Maxon MTB-25 & MTB-30 REV. L (SEPTEMBER 2015) Installation guide

M-00-39

REV. L

SEPTEMBER 2015

MTB-25 & MTB-30

INSTALLATION MANUAL

To nd maintenance & parts informa-

tion for your MTB Liftgate, go to www.

maxonlift.com. Click the PROD-

UCTS, TUK-A-WAY & MTB buttons.

Open the Maintenance Manual in

the PRODUCT DOCUMENTATION

window.

TABLE OF CONTENTS

SUMMARY OF CHANGES: M-00-39, REVISION L ............................................................. 4

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

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

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

MTB-25 & MTB-30 LIFTGATE COMPONENTS ................................................................... 7

PARTS BOX FOR MTB-25 GRAVITY DOWN ....................................................................... 8

PARTS BOX FOR MTB-30 GRAVITY DOWN ....................................................................... 9

PARTS BOX FOR MTB-25 POWER DOWN ....................................................................... 10

PARTS BOX FOR MTB-30 POWER DOWN ........................................................................11

STEP 1 - PREPARE VEHICLE ........................................................................................... 12

STEP 2 - MOUNT LIFTGATE ON VEHICLE BODY ............................................................ 17

OPTION 1 ............................................................................................................ 17

OPTION 2 ........................................................................................................... 22

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) . 28

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

STEP 5 - CONNECT GROUND CABLE ............................................................................. 36

STEP 6 - CONNECT POWER CABLE ................................................................................ 37

STEP 7 - INSTALL CONTROL SWITCH ............................................................................. 38

STEP 8 - CONNECT POWER CABLE TO BATTERY ......................................................... 40

STEP 9 - LOWER THE PLATFORM FOR ACCESS ........................................................... 41

STEP 10, PART A - WELDING METHOD FOR EXTENSION PLATE ................................. 42

STEP 10, PART B - BOLTING METHOD FOR EXTENSION PLATE .................................. 43

STEP 11 - PLATFORM ADJUSTMENT (IF REQUIRED) .................................................... 44

STEP 12 - ADJUST SAFETY HOOK (IF REQUIRED) ....................................................... 46

STEP 13 - VEHICLE TAILLIGHT POSITIONING (IF REQUIRED) ...................................... 47

ATTACH DECALS .............................................................................................................. 48

TOUCHUP PAINT PRECAUTION ....................................................................................... 49

HYDRAULIC SYSTEM DIAGRAMS ................................................................................... 50

HYDRAULIC SCHEMATIC (GRAVITY DOWN) ................................................................... 50

HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 51

ELECTRICAL SYSTEM DIAGRAMS ................................................................................. 52

ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 52

ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 53

OPTIONS ........................................................................................................................... 54

OPTIONAL LIFTGATE COMPONENTS .............................................................................. 54

RUBBER DOCK BUMPER KIT ........................................................................................... 55

TABLE OF CONTENTS - Continued

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

4

SUMMARY OF CHANGES: M-00-39, REVISION L

PAGE DESCRIPTION OF CHANGE

COVER Updated REV and date of release.

6

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

grab handles if needed.

54 Removed LVTS options from the OPTIONS table.

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

5

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.

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

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

instructions.

Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing

Liftgates. See Operation Manual for operating safety requirements.

• If it is necessary to stand on the platform while operating the Liftgate, keep your feet and any

objects clear of the inboard edge of the platform. Your feet or objects on the platform can become

trapped between the platform and the Liftgate extension plate.

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

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

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

people and vehicles passing by.

WARNING

• 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.

!

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

on the galvanized part (

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

adequate ventilation, and wear suitable respirator.

FIG. 5-1

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

6

SAFETY INSTRUCTIONS

• Comply with all WARNING and instruction decals attached to the Liftgate.

• Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement

decals are available from Maxon Customer Service.

• Consider the safety and location of bystanders and location of nearby objects when operating the

Liftgate. Stand to one side of the platform while operating the Liftgate.

• Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while

performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact

with battery acid may injure unprotected eyes and skin.

• Do not allow untrained persons to operate the Liftgate.

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

there are no ames or sparks near the battery. Never lay objects on the battery that can short the

terminals together. If battery acid gets in your eyes, immediately seek rst aid. If acid gets on your

skin, immediately wash it off with soap and water.

• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the con-

trol switch to stop the Liftgate.

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

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

Manual.

• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise

during operation comes from the power unit while the platform is raised and lowered. Listen for

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

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 (800) 227-4116 FAX (888) 771-7713

7

MTB-25 & MTB-30 LIFTGATE COMPONENTS

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 enclosed

in each box. If parts and components are missing or incorrect, call:

Maxon Customer Service

Call (800) 227-4116 or

Send e-mail to [email protected]

Prevent injuries and equipment damage. Before cutting the shipping straps from

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

Be careful lifting and moving components (such as extension plate) after ship-

ping straps are removed.

CAUTION

PARTS BOX

MTB-25 & MTB-30 LIFTGATE

!

MTB-25 & MTB-30 COMPONENTS

FIG. 7-1

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

8

PARTS BOX FOR MTB-25 GRAVITY DOWN

ITEM QTY. PART NO. DESCRIPTION

REF 1

280455-01 PARTS BOX, MTB-25 (GRAVITY DOWN)

1 15

050079 CLIP FRAME

2 4

205780 PLASTIC TIE, 7"

3 1 264422 CABLE ASSEMBLY, 175 AMP, 38 FT. LG.

4 1 267959-01 MOLDED SWITCH ASSEMBLY

5 1 280454-01 KIT, MANUAL & DECAL, MTB-25

5A 1 M-00-39 MANUAL, INSTALLATION MTB-25/30

5B 1 M-00-40 MANUAL, OPERATION MTB-25/30

5C 1 264507 DECAL UP & DOWN

5D 1 265438 DECAL WARNING & LOGO MTB-25 (SPARE)

5E 2 265736-03 DECAL,WARNING PINCH HAZARD (SPARE)

5F 2 282847-02 DECAL,WARNING,STOW,TUK-A-WAY

6 1 900009-2 CAP SCREW, 5/16"-18 X 1" LG, GR8

7 2 900057-5 SCREW, SELF TAP, 10-24 X 1" LG.

8 1 901001 LOCK NUT, 5/16"-18

9 10 901023 LOCK NUT, FLANGE

10 10 901024-2 HEX BOLT, 1/2"-13 X 1-3/4" LG.

11 1 902000-7 FLAT WASHER, 5/16"

12 1 903400-01 WASHER, EXTERNAL TOOTH, 5/16" I.D.

13 1 905286-01 HEAT-SHRINK TUBING, 4" LG.

14 1 906497-02 LUG, 2GA, 5/16"

15 1 907038 SPLICER REDUCER

TABLE 8-1

NOTE: To nd maintenance & parts information for your MTB Liftgate, go to www.

maxonlift.com. Click the PRODUCTS, TUK-A-WAY & MTB buttons. Open

the Maintenance Manual in the PRODUCT DOCUMENTATION window.

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

9

PARTS BOX FOR MTB-30 GRAVITY DOWN

TABLE 9-1

ITEM QTY. PART NO. DESCRIPTION

REF 1

280455-02 PARTS BOX, MTB-30 (GRAVITY DOWN)

1 15

050079 CLIP FRAME

2 4

205780 PLASTIC TIE, 7"

3 1 264422 CABLE ASSEMBLY, 175 AMP, 38 FT. LG.

4 1 267959-01 MOLDED SWITCH ASSEMBLY

5 1 280454-02 KIT, MANUAL & DECAL, MTB-30

5A 1 M-00-39 MANUAL, INSTALLATION MTB-25/30

5B 1 M-00-40 MANUAL, OPERATION MTB-25/30

5C 1 264507 DECAL UP & DOWN

5D 1 265439 DECAL WARNING & LOGO MTB-30 (SPARE)

5E 2 265736-03 DECAL,WARNING PINCH HAZARD (SPARE)

5F 2 282847-02 DECAL,WARNING,STOW,TUK-A-WAY

6 1 900009-2 CAP SCREW, 5/16"-18 X 1" LG, GR8

7 2 900057-5 SCREW, SELF TAP, 10-24 X 1" LG.

8 1 901001 LOCK NUT, 5/16"-18

9 10 901023 LOCK NUT, FLANGE

10 10 901024-2 HEX BOLT, 1/2"-13 X 1-3/4" LG.

11 1 902000-7 FLAT WASHER, 5/16"

12 1 903400-01 WASHER, EXTERNAL TOOTH, 5/16" I.D.

13 1 905286-01 HEAT-SHRINK TUBING, 4" LG.

14 1 906497-02 LUG, 2GA, 5/16"

15 1 907038 SPLICER REDUCER

NOTE: To nd maintenance & parts information for your MTB Liftgate, go to www.

maxonlift.com. Click the PRODUCTS, TUK-A-WAY & MTB buttons. Open

the Maintenance Manual in the PRODUCT DOCUMENTATION window.

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

10

PARTS BOX FOR MTB-25 POWER DOWN

TABLE 10-1

ITEM QTY. PART NO. DESCRIPTION

REF 1

280455-03 PARTS BOX, MTB-25 (POWER DOWN)

1 15

050079 CLIP FRAME

2 4

205780 PLASTIC TIE, 7"

3 1 264422 CABLE ASSEMBLY, 175 AMP, 38 FT. LG.

4 1 264951-04 MOLDED SWITCH & CABLE ASSEMBLY

5 2 280454-01 KIT, MANUAL & DECAL, MTB-25

5A 1 M-00-39 MANUAL, INSTALLATION MTB-25/30

5B 1 M-00-40 MANUAL, OPERATION MTB-25/30

5C 1 264507 DECAL UP & DOWN

5D 1 265438 DECAL WARNING & LOGO MTB-25 (SPARE)

5E 2 265736-03 DECAL,WARNING PINCH HAZARD (SPARE)

5F 1 282847-02 DECAL,WARNING,STOW,TUK-A-WAY

6 1 900009-2 CAP SCREW, 5/16"-18 X 1" LG, GR8

7 2 900057-5 SCREW, SELF TAP, 10-24 X 1" LG.

8 1 901001 LOCK NUT, 5/16"-18

9 10 901023 LOCK NUT, FLANGE

10 10 901024-2 HEX BOLT, 1/2"-13 X 1-3/4" LG.

11 1 902000-7 FLAT WASHER, 5/16"

12 1 903400-01 WASHER, EXTERNAL TOOTH, 5/16" I.D.

13 1 905286-01 HEAT-SHRING TUBING, 4" LG.

14 1 906497-02 LUG, 2GA, 5/16"

15 1 907038 SPLICER REDUCER

NOTE: To nd maintenance & parts information for your MTB Liftgate, go to www.

maxonlift.com. Click the PRODUCTS, TUK-A-WAY & MTB buttons. Open

the Maintenance Manual in the PRODUCT DOCUMENTATION window.

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

11

PARTS BOX FOR MTB-30 POWER DOWN

TABLE 11-1

ITEM QTY. PART NO. DESCRIPTION

REF 1

280455-04 PARTS BOX, MTB-30 (POWER DOWN)

1 15

050079 CLIP FRAME

2 4

205780 PLASTIC TIE, 7"

3 1 264422 CABLE ASSEMBLY, 175 AMP, 38 FT. LG.

4 1 264951-04 MOLDED SWITCH & CABLE ASSEMBLY

5 1 280454-02 KIT, MANUAL & DECAL, MTB-30

5A 1 M-00-39 MANUAL, INSTALLATION MTB-25/30

5B 1 M-00-40 MANUAL, OPERATION MTB-25/30

5C 1 264507 DECAL UP & DOWN

5D 1 265439 DECAL WARNING & LOGO MTB-30 (SPARE)

5E 2 265736-03 DECAL,WARNING PINCH HAZARD (SPARE)

5F 2 282847-02 DECAL,WARNING,STOW,TUK-A-WAY

6 1 900009-2 CAP SCREW, 5/16"-18 X 1" LG, GR8

7 2 900057-5 SCREW, SELF TAP, 10-24 X 1" LG.

8 1 901001 LOCK NUT, 5/16"-18

9 10 901023 LOCK NUT, FLANGE

10 10 901024-2 HEX BOLT, 1/2"-13 X 1-3/4" LG.

11 1 902000-7 FLAT WASHER, 5/16"

12 1 903400-01 WASHER, EXTERNAL TOOTH, 5/16" I.D.

13 1 905286-01 HEAT-SHRING TUBING, 4" LG.

14 1 906497-02 LUG, 2GA, 5/16"

15 1 907038 SPLICER REDUCER

NOTE: To nd maintenance & parts information for your MTB Liftgate, go to www.

maxonlift.com. Click the PRODUCTS, TUK-A-WAY & MTB buttons. Open

the Maintenance Manual in the PRODUCT DOCUMENTATION window.

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

12

STEP 1 - PREPARE VEHICLE

The MTB-25 and MTB-30 are body-mounted Liftgates that put force on the back of

the truck body as shown in FIG 12-1. For correct installation, truck body must be able

to withstand the vertical force and moment of force shown.

=4200 LBS. VERTICAL FORCE

=170,814 LBS-IN MOMENT OF FORCE

Consult truck body manufacturer for truck body strength data. Make sure the

forces created by the Liftgate are within the limits prescribed by truck body

manufacturer.

WARNING

TRUCK BODY STRENGTH REQUIREMENTS

!

FIG. 12-1

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13

STEP 1 - PREPARE VEHICLE - Continued

1. Check for correct clearances (FIG. 13-1) on vehicle to prevent interference between

vehicle and Liftgate.

32-1/4”

36-1/4”

39-1/4”

18-3/16”

54” MAX. (UNLOADED)

43” MIN. (LOADED)

22” MAX.

11” MIN.

4”- 6”

CLEARANCE FOR MTB-25 & MTB-30

FIG. 13-1

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.

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: BODY Maximum and Minimum Operating Bed Height:

For Standard Platform and Platform with Aluminum Retention Ramp -

Maximum height is 54” (Unloaded). Minimum height is 43” (Loaded).

For Wedge Platform -

Maximum height is 54” (Unloaded). Minimum height is 48” (Loaded).

Do not install this Liftgate on vehicle bodies equipped with swing open doors.

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14

STEP 1 - PREPARE VEHICLE - Continued

VEHICLE FRAME CUT FOR MTB-25 & MTB-30

FIG. 14-1

2. Fit the Liftgate to truck body by cutting frame as shown in FIG. 14-1.

NOTE: The platform cutout area shown below applies to trucks and trailers.

BODY FLOOR

10-3/8”

16-7/8”

16”

BODY CROSS MEMBERS

SPACER

PLATFORM CLEARANCE

CUTOUT AREA

(WITHIN DASHED LINES)

BODY FRAME

REAR SILL

TRUCK FRAME

7-5/8”

NOTE: The dimensions shown below are maximums except as indicated.

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15

STEP 1 PREPARE VEHICLE - Continued

4” to 6”

MAXIMUM

(FOR LIFTGATE

TO FIT

CORRECTLY)

VEHICLE BODY

FLOOR

3. Measure distance from vehicle body oor to bottom of rear sill as shown in FIG. 15-1

Note minimum and maximum rear sill thickness (FIG. 15-1) required for Liftgate to t

correctly.

FIG. 15-1

VEHICLE BODY

REAR SILL

Before installing Liftgate on a truck body, attach truck body to truck frame

to prevent body from moving out of position. Use body manufacturer’s pre-

scribed method for attaching body to frame.

CAUTION

FRAME

(TRUCK, ONLY)

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

16

NOTE: If you are going to weld the extention plate onto the truck body, skip this

drilling step and go to next item.

4. Measure, mark, and drill (11) 9/16” holes on vehicle body as shown in FIG. 16-1.

1-3/16” X 7 HOLES

1-7/8” X

4 HOLES

68”

58”

48”

28”

14”

7”

14”

24”

29”

34”

FRAME

(TRUCK ONLY)

CENTER OF BODY

DRILLING BOLT HOLES IN VEHICLE BODY

(REAR VIEW OF VEHICLE BODY)

FIGURE 16-1

9/16” DIA. x 11 HOLES

STEP 1 PREPARE VEHICLE - Continued

DRILL HOLES IN VEHICLE BODY

VEHICLE BODY

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17

STEP 2 - MOUNT LIFTGATE ON VEHICLE BODY

OPTION 1

NOTE: Do the OPTION 1 or OPTION 2 procedure to mount Liftgate on vehicle

body. The OPTION 1 procedure is for rst welding mounting angles to

vehicle body. The Liftgate is bolted to mounting angles. In the OPTION 2

procedure, mounting angles are bolted to Liftgate and then welded to ve-

hicle body.

1. Unbolt the mounting angles and

shims from Liftgate (FIG. 17-1).

UNBOLTING MOUNTING ANGLES

FIG. 17-1

FLAT

WASHERS

BOLTS

LOCK

NUTS

WASHERS

SHIMS

MOUNTING

ANGLE (RH)

MOUNTING

ANGLE (LH)

BOLTS

NOTE: Save the 4 bolts, at washers, and lock nuts removed from mounting

angles. Reuse to secure Liftgate to mounting angles near the end of this

OPTION 1 procedure.

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18

STEP 2 - MOUNT LIFTGATE ON VEHICLE BODY

- Continued

OPTION 1

2. Position 2 mounting angles against bottom of the truck

body cross members (FIGS. 18-1A and 18-1B).

Tack weld each angle in place (FIG. 18-1A).

POSITIONING MOUNTING ANGLES ON

TRUCK BODY

FIG. 18-1A

LH SIDE VIEW OF BODY SILL

& MOUNTING ANGLE

FIG. 18-1B

1/4” MAX

1/16” MIN

46-1/16”

92-1/8”

TRUCK BODY

MOUNTING

ANGLE

BODY

SILL

1/4”

TRUCK BODY

SILL

WELDING MOUNTING PLATES

(VIEW UNDER TRUCK BODY)

FIG. 18-2

3. Weld the 2 mounting angles to the truck

body cross members (FIG. 18-2).

MOUNTING

ANGLE (LH)

TRUCK BODY

CROSS MEMBERS

(5 SHOWN)

CENTER OF BODY

1/4”

TACK

MOUNTING

ANGLE (RH)

1/4”

MOUNTING

ANGLE (LH)

MOUNTING

ANGLE (RH)

1/4”

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

19

Keep Liftgate clamped to forklift until Liftgate is welded (or bolted if required)

to vehicle body. Liftgate may be damaged and create a hazard for the install-

er if it falls off the forklift.

WARNING

STEP 2 - MOUNT LIFTGATE ON VEHICLE BODY

- Continued

OPTION 1

4. Secure Liftgate to forklift with “C”-clamps

as shown in FIGS. 19-1A, 19-1B and

19-1C. Use an 8’ length of 4” x 4” steel

tubing to help support the Liftgate with

forklift (FIGS. 19-1A and 19-1C).

NOTE: Rest the Liftgate extension plate against the forklift mast.

C-CLAMPS

5. Use forklift to center the Liftgate in position on the

back of the truck body (FIG. 19-1A). If necessary,

have 1 person operate the forklift and another person

check alignment of Liftgate and truck body.

FIG. 19-1A

RH SIDE OF LIFTGATE SHOWN

FIG. 19-1C

FIG. 19-1B

C-CLAMPS

4” X 4” TUBING

!

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

20

6. Position the Liftgate against

the truck body (FIG. 20-1).

Make sure extension plate

ts tight against body sill.

BOLTING LH SIDE PLATE

FIG. 20-2

TRUCK

BODY

LH SIDE

PLATE

FRAME

BOLTS

FLANGE LOCK

NUTS

MOUNTING

ANGLE

STEP 2 - MOUNT LIFTGATE ON VEHICLE BODY

- Continued

OPTION 1

7. Bolt the LH and RH side plates

to the mounting angles on the

truck body (FIG. 20-2). Use 5

bolts and 5 ange lock nuts

from part box for each side

plate (FIG. 20-2).

FIG. 20-1

EXTENSION PLATE

(FLUSH WITH TRUCK

BODY FLOOR)

LIFTGATE

TRUCK BODY

MOUNTING

ANGLE

BODY SILL

8. Tighten the 5 ange

lock nuts. Torque each

of the ange lock nuts

(FIG. 20-2) to 105 lbs-ft.

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Maxon MTB-25 & MTB-30 REV. L (SEPTEMBER 2015) Installation guide

Maxon MTB-25 & MTB-30 REV. L (SEPTEMBER 2015) Installation guide

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