installation manual conventional - maxon · pdf file11921 slauson avenue. santa fe springs,...

11921 Slauson Avenue.Santa Fe Springs, CA. 90670(800) 227-4116

TG-150 LMVTG-20 LMV

INSTALLATION MANUAL

C MAXON Lift Corp. 2000

CONVENTIONALLIFTLIFTLIFTLIFTLIFTGAGAGAGAGATE SERIESTE SERIESTE SERIESTE SERIESTE SERIES

M-99-44REV. 2APRIL. 2000

LIFT CORP.

11921 Slauson Ave.Santa Fe Springs, CA. 90670

CUSTOMERSERVICE:TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116

FAX: (888) 771-7713

WARRANTYPOLICY&PROCEDURE

NOTE: Check with Customer Service for updated versionsof Manuals on an annual basis.

NEWLIFTGATEWARRANTYTerm ofWarranty: 2 Years fromDate of In-ServiceType of Warranty: Full Parts and Labor

MAXON agrees to replace any components which are found to be defective during the first 2years of service, and will reimburse for labor based onMAXON�s LiftgateWarranty Flat Rate LaborSchedule. (Call MAXONCustomer Service for a copy).

All claims for warranty must be received within 30 Days of the repair date, and include thefollowing information:

1. LiftgateModel Number2. Liftgate Serial Number3. Detailed Description of Problem4. CorrectiveAction Taken, and Date of Repair.5. Parts used for Repair, IncludingMAXONPart Number(s).6. MAXONR.M.A. # and/orAuthorization # if applicable (see below).7. Person contacted at MAXON if applicable.

All warranty repairs must be performed by an authorized MAXONwarranty station. For majorrepairs, MAXONCustomer Servicemust be notified and an �Authorization Number� obtained. Majorrepairs would generally be considered repairs made to the structural assembly of the liftgate and/orrepairs not outlined in the MAXON LiftgateWarranty Flat Rate Schedule.

Major components (i.e. hydraulic pumps, cylinders, valves, or failed structural parts) must bereturned, freight pre-paid, prior to the claim being processed. To ensure timely processing of thesewarranty claims, an R.M.A. (ReturnedMerchandiseAuthorization) number must be obtained fromMAXONCustomer Service prior to the return of any defective part. Defective Parts must be returnedwithin 60 days of the claim date for consideration to:

MAXONLift Corp.16205 DistributionWay, Cerritos, CA90703

Attn:RMA#__MAXON�s warranty policy does not include the reimbursement for travel time, towing, vehicle

rental, service calls, oil, batteries, defects due to misuse or abuse, or loss of income due to downtime.Fabrication of parts, which are available fromMAXON, are also not covered.

MAXON�s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of aproblem.

PURCHASEPARTWARRANTYTerm of Warranty: 1 Year from Date of PurchaseType ofWarranty: Part Replacement

MAXONwill guarantee all returned genuine replacement parts upon receipt and inspection ofparts and invoice.

Table of ContentsINTRODUCTION................................................................................... PAGE 4

TRUCK FRAME CUTOUT .................................................................... PAGE 5

CYLINDER LOCK STRAP .................................................................... PAGE 6

PLATFORM INSTALLATION ................................................................. PAGE 7

WELDING LIFTGATE TO VEHICLE ..................................................... PAGE 8

CONTROL SWITCH MOUNTING ....................................................... PAGE 10

POWER CABLE INFORMATION ........................................................ PAGE 11

CONTROL SWITCH GRAVITY DOWN............................................... PAGE 12

PUMP ENCLOSURE INSTALLATION................................................. PAGE 13

HARNESS & SWITCH ASSEMBLY .................................................... PAGE 14

WIRE CONNECTIONS ....................................................................... PAGE 15

HYDRAULIC ASSEMBLY.................................................................... PAGE 16

BUMPER INSTALLATION ................................................................... PAGE 17

ASSEMBLY OF PLATFORM CLOSER ............................................... PAGE 18

PLATFORM ADJUSTMENT ................................................................ PAGE 19

PLATFORM SHIMING......................................................................... PAGE 20

FIXED RAMP INSTALLATION INSTRUCTIONS ................................ PAGE 21

DECALS .............................................................................................. PAGE 22

SAFETY CHAIN LATCH...................................................................... PAGE 23

LOW VOLTAGE / THERMAL SWITCH (LVTS) ................................... PAGE 24

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PAGE 4

INTRODUCTION

This publication contains the information required to install the followingmodels and their options:

TG-150 LMV & TG-20 LMVwith 1500 and 2000 pound capacities respectively. If there is doubt regardingthe suitability of these lifts being installed on the vehicle, or any portion ofthese instructions that you do not understand, please contact the MAXONCustomer Service Department for consultation.

BEFORE YOU START!The dimension of the open liftgate platform length must be added to the

body length when considering proper weight distribution on the truck chassis.In other words, be mindful of the possibility that a loaded liftgate could raisethe front wheels off of the ground.

Unauthorized modification to this equipment may cause failure or createhazards in it�s use that are not foreseen during installation. These changesshould be discussed with our Engineering Department before being under-taken.

CAUTION!

Bed height to ground requirements are: 34� Laden to 50� Unladen.These lifts may be installed on bodies with swing type doors.

Any additional painting on the cylinder rods that retractbeyond the seals, may cause premature failure and will void thewarranty on the cylinders.

Installation of liftgates may obstruct the visibility of existingconspicuity devices. It is the responsibility of the installer to in-sure the vehicle meets all conspicuity requirements.

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PAGE 5

TRUCK FRAME CUTOUT

5�

5�

10�

TOP OF VEHICLE FLOOR

VEHICLE FRAME

VEHICLE FRAME

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CYLINDER LOCK STRAP

1. There are two sets of pin holes for the Cylinder Lock Strap. The shorterset of holes (23-1/4� center to center), are for bed heights of 40� to 50�from the ground. (This will be the standard setting from the factory). Whilethe longer set of holes (24-1/2� center to center), are for bed heights of34� to 39� from the ground.

2. Verify that the Cylinder Lock Strap is set for the proper bed height prior toinstallation.

3. The Cylinder Lock Strap must not be removed until the unit has beenwelded to the vehicle, the wiring to the pump has been completed, and thehydraulic system has been activated to fill the hoses and cylinders underpressure.

23-1/4�

FactorySetting

Cylinder LockStrap


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PAGE 7

Position the Platform onto a stand.Raise the lifting unit and secure the Shacklesto the Platform with the two (2) Hinge Pins.Be certain the Torsion Spring is positioned asshown.

PLATFORM INSTALLATION

260830Pin, 1 x 6.75�

252685Pin, 1 x 13.75�

Torsion Spring

ShackleWeldment

ShackleWeldment

Lifting Unit

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WELDING LIFTGATE TO VEHICLE

1. The Platform should becentered with the vehiclebed. Tack Weld 1/2 of thescrap steel to the Platform.Let the other half of the flatrest on the vehicle bed. CL

Scrap SteelMin. 1/4� Thick

x 6� Lg.(Not Provided)

2. Burn a hole in a 1�x 3� Channel.Weld the Channel on thecenterline of the platform, justover the pivot holes. Hoist andJack the unit into position, withthe rear edge of the Platform asshown.

CHANNELTOP OF VEHICLE

BED

FLOORJACK

HINGE PINS(SHOULD BEAPPROX.90° TO VEHICLEFLOORASSHOWN.) 50� MAX.

34� MIN.

Tack WeldTyp. Both

Sides

Approx. 10�(Typ.)

NOTE: If a hoist is not available,a forklift may be used tosupport the platform duringthis operation.

90°


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PAGE 9

WELDING LIFTGATE TO VEHICLE

VEHICLE FRAME

MOUNT PLATES

1/4

1/4ALLAROUNDBOTH SIDESBOTH PLATES

The Mount Plates are shipped with a chassis spacing of 34�. For chas-sis spacing greater than 34�, burn off the tack welds and re-position theplates as needed.

IMPORTANT!Mount Plates are only tack welded when shipped fromthe factory. Complete the welds as shown before using.

ALLAROUNDBOTH SIDESBOTH PLATES

29�

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CONTROL SWITCH MOUNTING

2. FLATBED TRUCKS ONLY!The surface of the side railshould be at least 2-1/4� tall.Center the holes in the middleof the side rail and drill to thedimensions shown.

Approx.18�

1.78�

.89�

Drill.75� Dia.

Drill #21 (.159� Dia.)(2 Places)1. The Control Switch will

be mounted on thevertical post of thevehicle. The surface ofthe vertical post shouldbe at least 2-1/4� wideto accomodate theswitch. Center theholes on the verticalpost to the dimensionsshown.Positioning theswitch on the rear faceof the vertical cornerpost may result in theoperators hand beingpinched or crushed bythe closing platform.Make certain that theswitch is on the outsideof the corner post."

1-1/8� M

in.

NOTE: Positioning the switch onthe rear face of the vertical cornerpost may result in the operatorshand being pinched or crushed bythe closing platform. Make certainthat the switch is on the outside ofthe corner post


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PAGE 11

POWER CABLE INFORMATION

A proper crimp is one which does not have an air gap between the cableand the copper end fittings after crimping. The crimped end fitting shall nothave any cracks.

Proper sized crimping dies shall be used with a hydraulic or manualcrimping tool. Crimping dies which are struck with a hammer are not accept-able for initial installation, and should be used only in the case of an emer-gency repair. Heat Shrink tubing is provided and must be installed at each endfitting.

CRIMPING

For Trucks, route the cable along the chassis frame flange. Use cautionwhen routing through or around chassis cross members to avoid sharp edgeswhich could wear through the cable jacket. MAXON supplies cable installationclips as shown in Fig. 1.

For Trailers, clamps are provided in the Trailer Kit and can be bolted tothe trailer cross members. This allows the cable to run under the cross mem-bers. See Fig. 2.

Extra Heavy DutyCrimping Tool Never use a Hammer to flatten

the End Fitting when installingon Power Cable

ROUTING

FIGURE 1 FIGURE 2

2� to 3�Cable

Clamp

Heat Shrink Tubing

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CONTROL SWITCH GRAVITY DOWN

Assemble Switch to the vertical post as shown.

HarnessAssemblyP/N 264472

Switch & CableAssemblyP/N 264346

To Switch

DecalP/N 264507

LOWER

RAISE

P/N 264507

Battery Cable Assembly (32� Std.)(Includes Replacement Fuse Kit)

P/N 264422

200AMP Replacement FuseKit (P/N 264687)

Short End toVehicle Battery

CableAssembly

Extension Cable Assembly

Long End to MotorSolenoid

Do not attach cable tobattery until liftgate iscompletely installed.

WARNING

STIKELBACYRETTABELBAILIAVALANOITIDDA STIKELBACYRETTABELBAILIAVALANOITIDDA STIKELBACYRETTABELBAILIAVALANOITIDDA STIKELBACYRETTABELBAILIAVALANOITIDDA STIKELBACYRETTABELBAILIAVALANOITIDDA

TRAP TRAP TRAP TRAP TRAPREBMUN

YLBMESSAELBAC'04 YLBMESSAELBAC'04 YLBMESSAELBAC'04 YLBMESSAELBAC'04 YLBMESSAELBAC'04 848462 848462 848462 848462 848462

YLBMESSAELBACNOISNETXE'01 YLBMESSAELBACNOISNETXE'01 YLBMESSAELBACNOISNETXE'01 YLBMESSAELBACNOISNETXE'01 YLBMESSAELBACNOISNETXE'01 948462 948462 948462 948462 948462


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PAGE 13

PUMP BOX

COVER

MAINFRAME

PUMP MOUNTBRACKET

PUMP ENCLOSURE INSTALLATION

Bolt the Pump Box to the Mount Bracketusing (4) 1/2-13 x 1� Soc. Hd. Capscrews(P/N 900036-5), (4) 1/2� Flat Washers(P/N 902000-14), and (4) 1/2-13 NylockNut (P/N 901010). Hardware found inParts Box.

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HARNESS & SWITCH ASSEMBLY

Switch & CableAssemblyP/N 264346

Harness AssemblyP/N 264472

Switch Boot SealP/N 250876

REDWHT

RED

WHT

YEL

YEL

Switch GasketP/N 264589

Screw, self-tapping#10 x 5/8�P/N 030453


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PAGE 15

WIRE CONNECTIONS

REDRED

WHT

YEL

ABC

PUMP BOX

GND

FUSE HOLDER(P/N 263801)

CONNECTOR(P/N 907021)

MOTOR SOLENOID

SOLENOID

WHT THERMISTOR(Part of Motor)

BATTERYCABLE

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HYDRAULIC ASSEMBLY

PUMP

PRESSUREHOSE

PLASTIC RETURNHOSE

PRESSUREHOSE

(P/N 263714-01)

PLASTICRETURN HOSE(P/N 905239-01)

ELBOW, BRASS3/8�NPT x 3/8�TUBE

(P/N 905237)

ELBOW, BRASS3/8�NPT (M) x 3/8�NPT (F)

(P/N 227004)

PRESS. CNTRL.VALVE

(P/N 251739)

NOTE:Do not use liquid sealant

on these fittings

NOTE:Apply Sealant toconnections perinside back coverof this manual


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PAGE 17

BUMPER INSTALLATION

WELD TO VEHICLE,

TOP & BOTTOM

18� (TYP. 2 PLACES)

(Not Used on Flat Bed Installations)

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ASSEMBLY OF PLATFORM CLOSER

Pushing ArmAdjust Assembly

201966 Cam

Yoke Roller261455 &

261474-01

Roller & Brng.

261454

Spacer

Sleeve

040615

3/8-16 x 3� Lg.

030955

3/8-16 Lock

NutPushing Arm

Adjust Assembly

(Same Parts as

Other Side)


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PAGE 19

PLATFORM ADJUSTMENT

The Platform, when properly adjusted, should be in a vertical positionapproximately 1� from the Corner Post or �Swing Door� hardware, beforefinally closing against the bumpers. If this is not happening, adjust the Plat-form as follows:

1. Raise the Platform in the open position againstthe vehicle. ON ONE SIDE ONLY, remove theRoll Pin and Hinge Pin as shown to the right.

2. Use the Hinge Pin to twist the Bolt &Bushing Weldment in 1/4� increments toachieve the desired adjustment. Place theHinge Pin back into the original configura-tion without the Roll Pin and lower the Plat-

3. Once this side of the Platform isadjusted to the desired setting,replace the Hinge Pin and Roll Pin.Measure the distance from the endof the Adjusting Arm to the centerof the Bolt & Bushing Weldment.Using the same procedure as de-scribed above, adjust the oppositeside to the same measurement.

form enough to engage the handle to the closingprocess. The closed Platform should be vertical andflush with the bumpers. Repeat if needed.

HINGE PIN

ROLL PINHINGE PIN

BOLT &BUSHING

WELDMENT

�X�

ADJUSTINGARM

BOLT &BUSHINGWELDMENT

ADJUST

S TILT

AWAYFRO

M

BODY.

ADJUS

TSTILT

TOWARD BODY.

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PLATFORM SHIMING

2-1/2� Max.

The Platform should reflect the illustration abovewith the tip of the Platform as much as 2-1/2� higher thanthe vehicle floor. This dimension will vary, according tobed height. Before adjusting, check platform at bothupper and lower limits of travel. If a ramp is attached tothe platform, it should touch the ground.

WELD SHIMS HERE TO ADJUSTPLATFORM TIP UPWARD.

PLATFORM TIP


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PAGE 21

FIXED RAMP INSTALLATION INSTRUCTIONS

1. Lower the opened Platform to the ground.

2. Center the Fixed Ramp against the Platformsection, with the Diamond Plate surfaces flush,and the tip of the Fixed Ramp on the ground.Weld the top and bottom of the Fixed Ramp tothe Platform as indicated.

1/4� x 1�Weld overlength ofRamp top &bottom.

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DECALS

THE MAXIMUM CAPACITY OFTHIS LIFT IS

WHEN THE LOAD ISCENTERED ON THE LOADCARRYING PLATFORM

1500 LBS.P/N 220386

THE MAXIMUM CAPACITY OFTHIS LIFT IS

WHEN THE LOAD ISCENTERED ON THE LOADCARRYING PLATFORM

2000 LBS.P/N 220387

CACACACACAUTION!UTION!UTION!UTION!UTION!DO NOT USE BRAKE FLUID...USE: No. 10W S.A.E. Motor Oil

Hydraulic Hoist OilType �A� Transmission Fluid

�Fill only when lift is lowered toground� P/N 801358

CACACACACAUTION!UTION!UTION!UTION!UTION!STSTSTSTSTAND CLEARAND CLEARAND CLEARAND CLEARAND CLEAR

P/N 050092

These Decals should be read and completelyunderstood before operating the unit. They shouldalso be kept clean and readable at all times. If anydecal should become detached from the vehicle, ordefaced, it must be replaced. Free replacements areavailable from: MAXON Lift Corp., Parts Department.

DECAL #050092

DECAL #264081

DECAL #220386or #220387

Locate DECAL #801358on Pump Box

Sugessted DecalLocations

WARNINGREAD CAREFULLY

� Improper operation of this Lift can result in serious personal injury.Do not operate unless you have been properly instructed and haveread, and are familiar with the operating instructions. If you do nothave a copy of the instructions, please obtain them from youremployer, distributor, or lessor, before you attempt to operate Lift.� Be certain that the vehicle is properly and securely braked beforeusing the Lift.� Always inspect this Lift for maintenance or damage before using it. Ifthere are signs of improper maintenance, damage to vital parts, orslippery Platform surface, do not use the Lift until these problemshave been corrected.� Do not overload the Lift. The load limit is based on evenly distrib-uted cargo over the entire Platform surface. If you are using a palletjack, be sure it can be maneuvered safely. Do not operate a forklift onthe Platform or travel with the platform in an open position at any time.� Load should be placed in a stable position close to the edge of thePlatform nearest the truck. The heaviest portion of the load shouldnever be placed beyond the center of the Platform away from thetruck.� Never allow yourself, a helper, or bystander to stand in a positionwhere a falling load could land on either of you. Also do not allow anypart of yours or your helper�s body to be placed under, within, oraround any portion of the moving liftgate, or it�s mechanisms, or in aposition that would trap them between the platform and the ground ortruck when the liftgate is operated.� If a helper is riding the Platform with you, make sure you are bothdoing so safely and that you are not in danger of coming in contactwith any moving or potentially moving obstacles. USE GOODCOMMON SENSE. If load appears to be unsafe, do not lift or lower it.

MAXON LIFT CORP. PART NO. 264081

! !LOWER

RAISE

P/N 264507


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PAGE 23

SAFETY CHAIN LATCH

SAFETY CHAIN IN USE

One safety chain, one repair link, and one hasp are supplied with

the unit Parts Box. The hasp is to be welded to the truck corner post

(curb side), approximately 1� above the hasp welded to the platform.

Install the chain to the repair link, and the link to the hasp. Squeeze

the ends of the link together. Do Not Weld!

IMPORTANT! Loop �S� hook from

underneath the hasp as shown.

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LOW VOLTAGE / THERMAL SWITCH (LVTS)

Low Voltage/Thermal Switch

(LVTS)P/N 905197

Wire AssemblyP/N 264546

Wire HarnessP/N 264548

Extension WireAssemblyP/N 264755

WireHarness

Extension WireAssembly

LVTS

WireAssembly

ABCD

(IF EQUIPPED ON LIFTGATE)

SPLICE

ABCD


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PAGE 25

LOW VOLTAGE / THERMAL SWITCH (LVTS)(IF EQUIPPED ON LIFTGATE)

Instruction DecalP/N 264776

Instruction DecalP/N 264776

Switch DecalP/N 264775

Suggested DecalLocation

Top side

Decals should be read andcompletely understood beforeoperating the unit. They shouldalso be kept clean and readableat all times. If any decal becomesdetached from the vehicle, or isdefaced, it must be replaced. Freedecal replacements are availablefrom: MAXON Lift Corp., PartsDepartment.

Clean all threads with a soft brush and a suitable cleaning solvent.

Dry threads thoroughly with compressed air or shop towel.

Apply the Liquid Sealant (Compound PLS 2), to the external threads ofthe Male Connector.

Assemble the fitting and torque it to the prescribed value.

Check for leakage. If leakage exists, remove the fitting and return toStep # 1.

If fitting is loosened or removed, return to Step # 1.

1.

2.

3.

4.

5.

6.

P/N 260798-02

LIQUID SEALANT APPLICATION

NOTE:Apply Sealant to NPT threads only!

installation manual conventional - maxon · pdf file11921 slauson avenue. santa fe springs,...

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