Page 1
SEPTEMBER 2015 INSTALLATION MANUAL TE-20 & 72-150 To find maintenance & parts information for your TE-20 & 72-150 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-20 or 72-150 buttons. Open the Maintenance Manual in the PRODUCT DOCU- MENTATION window.
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”...
Page 3
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 .............
SUMMARY OF CHANGES: M-12-04, REVISION F PAGE DESCRIPTION OF CHANGE COVER Updated REV and date of release. Added note to installers to ensure that trucks and trailers are equipped with grab handles if needed. Removed AMSOIL from the table of recommended hydraulic oil. Removed LVTS options from the OPTIONS table.
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates. See Operation Manual for operating safety requirements. WARNINGS WARNING • Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your feet are clear of the Liftgate. •...
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.
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.
PARTS BOX FOR 72-150 GRAVITY DOWN (96” WIDE, PAINTED FINISH) NOTE: To find maintenance & parts information for your TE-20 & 72-150 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-20 or 72-150 button. Open the Maintenance Manual in the PRODUCT DOCU- MENTATION window.
PARTS BOX FOR 72-150 & TE-20 GRAVITY DOWN (96” WIDE, GALVANIZED FINISH, 12 VOLT & 24 VOLT) NOTE: To find maintenance & parts information for your TE-20 & 72-150 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-20 or 72-150 button. Open the Maintenance Manual in the PRODUCT DOCU- MENTATION window.
PARTS BOX FOR 72-150 POWER DOWN (96” WIDE, PAINTED FINISH) NOTE: To find maintenance & parts information for your TE-20 & 72-150 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-20 or 72-150 button. Open the Maintenance Manual in the PRODUCT DOCU- MENTATION window.
PARTS BOX FOR 72-150 & TE-20 POWER DOWN (96” WIDE, GALVANIZED FINISH) NOTE: To find maintenance & parts information for your TE-20 & 72-150 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-20 or 72-150 button. Open the Maintenance Manual in the PRODUCT DOCU- MENTATION window.
VEHICLE REQUIREMENTS NOTE: The maximum (unloaded) operating vehicle body bed height for the 72-150 & TE-20 Liftgates equipped with wedge flipover or ramp flipover is 54”. The minimum height for the 72-150 & TE-20 Liftgates equipped with wedge flipover is 44” (loaded). The minimum height for 72-150 and TE- 20 Liftgates equipped with ramp flipover is 38”...
Page 13
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...
VEHICLE REQUIREMENTS - Continued PLATFORM WITH RAMP FLIPOVER 29” 22-1/2” 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.
Page 15
BODY FRAME 10” SPACER PLATFORM CLEARANCE TRUCK FRAME CUTOUT AREA (WITHIN DASHED LINES) 17” VEHICLE FRAME CUT FOR TE-20 & 72-150 (44” TO 54” BED HEIGHTS) FIG. 15-1 REAR SILL BODY FLOOR BODY CROSS MEMBERS 5-1/2” BODY FRAME 9” SPACER...
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 (flats), provided with parts bags, must be used.
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: •...
Page 18
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...
Page 19
STEP 1 - INSTALL EXTENSION PLATES - Continued 4” 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.
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.
Page 21
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 flush with top of rear sill. 2.
CAUTION To preserve the corrosion resistance properties of the galvanized finish, 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 flush with floor of vehicle body.
STEP 1 - INSTALL EXTENSION PLATES - Continued WELD INSTALLATION BRACKETS 4” WARNING Welding on galvanized parts gives off especially hazardous fumes. To mini- mize hazard remove galvanizing from weld area, provide adequate ventila- 5” tion, and wear suitable respirator. 1.
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. 23-1/4” NOTE: Liftgates are shipped with the locking angle set up for low bed.
Page 25
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.
Page 26
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”...
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.
Page 28
STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued 2. Select holes on top of battery box LOCK LOCK NUT WASHER frame to align mounting brackets WASHER flush to cross members. Refer CROSS to FIGS. 28-1A & 28-1B for trail- MEMBER ers and FIG.
Page 29
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 cross members (FIG.
Page 30
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.
Page 31
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.
Page 32
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) 150 AMP CIRCUIT BREAKER...
Page 33
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) FIG.
Page 34
STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued LOCK NUT, 1/4”-20 175 AMP FUSED (2 PLACES) FLAT WASHER CABLE TO PAN HEAD SCREW 1/4” PUMP BOX 1/4”-20 X 1” LG. (4 PLACES) CHARGE LINE FROM (2 PLACES) VEHICLE BATTERY GROUND CABLE...
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 TRACTOR BATTERIES, shown in FIG.
Page 36
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, first check behind the drilling surface so you do not damage any fuel lines, vent lines, brake lines or wires.
STEP 5 - CONNECT POWER CABLE 1. Unbolt the pump cover as shown in FIG. 37-1. UNBOLTING PUMP COVER FIG. 37-1...
Page 38
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. MOTOR NOTE: MAXON recommends using dielectric BATTERY SOLENOID grease on all electrical connections.
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.
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. 40- 1A. Use template shown in FIG. 40-1B. VEHICLE BODY VERTICAL POST (CURB SIDE) 18”...
Page 41
STEP 7 - INSTALL CONTROL SWITCH - Continued NOTE: MAXON recommends using dielectric grease on all electrical connections. 3. Run wiring harness under VEHICLE BODY vehicle body (see dashed VERTICAL POST line - FIG. 41-1) and up through inside of verti- cal post.
Page 42
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. CONTROL 5. If liftgate is equipped with HANDLE GRIP painted extension plate, get the CONTROL control handle grip (FIG.
STEP 8 - ADD HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydrau- lic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
Page 44
STEP 8 - ADD HYDRAULIC FLUID - Continued ISO 32 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 V32 EXXON UNIVIS N-32 DTE-13M, DTE-24, MOBIL HYDRAULIC OIL-13 TABLE 44-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS...
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.
Page 47
STEP 10 - REMOVE LOCKING ANGLE AND CHECK FOR INTERFERENCE - Continued 3. Remove floor 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.
Page 48
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 flats and spacers (FIG. 48-2). FLAT & SPACER (2 PLACES) EXTENSION PLATE REMOVING FLATS &...
Page 49
STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued NOTE: Correct any fit 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.
Page 50
STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued NOTE: Correct any fit and interference problems before continuing with installation. 8. Ensure top surface of platform and extension plate are flush at the RH & LH sides of platform (FIGS. 50-1 and 50-2).
OPENER POSITION FOR HIGH BED HEIGHT POSITION DIMENSIONS FIG. 51-1 TABLE 51-1 2. Position the opener on main frame as shown. • TE-20 Liftgates, high bed height: 21” See FIG. 51-1 and TABLE 51-1 • TE-20 Liftgates, low bed height: See FIG. 51-2 38”-46”...
Page 52
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, flipover, and the hinge in between. A damaged platform or flipover may result in personal injury and additional damage to Liftgate.
Page 53
STEP 11 - BOLT PLATFORM OPENER TO LIFTGATE - Continued 5. If the platform does not VEHICLE BED HOLE stow correctly, or if there is MOUNT HEIGHT NUMBERS interference, adjustments may 52”-54” 4, 7 TILTED be necessary. To adjust opener, 48”-52”...
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 flipover. As the platform first touches the ground, shackles and tip of flipover must touch the ground at the same time (FIG.
Page 55
STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED) - Continued 3. Make shims as needed (FIG. 55-1). Posi- 2-1/4” tion bottom edge of shim to line up with mark on shackle (see FIG. 55-2). Next, 1-1/2” weld the shim to shackle as shown in FIG. 55-2.
Page 56
STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED) Continued 4. Make sure platform is still at ground lev- el. If the tip of flipover 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 TIP OF to grind from the platform stops (FIG.
STEP 13 - FINISH WELDING LIFTGATE 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 Prevent damage to hydraulic hoses. Before welding next to hydraulic hoses, protect the hoses with a heat-resistant cover such as a welding blanket.
STEP 14 - ADJUST SAFETY HOOK (IF REQUIRED) CHECK SAFETY HOOK FUNCTION EXTENSION PLATFORM LOOP CORRECT 1. When raising platform to stowed position, PLATE (WRONG POSITION) POSITION 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.
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.
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 FIG.
• 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. •...
HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC (GRAVITY DOWN) HYDRAULIC CYLINDER 2 GPM FLOW CONTROL VALVE RETURN PORT FILLER HOLE (PLUGGED) (PLUGGED) PRESSURE PORT VENT PORT VALVE A RELIEF VALVE CHECK VALVE (SET AT 3250 PSI) AUX. HAND PUMP PORT (PLUGGED) PUMP MOTOR (REFERENCE) FILTER...
HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDER 2 GPM FLOW CONTROL VALVE PORT B - LOWER PORT A - RAISE (POWER DOWN) VALVE A RELIEF VALVE 2 (SET AT 1100 PSI) VALVE E RELIEF VALVE 1 (SET AT 3200 PSI) AUX.
ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC (GRAVITY DOWN) CONTROL SWITCH (DOWN) (UP) WHITE GREEN BLACK WHITE GREEN BLACK CABLE ASSEMBLY THERMAL SWITCH SOLENOID, (IN MOTOR VALVE A CASING) STARTER SOLENOID CABLE WITH 175 AMP FUSE MOTOR BATTERY FIG. 66-1...
ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC (POWER DOWN) BLACK (DOWN) (UP) WHITE CONTROL SWITCH BLACK WHITE GREEN GREEN CABLE ASSEMBLY THERMAL SOLENOID, SOLENOID, SWITCH VALVE E VALVE A (IN MOTOR CASING) STARTER SOLENOID GREEN CABLE WITH 175 AMP FUSE BATTERY FIG. 67-1...
Need help?
Do you have a question about the TE-20 and is the answer not in the manual?
Questions and answers