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

72-150 LMVTE-20 LMV

C MAXON Lift Corp. 2000

MAINTENANCE MANUAL

M-99-42REV. 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

LIFTGATE TERMINOLOGY .................................................................. PAGE 4

WARNING ............................................................................................. PAGE 5

PERIODIC MAINTENANCE CHECKLIST............................................. PAGE 6

DECALS ................................................................................................ PAGE 7

PLATFORM ADJUSTMENT .................................................................. PAGE 8

HYDRAULIC ASSEMBLY...................................................................... PAGE 9

72-150LMV / TE-20LMV ASSEMBLY.................................................. PAGE 10

PUMP ASSEMBLY, GRAVITY DOWN................................................. PAGE 12

CONTROL SWITCH GRAVITY DOWN............................................... PAGE 14

HARNESS & SWITCH ASSEMBLY .................................................... PAGE 15

SAFETY HOOK ................................................................................... PAGE 16

WIRE CONNECTIONS, GRAVITY DOWN ......................................... PAGE 17

LOW VOLTAGE / THERMAL SWITCH (LVTS) ................................... PAGE 18

TROUBLESHOOTING............................................ PAGE 20PLATFORM WILL NOT RAISE ........................................................... PAGE 21

PLATFORM RAISES BUT LEAKS DOWN.......................................... PAGE 22

PLATFORM RAISES PARTIALLY AND STOPS.................................. PAGE 23

LIFTGATE WILL NOT LIFT RATED CAPACITY.................................. PAGE 24

PLATFORM RAISES SLOWLY ........................................................... PAGE 25

PLATFORM WILL NOT LOWER ......................................................... PAGE 26

11921Slauson

Ave.Santa

FeSprings,C

A.90670

(800)227-4116

FAX(888)

771-7713

PAGE 4

INTRODUCTIONThis publication contains the information required to maintain the 72-150LMVand the TE-20LMV If there is any doubt regarding the suitability of these liftsbeing maintained on it�s intended vehicle, or any portion of these instructionsthat you do not understand, please contact the MAXON Customer ServiceDepartment for consultation.

Unauthorized modification to this equipment may cause premature failureor create hazards in its use that are not foreseen at the time of installation.These kinds of changes should be discussed with our Engineering Depart-ment before being undertaken.

LIFTGATE TERMINOLOGY

FLIPOVER

PLATFORM

RUBBERBUMPER

DOCKBUMPER

LIFTCYLINDER

MAINFRAME

LIFTFRAME

PARALLELARM

CONTROLSWITCH

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

FAX(888)771-7713

PAGE 5

1. Read the Maintenance Manual and understand it thoroughly before any maintenance ofthis unit is done.

2. Read the YELLOW urgent warning decal on the side of the vehicle close to the unit beforeoperating.

3. If decals are dirty, clean them. If decals are defaced or missing, replace them. Free replace-ments are available from the manufacturer. See information at the end of the Warnings

4. Be aware that the safety and location of other people or objects should be consideredbefore operation of this unit. Stand to one side of platform while operating this unit. Do notstand in a position that would put you in the path of any moving vehicles around you.

5. Do not stand under, or have any foreign object under the Platform when lowering. Be surethat the lowering of the Platform and/or Flipover will miss your feet!

6. Keep fingers, hands, arms, legs, and feet clear of moving parts when operating this unit.

7. If during your maintenance procedure, it becomes necessary to ride the platform, keep yourfeet and any foreign objects clear of the rear edge of the platform. Otherwise your feet orthe foreign objects could become trapped between the edge of the platform and the vehiclebed.

8. Inspect all Roll Pins monthly, to insure that they are not broken. Replace if broken.

9. Inspect all hydraulic hoses and fittings annually. Check for cracks and deterioration, andreplace if necessary.

10. Disconnect battery when replacing parts or servicing.

11. Do not allow children to ride, play with, or operate this unit.

12. In the event of an emergency while operating the unit, release the toggle switch and the unitwill stop immediately.

13. A properly installed Lift should operate smoothly and the only noise during the operation ofthis unit should be from the Pump Unit during the raising of the Platform. Any scraping,grating or audible indications of rough operation will need investigating. The cause will needresolving before any further deterioration of performance occurs.

14. Use only Maxon Authorized Parts for replacement. Replacement parts should be orderedfrom:

MAXON LIFT CORP. Parts Department11921 Slauson Ave., Santa Fe Springs, Ca. 90670

Phone: (800) 227-4116

WARNING

11921Slauson

Ave.Santa

FeSprings,C

A.90670

(800)227-4116

FAX(888)

771-7713

PAGE 6

* COLD WEATHER OPERATION

OIL SPECIFICATIONS:Grade ISO-(32)

Gravity, API - 29.5 DegreesPour Point, F- (-54 Degrees)

VISCOSITY:@ 40 Degrees C - 31.2 cSt@100 Degrees C - 6.2 cStVISCOSITY INDEX - 154 VIFlash Point, F - 325 Degrees

Visually check the complete unit for excessive wear, worn parts or broken welds.Check all Hinge Pins for excessive wear or broken welds. For parts replacement,see the Assembly Breakdown Drawings.

PERIODIC MAINTENANCE CHECKLIST

Check the oil in the Pump Reservoir. The oil should be Grade ISO-(32) HydraulicFluid. *See below for Cold Weather operation.

Check Hoses and Fittings for scuffing and leaks. Replace if necessary.

Check the electrical wiring for worn insulation, and the terminals for corrosion andsecure fit.

Check all bolts for tightness.

Check that all Warning Decals are in place and readable.

Check that all roll pins are properly installed. Replace if necessary.

Inspect the Hook & Chain Assembly for proper operation.

Annually

Quarterly

Six MonthsVisually check the Platform Hinge Pins for excessive wear or broken welds. Forparts replacement, see the Assembly Breakdown Drawings.

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

FAX(888)771-7713

PAGE 7

2000 LBS.

P/N 220387

THE MAXIMUM CAPACITY OFTHIS LIFT IS

WHEN THE LOAD ISCENTERED ON THE LOADCARRYING PLATFORM

THE MAXIMUM CAPACITY OFTHIS LIFT IS

WHEN THE LOAD ISCENTERED ON THE LOADCARRYING PLATFORM

1500 LBS.

P/N 220386

DECALS

These Decals should beread and completely understoodbefore operating the unit. Theyshould also be kept clean andreadable at all times. If any decalshould become detached fromthe vehicle, or defaced, it mustbe replaced. Free replacementsare available from: MAXON LiftCorp., Parts Department.

Suggested DecalLocations

OperatingDecal

WarningDecal

CapacityDecal

Up/DownDecal

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

! !

LIFTGATE OPERATION

P/N 263872OFF

ON

LOWER

RAISE

P/N 264507

Operating InstructionsUnits

1

2

3

4

5

LIFT CORP. P/N 251867

To Tuck unit away,reverse steps 1,2,& 3.

Activate toggleswitch to Raise orLower platform

OpenFlipover

OpenPlatform

Depress handle& activate ToggleSwitch to lowerstowed liftgate.

This point musttouch ground.

This Decal isfor cab cut-offoption and islocated insidethe Cab.

11921Slauson

Ave.Santa

FeSprings,C

A.90670

(800)227-4116

FAX(888)

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PAGE 8

PLATFORM ADJUSTMENT

Before adjusting platform, remove and inspect each of the hinge pins forwear. (Ref. Hinge Pin Location Sheet) If any are worn, replace them. Alsocheck for structural damage. Either condition could make the platform appearin need of adjustment. The Platform should reflect the YES illustrations belowwith the Platform as much as 2-1/2� higher than the extension plate or floorbed. There should be NO SAG in the Platform as pictured below.

Shackles also rest on theground. If Platform is straight, noshimming is required. If Platformsags, appropriate shims must beadded to both sides. Shims canbe placed in either or both posi-tions.

YES

YES NO

NO

NO SAGSAG

WELD SHIMS

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

FAX(888)771-7713

PAGE 9

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

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116FAX(888)771-7713

PAGE10

72-150LMV/TE-20LM

VASSEM

BLY

1

23 4,5

2

3

6

7

8

5

5

5

5

5

5

55

13

1415

10,912,9

11,9

12,9

12,9

12,9

24

20

19 21

23

18,9

18,9

16,17

12,912,9

MAXMAXMAXMAXMAXONONONONON

22

25

26,27

28

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

FAX(888)771-7713

PAGE 11

72-150LMV / TE-20LMV ASSEMBLYMETI METI METI METI METI .YTQ .YTQ .YTQ .YTQ .YTQ .ONTRAP .ONTRAP .ONTRAP .ONTRAP .ONTRAP NOITPIRCSED NOITPIRCSED NOITPIRCSED NOITPIRCSED NOITPIRCSED

11111 11111210502 210502 210502 210502 210502 )"4+"01x"27(YLBMESSAPMARREVOPILF )"4+"01x"27(YLBMESSAPMARREVOPILF )"4+"01x"27(YLBMESSAPMARREVOPILF )"4+"01x"27(YLBMESSAPMARREVOPILF )"4+"01x"27(YLBMESSAPMARREVOPILF

10-210502 10-210502 10-210502 10-210502 10-210502 )"4+"01x"48(YLBMESSAPMARREVOPILF )"4+"01x"48(YLBMESSAPMARREVOPILF )"4+"01x"48(YLBMESSAPMARREVOPILF )"4+"01x"48(YLBMESSAPMARREVOPILF )"4+"01x"48(YLBMESSAPMARREVOPILF

22222 11111 274040 274040 274040 274040 274040 )8EDARG(.GL"4/1-1x02-2/1,TLOB )8EDARG(.GL"4/1-1x02-2/1,TLOB )8EDARG(.GL"4/1-1x02-2/1,TLOB )8EDARG(.GL"4/1-1x02-2/1,TLOB )8EDARG(.GL"4/1-1x02-2/1,TLOB

33333 11111 968302 968302 968302 968302 968302 02-2/1,TUN 02-2/1,TUN 02-2/1,TUN 02-2/1,TUN 02-2/1,TUN

44444 1111110-389262 10-389262 10-389262 10-389262 10-389262 )"4+"22x"27(YLBMESSAMROFTALP )"4+"22x"27(YLBMESSAMROFTALP )"4+"22x"27(YLBMESSAMROFTALP )"4+"22x"27(YLBMESSAMROFTALP )"4+"22x"27(YLBMESSAMROFTALP

20-389262 20-389262 20-389262 20-389262 20-389262 )"4+"22x"48(YLBMESSAMROFTALP )"4+"22x"48(YLBMESSAMROFTALP )"4+"22x"48(YLBMESSAMROFTALP )"4+"22x"48(YLBMESSAMROFTALP )"4+"22x"48(YLBMESSAMROFTALP

55555 66666 30-619062 30-619062 30-619062 30-619062 30-619062 EBULFLES"2x"1,GNIRAEB EBULFLES"2x"1,GNIRAEB EBULFLES"2x"1,GNIRAEB EBULFLES"2x"1,GNIRAEB EBULFLES"2x"1,GNIRAEB

66666 11111 10-979262 10-979262 10-979262 10-979262 10-979262 HLYLBMESSAELKCAHS HLYLBMESSAELKCAHS HLYLBMESSAELKCAHS HLYLBMESSAELKCAHS HLYLBMESSAELKCAHS

77777 11111 20-979262 20-979262 20-979262 20-979262 20-979262 HRYLBMESSAELKCAHS HRYLBMESSAELKCAHS HRYLBMESSAELKCAHS HRYLBMESSAELKCAHS HRYLBMESSAELKCAHS

88888 11111 046102 046102 046102 046102 046102 .GL"6x"2/1NOISROT,GNIRPS .GL"6x"2/1NOISROT,GNIRPS .GL"6x"2/1NOISROT,GNIRPS .GL"6x"2/1NOISROT,GNIRPS .GL"6x"2/1NOISROT,GNIRPS

99999 4141414141 614122 614122 614122 614122 614122 .GL"2x"8/3,NIPLLOR .GL"2x"8/3,NIPLLOR .GL"2x"8/3,NIPLLOR .GL"2x"8/3,NIPLLOR .GL"2x"8/3,NIPLLOR

0101010101 11111 189262 189262 189262 189262 189262 HRMRALELLARAP,NIP HRMRALELLARAP,NIP HRMRALELLARAP,NIP HRMRALELLARAP,NIP HRMRALELLARAP,NIP

1111111111 11111 038062 038062 038062 038062 038062 HLMRALELLARAP,NIP HLMRALELLARAP,NIP HLMRALELLARAP,NIP HLMRALELLARAP,NIP HLMRALELLARAP,NIP

2121212121 686252 686252 686252 686252 686252 EMARFTFIL,NIP EMARFTFIL,NIP EMARFTFIL,NIP EMARFTFIL,NIP EMARFTFIL,NIP

3131313131 11111 10-569262 10-569262 10-569262 10-569262 10-569262 HL,MRALELLARAP HL,MRALELLARAP HL,MRALELLARAP HL,MRALELLARAP HL,MRALELLARAP

4141414141 11111 20-569262 20-569262 20-569262 20-569262 20-569262 HR,MRALELLARAP HR,MRALELLARAP HR,MRALELLARAP HR,MRALELLARAP HR,MRALELLARAP

5151515151 11111 469262 469262 469262 469262 469262 YLBMESSAEMARFTFIL YLBMESSAEMARFTFIL YLBMESSAEMARFTFIL YLBMESSAEMARFTFIL YLBMESSAEMARFTFIL

6161616161 11111273062 273062 273062 273062 273062 )051-27("01x"3REDNILYC )051-27("01x"3REDNILYC )051-27("01x"3REDNILYC )051-27("01x"3REDNILYC )051-27("01x"3REDNILYC

293062 293062 293062 293062 293062 )02-ET("01x"2/1-3REDNILYC )02-ET("01x"2/1-3REDNILYC )02-ET("01x"2/1-3REDNILYC )02-ET("01x"2/1-3REDNILYC )02-ET("01x"2/1-3REDNILYC

7171717171 11111KS-273062 KS-273062 KS-273062 KS-273062 KS-273062 )051-27(TIKLAES )051-27(TIKLAES )051-27(TIKLAES )051-27(TIKLAES )051-27(TIKLAES

KS-293062 KS-293062 KS-293062 KS-293062 KS-293062 )02-ET(TIKLAES )02-ET(TIKLAES )02-ET(TIKLAES )02-ET(TIKLAES )02-ET(TIKLAES

8181818181 22222 598162 598162 598162 598162 598162 REDNILYC,NIP REDNILYC,NIP REDNILYC,NIP REDNILYC,NIP REDNILYC,NIP

9191919191 11111 101462 101462 101462 101462 101462 YLBMESSAEMARFNIAM YLBMESSAEMARFNIAM YLBMESSAEMARFNIAM YLBMESSAEMARFNIAM YLBMESSAEMARFNIAM

0202020202 11111 640622 640622 640622 640622 640622 RENEPOMROFTALP RENEPOMROFTALP RENEPOMROFTALP RENEPOMROFTALP RENEPOMROFTALP

1212121212 11111 143512 143512 143512 143512 143512 YLBMESSAKOOHYTEFAS YLBMESSAKOOHYTEFAS YLBMESSAKOOHYTEFAS YLBMESSAKOOHYTEFAS YLBMESSAKOOHYTEFAS

2222222222 11111 606102 606102 606102 606102 606102 ESAELERKOOH,ELDNAH ESAELERKOOH,ELDNAH ESAELERKOOH,ELDNAH ESAELERKOOH,ELDNAH ESAELERKOOH,ELDNAH

3232323232 11111 090402 090402 090402 090402 090402 YLBMESSAETALPNOISNETXE YLBMESSAETALPNOISNETXE YLBMESSAETALPNOISNETXE YLBMESSAETALPNOISNETXE YLBMESSAETALPNOISNETXE

4242424242 11111 543512 543512 543512 543512 543512 KOOHYTEFAS,GNIRPS KOOHYTEFAS,GNIRPS KOOHYTEFAS,GNIRPS KOOHYTEFAS,GNIRPS KOOHYTEFAS,GNIRPS

5252525252 11111 571050 571050 571050 571050 571050 NOXAM,ETALPEMAN NOXAM,ETALPEMAN NOXAM,ETALPEMAN NOXAM,ETALPEMAN NOXAM,ETALPEMAN

6262626262 11111 224462 224462 224462 224462 224462 PMA002.YSSAELBACREWOP PMA002.YSSAELBACREWOP PMA002.YSSAELBACREWOP PMA002.YSSAELBACREWOP PMA002.YSSAELBACREWOP

7272727272 11111 512509 512509 512509 512509 512509 ESUFSPMA002 ESUFSPMA002 ESUFSPMA002 ESUFSPMA002 ESUFSPMA002

8282828282 11111 316362 316362 316362 316362 316362 NWODYTIVARG,YLBMESSAPMUP NWODYTIVARG,YLBMESSAPMUP NWODYTIVARG,YLBMESSAPMUP NWODYTIVARG,YLBMESSAPMUP NWODYTIVARG,YLBMESSAPMUP

11921Slauson

Ave.Santa

FeSprings,C

A.90670

(800)227-4116

FAX(888)

771-7713

PAGE 12

PUMP ASSEMBLY, GRAVITY DOWN

METI METI METI METI METI .YTQ .YTQ .YTQ .YTQ .YTQ .ONTRAP .ONTRAP .ONTRAP .ONTRAP .ONTRAP NOITPIRCSED NOITPIRCSED NOITPIRCSED NOITPIRCSED NOITPIRCSED

11111 11111 216362 216362 216362 216362 216362 CDV21YLBMESSAPMUPENILMILS CDV21YLBMESSAPMUPENILMILS CDV21YLBMESSAPMUPENILMILS CDV21YLBMESSAPMUPENILMILS CDV21YLBMESSAPMUPENILMILS

22222 11111 669262 669262 669262 669262 669262 RABSUB RABSUB RABSUB RABSUB RABSUB

33333 11111 939262 939262 939262 939262 939262 DIONELOSROTOM DIONELOSROTOM DIONELOSROTOM DIONELOSROTOM DIONELOSROTOM

44444 11111 353352 353352 353352 353352 353352 YAW-2,DIONELOS,EVLAV YAW-2,DIONELOS,EVLAV YAW-2,DIONELOS,EVLAV YAW-2,DIONELOS,EVLAV YAW-2,DIONELOS,EVLAV

a4a4a4a4a4 11111 495622 495622 495622 495622 495622 EVLAVYAW-2,TIKGNIR-O EVLAVYAW-2,TIKGNIR-O EVLAVYAW-2,TIKGNIR-O EVLAVYAW-2,TIKGNIR-O EVLAVYAW-2,TIKGNIR-O

55555 11111 977362 977362 977362 977362 977362 GULP GULP GULP GULP GULP

66666 11111 963362 963362 963362 963362 963362 RELLIF RELLIF RELLIF RELLIF RELLIF

77777 11111 118362 118362 118362 118362 118362 "8/3,ROTCENNOC "8/3,ROTCENNOC "8/3,ROTCENNOC "8/3,ROTCENNOC "8/3,ROTCENNOC

88888 11111 005362 005362 005362 005362 005362 YLBMESSAXOB YLBMESSAXOB YLBMESSAXOB YLBMESSAXOB YLBMESSAXOB

a8a8a8a8a8 11111 794362 794362 794362 794362 794362 REVOC REVOC REVOC REVOC REVOC

b8b8b8b8b8 11111 994362 994362 994362 994362 994362 TNEMDLEWXOB TNEMDLEWXOB TNEMDLEWXOB TNEMDLEWXOB TNEMDLEWXOB

c8c8c8c8c8 11111 197362 197362 197362 197362 197362 HCTAL HCTAL HCTAL HCTAL HCTAL

99999 11111 739030 739030 739030 739030 739030 "4/1,GULPXEH "4/1,GULPXEH "4/1,GULPXEH "4/1,GULPXEH "4/1,GULPXEH

0101010101 11111 073362 073362 073362 073362 073362 THGISWOLF THGISWOLF THGISWOLF THGISWOLF THGISWOLF

1111111111 22222 418362 418362 418362 418362 418362 .AID"1,TEMMORG .AID"1,TEMMORG .AID"1,TEMMORG .AID"1,TEMMORG .AID"1,TEMMORG

2121212121 11111 597362 597362 597362 597362 597362 .AID"2/1,TEMMORG .AID"2/1,TEMMORG .AID"2/1,TEMMORG .AID"2/1,TEMMORG .AID"2/1,TEMMORG

3131313131 11111 897362 897362 897362 897362 897362 SSENRAHXOBPMUP SSENRAHXOBPMUP SSENRAHXOBPMUP SSENRAHXOBPMUP SSENRAHXOBPMUP

a31 a31 a31 a31 a31 11111 208362 208362 208362 208362 208362 TEKSAG TEKSAG TEKSAG TEKSAG TEKSAG

4141414141 11111 052062 052062 052062 052062 052062 RETLIF RETLIF RETLIF RETLIF RETLIF

5151515151 11111 001509 001509 001509 001509 001509 6#CIJ,ELAM,DAEHKLUB 6#CIJ,ELAM,DAEHKLUB 6#CIJ,ELAM,DAEHKLUB 6#CIJ,ELAM,DAEHKLUB 6#CIJ,ELAM,DAEHKLUB

6161616161 22222 930030 930030 930030 930030 930030 .GL"4/3-1x61-8/3,TLOB .GL"4/3-1x61-8/3,TLOB .GL"4/3-1x61-8/3,TLOB .GL"4/3-1x61-8/3,TLOB .GL"4/3-1x61-8/3,TLOB

7171717171 22222 555030 555030 555030 555030 555030 "8/3,KCOL,REHSAW "8/3,KCOL,REHSAW "8/3,KCOL,REHSAW "8/3,KCOL,REHSAW "8/3,KCOL,REHSAW

8181818181 22222 655030 655030 655030 655030 655030 "8/3,TALF,REHSAW "8/3,TALF,REHSAW "8/3,TALF,REHSAW "8/3,TALF,REHSAW "8/3,TALF,REHSAW

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

FAX(888)771-7713

PAGE 13

PUMP ASSEMBLY, GRAVITY DOWN

10 9

11

12

11

13

8

65

7

14

15

16,17,18

1

2

3

4

P/N 263613

11921Slauson

Ave.Santa

FeSprings,C

A.90670

(800)227-4116

FAX(888)

771-7713

PAGE 14

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

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

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PAGE 15

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 16

SAFETY HOOK

OIL ALL HOLES THEROD PASSES THRU

GREASE FRONTSURFACE OF HOOK USEAUTOMOBILE TYPE

GREASE

When the Platform is raised tofull �Stowed� position, there shouldbe an audible snap of the SafetyHook engaging the Platform Loop.Visually check to see that the loop ispositioned over the Safety Hook.

EXTENSIONPLATE

PLATFORMLOOP

PLATFORM

SAFETYHOOK

EXTENSIONPLATE

PLATFORMLOOP

PLATFORM

SAFETYHOOK

INCORRECT

CORRECTBEND

DIRECTION

To insure that the Hook is seatedas described, test by activating theToggle Switch in the �Down� mode.Gate should not go down. If it does,adjust the loop as shown in, toachieve adjustment shown.

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

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PAGE 17

WIRE CONNECTIONS, GRAVITY DOWN

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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PAGE 18

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

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

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PAGE 19

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.

11921Slauson

Ave.Santa

FeSprings,C

A.90670

(800)227-4116

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PAGE 20

TROUBLESHOOTING

------------------------------------------------------------------------------------------------------------

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

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PAGE 21

PLATFORM WILL NOT RAISE

1. Verify that power is being supplied to the Solenoid Terminal �A�. Rechargethe battery if less than 12 volts.

2. Fill Reservoir to within 1/2� below the top with the recommended hydraulicfluid.

3. Touch a jumper wire to terminals �A� & �C�. If motor runs, check Switch,Switch connections, and White wire. Correct the connections or replacethe Switch.

4. Touch heavy jumper cables to terminals �A� & �B�.a. If motor runs, replace the motor solenoid.b. If motor does not run, repair or replace the pump motor.

5. Check for structural damage. Replace worn parts.

6. Check filter in the pump Reservoir. Replace if necessary.

7. Check for a broken motor-to-pump coupler. Replace if necessary. A wornpump is extremely noisy, and needs replacement.

8. If equipped with a Low Voltage Thermal Switch (LVTS), system could shutdown if the motor temperature or battery voltage level reach an unaccept-able level. Read decal P/N 264776 located near the switch to determinewhat steps need to be taken to correct the problem.

Terminal �A�

Terminal �B�Terminal�C�

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FeSprings,C

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PAGE 22

PLATFORM RAISES BUT LEAKS DOWN

1. Check Solenoid Valves for electrical shorts byholding a screwdriver approximately 1/4� fromthe top nut of the Solenoid. (See Fig. 1). Thesolenoid should not draw the screwdriver tothe nut with a magnetic force, unless thetoggle switch is actuated. The Coil can bereplaced by removing the Nut and Wires.

2. Check the Valve Stem by removing theCoil Assembly, (Item 1, Fig. 2). Unscrewthe Valve Stem, (Item 2, Fig. 2), from thePump. Push on the plunger that is locatedinside the Valve Stem by inserting a paperclip in the end. If the Plunger does notmove freely approximately 1/8�, replacethe Valve Stem.

3. Check the Hydraulic Cylinder. With thePlatform on the ground, remove theBreather Plug or Vent Line from the VentPort of the Cylinder. Raise the Platform tobe level with the bed. If hydraulic fluidstreams from the Vent Port, the PistonSeals are worn. Replace the Seals.(See Fig. 3).

FIGURE 1

FIGURE 2

FIGURE 3

1/4�

Coil

1

2

1/8�

PressurePort

Vent Port

11921SlausonAve.SantaFeSprings,CA.90670(800)227-4116

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PAGE 23

PLATFORM RAISES PARTIALLY AND STOPS

1. Lower the opened Platform to the ground. Fill the Reservoir to within 1�from the top with the recommended Hydraulic Fluid.

2. Verify that the Battery shows 12 volts or better under load from pumpmotor. The use of a voltage load tester is recommended.

3. Check for Structural damage, or lack of lubrication. Replace worn parts.

4. Check Filter in the Pump Reservoir. Replace if necessary.

5. Check for a broken motor-to-pump coupler. Replace if necessary. A wornpump is extremely noisy, and needs replacement.

6. If equipped with a Low Voltage Thermal Switch (LVTS), system couldshut down if the motor temperature or battery voltage level reach anunacceptable level. Read decal P/N 264776 located near the switch todetermine what steps need to be taken to correct the problem.

11921Slauson

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FeSprings,C

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PAGE 24

LIFTGATE WILL NOT LIFT RATED CAPACITY

1. Verify that the Battery shows 12 volts or better under load from pumpmotor. The use of a voltage load tester is recommended.

2. Check for Structural damage or lack of lubrication.Replace worn parts.

3. Check the Hydraulic Cylinder. With thePlatform on the ground, remove theBreather Plug or Vent Line from theVent Port of the Cylinder. Raise thePlatform. If hydraulic fluid streams fromthe Vent Port, the Piston Seals areworn. Replace the Seals.

4. With Platform on the ground, removethe pressure hose and fitting from thePump and replace it with a 0-3000 PSI Pressure Gauge. Hold theswitch in the �UP� position. Adjust the Relief Valve on the side of thePump until the gauge shows 2800 to 3000 PSI . (See Fig. 2)

5. If Pump cannot produce 2800-3000 PSI with a minimum of 12 Voltsavailable, the Pump is worn and needs to be replaced.

FIGURE 2

FIGURE 1

PressurePort

Vent Port

PressureGauge Relief Valve

Adjust Screw

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PAGE 25

PLATFORM RAISES SLOWLY

1. Verify that power is being supplied toTerminal �A�. Recharge the battery if lessthan 12 Volts registers on the VoltageTester. (See Fig. 1)

2. Lower the opened Platform to the ground.Fill the Pump Reservoir to within 1� fromthe top with the recommended hydraulicfluid.

3. Verify the Pump Motor is grounded to thevehicle frame.

4. Check for leaking hoses and fittings.Tighten or replace as required.

5. Check for structural damage or lack oflubrication. Replace worn parts.

6. Check the Filter in the Pump Reservoir. Replace if necessary.

7. With Platform on the ground, remove the pressure hose and fitting from the Pump andreplace it with a 0-3000 PSI Pressure Gauge. Hold the switch in the �UP� position.Adjust the Relief Valve on the side of the Pump until the gauge shows 2800 to 3000 PSI(See Fig. 2).

8. With the Platform on the ground, remove breather plug or vent line from vent port ofcylinder. Raise the Platform to bed level. If hydraulic fluid streams from the Vent Port,

FIGURE 2

FIGURE 1

FLOWCONTROLVALVE

FIGURE 3

Vent Port

PressurePort

the Piston Seals are worn. (See Fig. 3) Replacethe Seals.

9. Check the Flow Control Valve. The arrow on thevalve shows the direction of flow that is re-stricted, and Must point back to the Pump. (SeeFig. 3)

PressureGauge

Terminal�A�

Relief ValveAdjust Screw

11921Slauson

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PAGE 26

PLATFORM WILL NOT LOWER

1. Verify that power is being supplied tothe Solenoid Terminal �A� (Ref. Fig. 1).Recharge the battery if less than 12volts.

2. Check for structural damage or lack oflubrication. Replace worn parts.

3. Check Solenoid Valve for power by holding a screwdriver approximately1/4� from the top nut of the Solenoid. Energize the unit. (See Fig. 2). Agood solenoid will draw the screwdriver to the nut by a magnetic force.The Coil can be replaced by removing the Nut and Wires.

4. Check the Valve Stem by removing the Coil Assembly, (Item 1, Fig. 3).Unscrew the Valve Stem, (Item 2, Fig. 3), from the Pump. Push on theplunger that is located inside the Valve Stem by inserting a paper clip inthe end. If the Plunger does not move freely approximately 1/8�, replacethe Valve Stem.

5. If equipped with a Low Voltage Thermal Switch (LVTS), system couldshut down if the motor temperature or battery voltage level reach anunacceptable level. Read decal P/N 264776 located near the switch todetermine what steps need to be taken to correct the problem.

FIGURE 2 FIGURE 3

FIGURE 1

1/4�

Coil 1

2

1/8�

Terminal�A�

LIQUID SEALANT APPLICATION

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

NOTE:Apply Sealant to NPT threads only!