FIG. 31-1

31

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

GROUND CABLE TO

PUMP BOX OR COMMON

CHASSIS GROUND, 74” LG.

(BATTERY BOX KIT ITEM)

(-) BATTERY CABLE

TO COMMON

GROUND

FUSED CABLE

(SEE NOTE)

FUSED CABLE TO PUMP

BOX, 42” LG.

(BATTERY BOX KIT ITEM)

CABLE
10” LG.

12 VOLT BATTERY CONNECTIONS

FOR 24 VOLT POWER

FIG. 32-1

150 AMP
CIRCUIT

BREAKER

CABLE

12” LG.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

32

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

!

WARNING

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 holes in battery box are not plugged or covered.

VENTILATION HOLES

BATTERY BOX ASSEMBLY (REAR VIEW SHOWN)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 33-1

33

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

175 AMP FUSED

CABLE TO

PUMP BOX

GROUND CABLE

TO PUMP BOX

HEX NUT

5/16”-18, GR8

(3 PLACES)

FLAT WASHER

5/16”

(3 PLACES)

LOCK NUT, 1/4”-20

PAN HEAD SCREW

1/4”-20 X 1” LG.

(2 PLACES)

(2 PLACES)

FLAT WASHER

1/4”

(4 PLACES)

CHARGE LINE FROM

VEHICLE BATTERY

150 AMP CIRCUIT

BREAKER

CAP SCREW

1/2”-20 X 2 1/4” LG. GR8

(4 PLACES)

J-BOLT

BATTERY

TIE DOWN

J-BOLT ANCHOR

(PART OF

BATTERY PLATE)

(12 VOLT POWER CONNECTIONS SHOWN)

BATTERY

BATTERY

PLATE

STRAP

LOCK WASHER

9/16”

(4 PLACES)

BATTERY BOX ASSEMBLY

FIG. 34-1

34

HEX NUT

1/2”-20

(4 PLACES)

FLAT WASHER

9/16”

(4 PLACES)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

STEP 4 - RUN POWER CABLE

NOTE: Make sure the Liftgate power unit, and all batteries on the vehicle for the

power unit, are connected correctly to a common chassis ground.

RECOMMENDED CONFIGURATION

1. Liftgate powered from

truck batteries is typically
installed on trailers as
shown in FIG. 35-1 and
on trucks as shown in
FIG. 35-2. See the fol­lowing page for running
the battery cable.

LIFTGATE

175 AMP

FUSED CABLE

LIFTGATE

POWER UNIT

TRACTOR BATTERIES,

TYPICAL LOCATION

175 AMP

FUSED CABLE

RECOMMENDED LIFTGATE & OPTIONAL BATTERY BOX

INSTALLATION ON TRAILER

FIG. 35-1

TRUCK BATTERIES,

TYPICAL LOCATION

175 AMP

FUSED CABLE

LIFTGATE

LIFTGATE

POWER UNIT

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

RECOMMENDED LIFTGATE & BATTERY BOX

INSTALLATION ON TRUCK

FIG. 35-2

35

STEP 4 - RUN POWER CABLE - Continued

CAUTION

!

Never route an energized wire. Make sure the vehicle battery is disconnected.

Always route electrical wires clear of moving parts, brake lines, sharp edges

and exhaust systems. Avoid making sharp bends in wiring. Attach securely.
If drilling is necessary, rst check behind the drilling surface so you do not

damage any fuel lines, vent lines, brake lines or wires.

2. Clip fused power cable to vehicle chassis with fuse nearest the vehicle battery, as

shown in FIG. 36-1. Keep enough cable near the battery to reach the positive terminal
without straining cable (after connection). Run cable to pump box on Liftgate.

VEHICLE FRAME

(TRUCK FRAME SHOWN)

18” - 24”

SPACING

175 AMP FUSE

SHORTEST

CABLE END

TERMINAL LUG

(TO VEHICLE BATTERY)

CABLE

CLIPS

CHARGE LINE

(TO PUMP BOX)

FRONT OF VEHICLE

REAR OF VEHICLE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 36-1

36

STEP 5 - CONNECT POWER CABLE

1. Unbolt the pump cover as

shown in FIG. 37-1.

MOUNTING

PLATE

PUMP MOUNT

PLATE

MAIN

FRAME

CAP

SCREWS

(5 PLACES)

POWER UNIT

UNBOLTING PUMP COVER

FIG. 37-1

(REF)

FLAT

WASHERS

(5 PLACES)

PUMP COVER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

37

STEP 5 - CONNECT POWER CABLE - Continued

NOTE: Hydraulic lines and electrical lines must be run into pump box through seal-

ing grommets (FIG. 38-3). To ensure a good seal on hydraulic & electrical
lines, never cut the sealing grommets.

2. On the bare wire end of fused power

cable, keep enough length to attach
copper terminal lug and reach motor

COPPER TERMINAL LUG

HEAT SHRINK TUBING

(P/N 253316-04)

solenoid without putting tension on
cable (after connection) (FIG. 38-1).

FUSED POWER CABLE

(BARE WIRE END)

Measure (if needed) and then cut

excess cable from bare wire end of
cable. Put heat shrink tubing (parts

box) (FIG. 38-1) on the end of the

PLACING TERMINAL LUG & HEAT SHRINK

TUBING ON FUSED POWER CABLE

FIG. 38-1

cable (leave room for terminal lug).

Crimp copper terminal lug (from parts
box) on the fused power cable and
shrink the heat shrink tubing (FIG. 38-2).

TYPICAL FUSED POWER CABLE WITH

TERMINAL LUG INSTALLED

FIG. 38-2

CAUTION

To prevent damage to metal case starter solenoid, hold bottom terminal nut
securely with wrench when loosening and tightening top terminal nut. Do not

over-tighten the terminal nuts. For the 5/16” load terminals, torque nuts to 35

lbs.-in. Torque the nuts on #10-32 control terminals to 15 lbs.-in.

NOTE: MAXON recommends using dielectric

grease on all electrical connections.

3. Remove hex nut and lock washer

from battery terminal post on the
motor solenoid. Connect the fused
power cable to the motor solenoid
as shown in FIG. 38-3. Reinstall
and tighten lock washer and hex
nut.

TYPICAL FUSED POWER CABLE CONNECTION

FUSED

POWER CABLE

(GRAVITY DOWN PUMP SHOWN)

38

MOTOR

SOLENOID

FIG. 38-3

BATTERY

TERMINAL

POST

LOCK

WASHER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

HEX
NUT

STEP 6 - CONNECT GROUND CABLE (RECOMMENDED)

NOTE: To ensure power unit is correctly grounded, MAXON recommends

connecting optional 2 gauge ground cable from grounding stud on pump
assembly to a grounding point on the frame, or negative battery terminal in
the optional battery box.

NOTE: MAXON recommends using dielectric grease on all electrical connections.

1. Use lock nut to attach ground cable lug

to ground stud on the pump assembly
(FIGS. 39-1A and 39-1B).

TERMINAL LUG

(GROUND CABLE)

GROUND STUD

PUMP

ASSEMBLY

FIG. 39-1A

NOTE: If there is a grounding point on the frame,

use it to connect ground cable. Then, skip
the step for drilling a hole.

NOTE: Clean the ground cable connection point

on the frame down to bare metal.

2. Extend the ground cable to reach

TERMINAL LUG

(GROUND CABLE)

vehicle frame (FIG. 39-2) without
putting tension on cable (after con­nection). Connect to an existing
grounding point if available.

3. If necessary, drill a 11/32” (0.343”)

hole in vehicle frame for bolting
the ground cable terminal lug
(FIG. 39-2).

5/16"-18 X 1" LG

CAP SCREW

CONNECTING GROUND CABLE

TO PUMP ASSEMBLY GROUND

FIG. 39-1B

VEHICLE CHASSIS

(TRUCK FRAME SHOWN)

BARE

METAL

5/16” FLAT

WASHER

5/16”-18

LOCK NUT

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

4. Bolt the ground cable terminal

lug to vehicle frame as shown in
FIG. 39-2.

FIG. 39-2

39

STEP 7 - INSTALL CONTROL SWITCH

1. Drill one 3/4“ hole and two #21–size holes in the vertical

post on curb side of vehicle body as shown in FIG. 40­1A. Use template shown in FIG. 40-1B.

7/8”

VEHICLE BODY

VERTICAL POST

(CURB SIDE)

18”

1-3/4”

HOLE DRILLING TEMPLATE

FIG. 40-1B

NOTE: Hydraulic lines and electrical lines

must run into pump box through
sealing grommets (FIG. 40-2). To
ensure a good seal on hydraulic &
electrical lines, never cut the sealing
grommets.

2. Cut tie strap on coiled wiring harness

(FIG. 40-2). Pull the wiring har­ness through grommet on the pump
mounting plate (FIG. 40-2).

RECOMMENDED POSITION FOR

CONTROL SWITCH

FIG. 40-1A

GROMMET

TIE

STRAP

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

WIRING

HARNESS

PUMP

MOUNTING

PLATE

FIG. 40-2

40

STEP 7 - INSTALL CONTROL SWITCH - Continued

NOTE: MAXON recommends using dielectric grease on all electrical connections.

3. Run wiring harness under

vehicle body (see dashed
line - FIG. 41-1) and
up through inside of verti­cal post. Then pull control
switch wiring harness out
the 3/4“ hole drilled in
vertical post (FIG. 41-1).
Connect the control switch
wiring to the wiring harness
as shown in FIG. 41-2.
Push extended wiring back
into the ¾” hole in the verti­cal post until control switch
touches the post. Attach
control switch to vertical
post with 2 self-tapping
screws (FIG. 41-2).

VEHICLE BODY

VERTICAL POST

3/4” HOLE

ROUTING CONTROL SWITCH WIRING

FIG. 41-1

4. If necessary, use clamps and

tapping screws, from instal­lation parts bag, to secure
switch wiring harness to
vehicle (FIG. 41-1).

CONTROL SWITCH

DECAL

(SEE DECALS PAGE)

SCREW,

SELF-TAPPING

BLACK

WHITE

BLACK

WHITE

GREEN

GREEN

RED

(POWER DOWN

ONLY)

CONTROL SWITCH WIRING CONNECTIONS

FIG. 41-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

41

STEP 7 - INSTALL CONTROL SWITCH - Continued

NOTE: If you plan to install rental lock (see STEP 15), wait until STEP 15 to install

the control handle grip.

5. If liftgate is equipped with

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.

CONTROL

HANDLE GRIP

CONTROL

HANDLE

EXTENSION

PLATE (REF)

INSTALLING CONTROL HANDLE GRIP

FIG. 42-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

42

STEP 8 - ADD HYDRAULIC FLUID

CAUTION

Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic uid reservoir ller cap, drain plug and hydrau-

lic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.

NOTE: Use correct grade of hydraulic uid for your location.

+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606

See TABLES 44-1 and 44-2 for recommended brands.

1. Pull out ller cap (no threads) shown in

FIG. 43-1. Fill the reservoir (FIG. 43-1)

with hydraulic uid to 4” above the bottom

(FIG. 43-1).

RESERVOIR

2. Reinstall ller cap (FIG. 43-1).

3. Bolt on the pump cover as shown

in FIG. 43-2. Torque the bolts (cap
screws) to 10 - 14 lbs.- in.

3-1/2” - 4”

FILLER CAP

PUMP RESERVOIR

(GRAVITY DOWN POWER UNIT SHOWN)

FIG. 43-1

POWER UNIT

(REF)

CAP

SCREWS

(5 PLACES)

FLAT

WASHERS

(5 PLACES)

PUMP COVER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BOLTING ON PUMP COVER

FIG. 43-2

43

STEP 8 - ADD HYDRAULIC FLUID - Continued

ISO 32 HYDRAULIC OIL

RECOMMENDED

BRANDS

CHEVRON HIPERSYN 32

KENDALL GOLDEN MV

SHELL TELLUS S2 V32

EXXON UNIVIS N-32

MOBIL

PART NUMBER

DTE-13M, DTE-24,
HYDRAULIC OIL-13

TABLE 44-1

ISO 15 OR MIL-H-5606 HYDRAULIC OIL

RECOMMENDED

BRANDS

CHEVRON FLUID A, AW-MV-15

PART NUMBER

KENDALL GLACIAL BLU

SHELL TELLUS S2 V15

EXXON UNIVIS HVI-13

MOBIL DTE-11M

ROSEMEAD THS FLUID 17111

TABLE 44-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

44

STEP 9 - CONNECT POWER CABLE TO BATTERY

NOTE: MAXON recommends using dielectric grease on all electrical connections.

1. Remove nut from negative (-) bat-

tery terminal. Disconnect negative
(-) battery cable (FIG. 45-1).

BATTERY CABLE

2. Remove nut from positive (+)

battery terminal (FIG. 45-2).

3. Connect fused positive (+) cable

to positive (+) battery terminal
(FIG. 45-2). Then, reinstall nut
on positive (+) battery terminal

(FIG. 45-2).

NEGATIVE (-)

DISCONNECTING (-) BATTERY CABLE

POSITIVE (+)

BATTERY CABLE

NUT

NUT

NUT

POSITIVE (+)

BATTERY TERMINAL

NEGATIVE (-)

BATTERY TERMINAL

FIG. 45-1

FUSED (+)

CABLE

POSITIVE (+)

BATTERY TERMINAL

4. Reconnect negative (-) battery

cable to negative (-) battery ter­minal (FIG. 45-3). Then, reinstall
nut on negative (-) battery termi­nal (FIG. 45-3).

CONNECTING FUSED (+) CABLE

FIG. 45-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

NEGATIVE (-)

BATTERY TERMINAL

NUT

NEGATIVE (-)

BATTERY CABLE

RECONNECTED BATTERY CABLES

FIG. 45-3

45

STEP 10 - REMOVE LOCKING ANGLE AND CHECK FOR

INTERFERENCE

CAUTION

Do not fully pressurize the system in this step. Fully pressurize the system and

check for hydraulic leaks after Liftgate is fully welded.

1. Push control switch to UP position and hold just enough time to pressurize hydraulic

system. Release control switch. Hydraulic system is ready.

WARNING

!

To prevent possible injury, never work in the area under the platform. Get ac­cess to the locking angle from the back of the Liftgate.

NOTE: To operate Liftgate, locking angle must be removed from hydraulic cylinder.

2. Remove locking angle (FIG. 46-1) from cylinder

pins. Remove the locking angle (FIG. 46-1).

PLATFORM

(UNFOLDED)

COTTER PIN

REMOVING LOCKING ANGLE

FIG. 46-1

LOCKING

ANGLE

CYLINDER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BACK OF

LIFTGATE

(REF)

46

STEP 10 - REMOVE LOCKING ANGLE AND CHECK FOR

INTERFERENCE - Continued

3. Remove oor jack and

hoist supporting Liftgate
(FIG. 47-1).

FLOOR JACK

FIG. 47-1

4. Lower platform to the ground (FIG. 47-2).

Look for any interference 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
DOWN position until you hear air escaping

into the hydraulic uid reservoir. Then, raise

the platform (FIG. 47-3). Look for any interfer­ence between liftgate and vehicle as platform
is raised. Repeat step until there is no air left
in the system and platform lowers smoothly
(FIG. 47-2).

LOWERING PLATFORM

FIG. 47-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

RAISING PLATFORM

FIG. 47-3

47

STEP 10 - REMOVE LOCKING ANGLE AND CHECK FOR

INTERFERENCE - Continued

5. Lower platform to the ground (FIG. 48-1).

LOWERING PLATFORM

FIG. 48-1

6. Remove the 2 tack-welded ats

and spacers (FIG. 48-2).

FLAT & SPACER

(2 PLACES)

EXTENSION

PLATE

REMOVING FLATS & SPACERS

(PAINTED EXTENSION PLATE ONLY)

FIG. 48-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

48

STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR

INTERFERENCE - Continued

NOTE: Correct any t and interference problems before continuing with installation.

7. Raise platform to bed height

(FIG. 49-1). Heel of platform
should butt against the edge of
extension plate (FIG. 49-2).

RAISING PLATFORM

FIG. 49-1

PLATFORM

EDGES BUTTED

TOGETHER OVER

WIDTH OF PLATFORM

EXTENSION

PLATE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

PLATFORM & EXTENSION PLATE WITH

EDGES BUTTED TOGETHER

FIG. 49-2

49

STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR

INTERFERENCE - Continued

NOTE: Correct any t and interference problems before continuing with installation.

8. Ensure top surface of platform and

extension plate are ush at the RH

& LH sides of platform (FIGS. 50-1
and 50-2). The allowable difference
in height is +/- 1/8” maximum as
shown.

PLATFORM

+/- 1/8” (MAX)

SURFACES FLUSH

EXTENSION

PLATE

DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM

& EXTENSION PLATE (RH VIEW)

FIG. 50-1

SURFACES FLUSH

PLATFORM

+/- 1/8” (MAX)

EXTENSION

PLATE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM

& EXTENSION PLATE (LH VIEW)

FIG. 50-2

50

STEP 11 - BOLT PLATFORM OPENER TO LIFTGATE

1. Make sure platform is at

ground level.

VEHICLE BED

HEIGHT

(TE-20 ONLY)

54 19-1/2”

52 21-1/2”

50 22-1/2”

48 24-1/2”

46 26”

44 27”

“L”

TE-20 LIFTGATE OPENER

POSITION DIMENSIONS

TABLE 51-1

“L”

(TABLE 51-1)

44”- 54”

BED HEIGHT

MAIN

FRAME

PLATFORM

OPENER

OPENER POSITION FOR HIGH BED HEIGHT

FIG. 51-1

2. Position the opener on main frame as shown.

• TE-20 Liftgates, high bed height:

See FIG. 51-1 and TABLE 51-1

• TE-20 Liftgates, low bed height:

See FIG. 51-2

MAIN

FRAME

OPENER POSITION FOR LOW BED HEIGHT

PLATFORM

OPENER

21”

FIG. 51-2

38”-46”

BED HEIGHT

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

51

STEP 11 - BOLT PLATFORM OPENER TO LIFTGATE

- Continued

!

CAUTION

If there is any interference with the platform while stowing Liftgate, check for

damage on bottom of platform, ipover, and the hinge in between. A damaged
platform or ipover may result in personal injury and additional damage to

Liftgate.

3. Bolt opener to main frame (FIG. 52-1).

CAP SCREW

1/2”-20 X 3/1/2” LG

4. Stow and unstow platform several

times to verify it stows and unstows
correctly and there is no interfer­ence (FIGS. 52-2 and 52-3).

MAIN

FRAME

LOCK NUT

1/2”-20

PLATFORM

OPENER

BOLTING PLATFORM OPENER

FIG. 52-1

STOWED PLATFORM

FIG. 52-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

PLATFORM UNSTOWED & LOWERED

FIG. 52-3

52

STEP 11 - BOLT PLATFORM OPENER TO LIFTGATE

TILT

MOUNT

HOLE

OPENER

1

2 3 4

5 6 7 8 9

- Continued

5. If the platform does not

stow correctly, or if there is
interference, adjustments 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 53-1 and

FIG. 53-2.

6. Repeat process of stowing

and unstowing platform
several times to verify opener
is operating correctly.

STRAIGHT

MOUNT

HOLE

VEHICLE BED

HEIGHT

52”-54” 4, 7 TILTED

48”-52” 1, 4 TILTED

44”-48” 1, 4 STRAIGHT

38”-44” 1, 4 STRAIGHT

HOLE

NUMBERS

MOUNT

LIFTGATE OPENER POSITIONS

TABLE 53-1

MAIN

FRAME

PLATFORM OPENER ADJUSTMENT HOLES

FIG. 53-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 53-1

53

STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED)

NOTE: Before doing the following procedure, make sure vehicle is parked on level

ground.

1. Make sure platform is at ground level. Unfold

the platform and ipover. As the platform rst
touches the ground, shackles and tip of ipover

must touch the ground at the same time (FIG.
54-1). If the shackles and the tip of ipover
touch the ground at the same time, raise plat­form to bed height. Outboard edge on top of
ipover should be above bed level (FIG. 54-2).
If indications are correct in both cases (FIGS.
54-1 & 54-2), Liftgate is installed correctly and
no adjustment is needed. If indications are
incorrect, continue with instruction 2.

NOTE: If tip of ipover touches rst (FIG. 54-3A),

do instructions 2 and 3. If the shackle

touches rst (see FIG. 54-1), skip 2 and
3 and do instructions 4 and 5.

TIP OF

FLIPOVER

PLATFORM & SHACKLES TOUCH

GROUND (RAMP FLIPOVER SHOWN)

FIG. 54-1

OUTBOARD

EDGE

LEVEL LINE

2. Make sure platform is still at ground level. If

the shackle is not touching the ground, mea­sure and compare distance “A” (FIG. 54-
3A) with TABLE 54-1 or TABLE 54-2 to
determine the correct shim. Next, mark posi­tion on shackle (FIG. 54-3B).

RAISE TIP OF

RAMP FLIPOVER

THIS DISTANCE “A”

11/16” 1/16” 1/16”

1-3/8” 1/8” 1/8”

2-1/16” 3/16” 3/16”

2-3/4” 1/4” 1/4”

REQUIRED SHIM

THICKNESS

WELD

SIZE “W”

1/4”

SHIMS TO RAISE RAMP FLIPOVER

TABLE 54-1

MARKING SHIM

RAISE TIP OF

RAMP FLIPOVER

THIS DISTANCE “A”

9/16” 1/16” 1/16”

1-1/4” 1/8” 1/8”

1-15/16” 3/16” 3/16”

2-5/8” 1/4” 1/4”

REQUIRED SHIM

THICKNESS

WELD

SIZE “W”

SHIMS TO RAISE WEDGE FLIPOVER

TABLE 54-2

PLATFORM EDGE ABOVE BED

LEVEL (RAMP FLIPOVER SHOWN)

FIG. 54-2

PLATFORM STOP

SHACKLE

MARK HERE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

POSITION

FIG. 54-3B

“A”

(TABLES 54-1

OR 54-2)

SHACKLES DO NOT TOUCH GROUND

(RAMP FLIPOVER SHOWN)

FIG. 54-3A

54

STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED)

- Continued

3. Make shims as needed (FIG. 55-1). Posi-

tion bottom edge of shim to line up with
mark on shackle (see FIG. 55-2). Next,
weld the shim to shackle as shown in FIG.
55-2.

2-1/4”

SHIM (1/16”, 1/8”, 3/16”, or 1/4”)

MADE FROM STEEL FLAT

FIG. 55-1

SHIM

(TABLES 56-1

OR 56-2)

CENTERED

PLATFORM

SHACKLE

1-1/2”

(REF)

“W”

(TABLES 56-1 OR 56-2)

2 PLACES

WELDING SHIMS (RH SHACKLE SHOWN)

FIG. 55-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

55

STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED)

Continued

4. Make sure platform is still at ground lev-

el. If the tip of ipover is not touching the

ground, measure and compare distance

“B” (FIG. 56-1) with TABLE 56-1 or
TABLE 56-2 to determine how much

to grind from the platform stops (FIG.
56-2).

“B”

(TABLES 56-1

OR 56-2)

TIP OF

FLIPOVER

LOWER TIP OF

RAMP FLIPOVER

THIS DISTANCE “B”

11/16” 1/16”

1-3/8” 1/8”

2-1/16” 3/16”

2-3/4” 1/4”

GRIND METAL FROM

PLATFORM STOP

GRIND TO LOWER TIP

(RAMP FLIPOVER)

TABLE 56-1

LOWER TIP OF

WEDGE FLIPOVER

THIS DISTANCE “B”

9/16” 1/16”

1-1/4” 1/8”

1-15/16” 3/16”

2-5/8” 1/4”

GRIND METAL FROM

PLATFORM STOP

GRIND TO LOWER TIP

(WEDGE FLIPOVER)

TABLE 56-2

5. Grind correct amount of metal (TABLE

56-1 or 56-2) from platform stop as
shown in FIG. 56-2.

TIP OF FLIPOVER DOES NOT TOUCH

GROUND (RAMP FLIPOVER SHOWN)

FIG. 56-1

PLATFORM

STOP

GRIND ENTIRE

SURFACE HERE

(TABLES 56-1

OR 56-2)

PLATFORM

SHACKLE

(REF)

GRINDING PLATFORM STOPS

(RH SHACKLE SHOWN)

FIG. 56-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

6. Raise the platform, then lower it to the

ground. As the platform rst touches the
ground, the tip of ipover and shackle

should touch at the same time as shown
in FIG. 56-3.

TIP OF

FLIPOVER

PLATFORM & SHACKLES TOUCH

GROUND (RAMP FLIPOVER SHOWN)

FIG. 56-3

56

STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE

`

Welding on galvanized parts gives off especially hazardous fumes. To mini-

mize hazard remove galvanizing from weld area, provide adequate ventilation,

and wear suitable respirator.

WARNING

!

CAUTION

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 equipped, a 3” wide area of paint must

be removed from all sides of the weld area before welding.

Weld each of the two mounting plates to
main frame and vehicle frame (FIG. 57-1).

VEHICLE FRAME

(TYPICAL TRUCK FRAME

SHOWN)

TYPICAL - BOTH
MOUNTING PLATES

1/4”

MOUNTING PLATE

MAIN FRAME

1/4”

FIG. 57-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

57

STEP 14 - ADJUST SAFETY HOOK (IF REQUIRED)

CHECK SAFETY HOOK FUNCTION

1. When raising platform to stowed position,

EXTENSION

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. 58-1.

LOOP ADJUSTMENT

1. If the safety hook is not positioned 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. Repeat adjustment if
required.

PLATE

SAFETY

HOOK

SAFETY

HOOK

CORRECT

POSITION

FIG. 58-1

EXTENSION
PLATE

CORRECT

POSITION

PLATFORM LOOP

(WRONG POSITION)

PLATFORM

PLATFORM LOOP

(WRONG POSITION)

BEND IN

THIS

DIRECTION

LUBRICATION (IF REQUIRED)

1. Make sure front surface of safety

hook (FIG. 58-3) is lubricated with
automotive grease. Apply grease
if required.

2. Make sure control handle rod

(FIG. 58-3) is lubricated where it
has contact with brackets. Apply
automotive grease if required.

CONTROL HANDLE ROD

(TYPICAL LUBE POINT)

58

FIG. 58-2

BRACKETS

FIG. 58-3

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

SAFETY HOOK

-FRONT SURFACE

STEP 15 - WELD ON LOCK BRACKET (IF EQUIPPED)

CAUTION

To protect the original paint system if equipped, a 3” wide area of paint must

be removed from all sides of the weld area before welding.

CAUTION

Prevent damaged grip. Finish welding rental lock before installing control
handle grip.

NOTE: Before positioning the locking bracket, make sure safety hook is hooked

correctly to platform loop (see previous step).

1. From parts box, get the 6-1/2” lock bracket

(P/N 203417), 1” inner bracket (P/N 203570),
3/8”-16 x 1” bolt and 3/8”-16 nut (if available)
shown in FIG. 59-1. Bolt inner bracket to lock
bracket with 3/8”-16 bolt and 3/8”-16 nut. Keep
nut loose so bracket can rotate.

2. Fit the half-round cut-out end of lock bracket

to control handle as shown in FIG. 59-2. Butt
the top face of inner bracket against bottom of
extension plate.

3. Position right hand (RH) side face of inner bracket

ush with RH side of extension plate (FIG. 59-2).
Weld top face of inner bracket to bottom of ex­tension plate (FIG. 59-2). Make sure there is a
1/16” gap between inner bracket and lock bracket

(FIG. 59-2). Weld lock bracket to control handle
(FIG. 59-2). Remove nut and bolt (FIG. 59-2). (If

required, a padlock or freight car-type seal can be
used to lock control handle.)

HANDLE GRIP

(BRACKET FLUSH WITH

EXTENSION PLATE)

3/8”-16 NUT

INNER

BRACKET

3/8”-16 BOLT

FIG. 59-1

LOCK

BRACKET

EXTENSION

PLATE

4. Install handle grip (parts box item)

on control handle (FIG. 59-2).

1/8”
1/8”

INNER BRACKET

(TOP FACE)

NUT

INNER BRACKET

(RH SIDE FACE)

1/16” GAP

59

BOLT

FIG. 59-2

CONTROL

HANDLE

(LOCK BRACKET)

LOCK

BRACKET

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

HALF-ROUND

CUT-OUT

1/8”

STEP 16 - VEHICLE TAILLIGHT POSITIONING

(IF REQUIRED)

NOTE: Positions are based on using taillights of 6-3/4” height by 5-3/4” width.

Larger taillights may interfere with Liftgate. Taillights and attaching hardware
are not provided with the Liftgate.

Position taillights as shown (FIGS. 60-1, 60-2 & 60-3).

TAILLIGHTS

TAILLIGHT

4”

7-3/4”

TAILLIGHT POSITIONS

(LEFT HAND SIDE VIEW)

FIG. 60-2

FIG. 60-1

TAILLIGHT HORIZONTAL SPACING,

TAILLIGHTS

23”

TOP VIEW

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

23”

FIG. 60-3

60

ATTACH DECALS

NOTE: Ensure there is no residue, dirt or corrosion where decals are attached.

If necessary, clean surface before attaching decals.

CAPACITY DECAL

(72-150 ONLY)

STOW WARNING DECAL

P/N 282847-02

RAISE/LOWER DECAL

P/N 264507

P/N 220386

CAPACITY DECAL

(TE-20 ONLY)

P/N 220387

WARNING DECAL

(2 PLACES, LH SIDE NOT SHOWN)

P/N 265736-03

WARNING & CAUTION DECAL

P/N 282522-01

NOTE: Preferred decal layout is shown, Decals on the

Liftgate are attached at the factory. If vehicle
does not permit this layout, decals in the manual
and decal kit must be applied so that they are
easily visible when approaching vehicle to
operate Liftgate. Use good common sense when
locating these decals on vehicle.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

INSTRUCTION DECAL

P/N 251867-06

FIG. 61-1

61

ATTACH DECALS - Continued

DECAL SHEET

P/N 282522-01

FIG. 62-1

62

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

TOUCHUP PAINTED OR GALVANIZED FINISH

CAUTION

Damaged cylinder seals and contaminated hydraulic uid can result from paint­ing the polished portion of the cylinder rod. To prevent damage, protect the

exposed polished portion of the cylinder rod while painting.

• 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 system, MAXON
recommends aluminum primer touchup paint kit, P/N 908134-01.

• If bare metal is exposed on galvanized portions of the Liftgate, touch up the galvanized

nish. To maintain the protection provided by the original galvanized nish, MAXON

recommends cold galvanize spray, P/N 908000-01.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

63

HYDRAULIC SYSTEM DIAGRAMS

HYDRAULIC SCHEMATIC (GRAVITY DOWN)

HYDRAULIC CYLINDER

2 GPM FLOW

CONTROL VALVE

AUX. HAND

PUMP PORT

(PLUGGED)

RETURN PORT

(PLUGGED)

VALVE A

RELIEF VALVE

(SET AT 3250 PSI)

PUMP

FILTER

PRESSURE PORT

CHECK VALVE

M

MOTOR

(REFERENCE)

RESERVOIR

VENT PORT

FILLER HOLE

(PLUGGED)

FIG. 64-1

64

DRAIN HOLE

(PLUGGED)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

HYDRAULIC SYSTEM DIAGRAMS

HYDRAULIC SCHEMATIC (POWER DOWN)

HYDRAULIC CYLINDER

PORT B - LOWER

(POWER DOWN)

2 GPM FLOW

CONTROL

VALVE

PORT A - RAISE

VALVE A

RELIEF VALVE 2

(SET AT 1100 PSI)

MOTOR

(REF)

VALVE E

FILTER

RELIEF VALVE 1

(SET AT 3200 PSI)

PUMP

RESERVOIR

DRAIN HOLE

(PLUGGED)

FIG. 65-1

AUX. HAND

PUMP PORT

(PLUGGED)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

65

ELECTRICAL SYSTEM DIAGRAMS

ELECTRICAL SCHEMATIC (GRAVITY DOWN)

CONTROL SWITCH

CABLE

ASSEMBLY

(IN MOTOR

STARTER

SOLENOID

THERMAL

SWITCH

CASING)

(UP)

WHITE BLACKGREEN

WHITE BLACKGREEN

(DOWN)

SOLENOID,

VALVE A

MOTOR

CABLE WITH

175 AMP FUSE

FIG. 66-1

66

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BATTERY

ELECTRICAL SYSTEM DIAGRAMS

ELECTRICAL SCHEMATIC (POWER DOWN)

RED

(UP)

CONTROL SWITCH

CABLE

ASSEMBLY

THERMAL

SWITCH

(IN MOTOR

CASING)

STARTER

SOLENOID

GREEN

GREEN

GREEN

(DOWN)

WHITE

WHITE

BLACK

BLACK

SOLENOID,

VALVE A

RED

SOLENOID,

VALVE E

CABLE WITH

175 AMP FUSE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BATTERY

FIG. 67-1

67

OPTIONS

OPTIONAL LIFTGATE COMPONENTS

MISCELLANEOUS KITS PART NO. GD PD

TRAFFIC CONES 268893-01 X X

MOUNTING KIT, RELOCATE PUMP (PAINTED, PUMP ASSY NOT INCLUDED) 287840-01 X

MOUNTING KIT, RELOCATE PUMP (PAINTED, PUMP ASSY NOT INCLUDED) 287840-02 X

MOUNTING KIT, RELOCATE PUMP (GALVANIZED, PUMP ASSY NOT INCLUDED) 287840-01G X

MOUNTING KIT, RELOCATE PUMP (GALVANIZED, PUMP ASSY NOT INCLUDED) 287840-02G X

EXTENSION PLATE HARDWARE KIT (96” & 102” WIDE VEH.) 283257-02 X X

STEP KITS

SINGLE STEP KIT, 72-150 & TE-20 GALVANIZED (LOW BED HEIGHT, ONLY) 285895-01G X X

SINGLE STEP KIT WITH BUMPER, 72-150 & TE-20 GALVANIZED (LOW BED HT,
ONLY)

SINGLE STEP KIT, 72-150 & TE-20 (LOW BED HEIGHT, ONLY) 285895-01 X X

SINGLE STEP KIT WITH BUMPER, 72-150 & TE-20 (LOW BED HEIGHT, ONLY) 285895-02 X X

DUAL STEP KIT, 72-150 & TE-20 (HIGH BED HEIGHT, ONLY) 285817-01 X X

DUAL STEP KIT, 72-150 & TE-20, GALVANIZED (HIGH BED HEIGHT, ONLY) 285817-01G X X

DUAL STEP KIT WITH 24” BUMPER, 72-150 & TE-20 (HIGH BED HEIGHT, ONLY) 285817-02 X X

DUAL STEP KIT WITH 24” BUMPER, 72-150 & TE-20, GALVANIZED (HIGH BED
HEIGHT, ONLY)

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” RUBBER DOCK BUMPER (DUAL STEP) 283295-01 X X

STANDARD BUMPER PADS (SINGLE STEP) 203410 X X

285895-02G X X

285817-02G X X

MECHANICAL KITS

MOUNTING BRACKET KIT 280010 X X

HAND PUMP KIT, GRAVITY DOWN 268075-01 X

EXTENSION KIT (FOR PAINTED, WELD-ON EXTENSION PLATES, 102” WIDE VEH) 282815-01 X X

EXTENSION KIT (102” WIDE VEH), 72-150 & TE-20, GALVANIZED 283134-02G X X

ELECTRICAL KITS

IN CAB ON-OFF SWITCH 250477 X X

TUK-A-WAY DUAL CONTROL KIT, GRAVITY DOWN 264845 X

TUK-A-WAY DUAL CONTROL KIT, POWER DOWN 264845-02 X

10’ EXTENSION TO POWER CABLE 264849 X X

CIRCUIT BREAKER KIT (150AMP) 251576 X X

STREET SIDE CONTROL KIT, TUK-A-WAY, GRAVITY DOWN 280265-01 X

STREET SIDE CONTROL KIT, TUK-A-WAY, POWER DOWN 280265-03 X

HAND HELD CONTROL ASSEMBLY, GRAVITY DOWN 280570-01 X

HAND HELD CONTROL ASSEMBLY, POWER DOWN 280570-03 X

GROUND CABLE, 2 GAUGE X 38’ LG. 269190-01 X X

CYCLE COUNTER KIT 280590-01 X X

FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS 282372-01 X X

TOUCH-UP PAINT KIT

TOUCH-UP PAINT (BCG) WITH ALUMINUM PRIMER, SMALL 908134-01 X X

COLD GALVANIZE SPRAY, 16 OZ 908000-01 X X

BRIGHT ZINC SPRAY PAINT, 16OZ 908100-01 X X

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

68