AHT HTK-750ST/AL User guide

INSTALLER’S MANUAL
FOR THE “AHT”
TAILLIFT
with underrun beam
Office: Factory:
Hauptplatz 23 Bahnstraße 34 A-2474 Gattendorf
Tel. [phone] (43) 2142 64360 E-Mail:
Fax. [phone] (43) 2142 64366 [e-mail]
ALUHEBETECHNIK
Gesellschaft mbH
Gattendorf,May 2007
HTK-500ST/AL
HTK-750ST/AL HTK-500ST/M
HTK-750ST/M

SERVICE QUALIFICATIONS TO INSTALL
THE TAILGATE LOADER
The installer should be well trained in the proper procedure for installing the AHT before
beginningtheinstallation.
Carefullyreadthe manualbefore starting to install the AHTtailgateloader.
Onlymatureadults,age 18 and above, should installtheAHTtailgate loader.
Installershouldbe well qualifiedforinstallinghydraulicequipment.
Installershouldbewell qualified for installing theelectricalequipment.
INSTALLATION GUIDELINES
1)Removebumpers,lights,tool box etc. fromrearofvehicleifnecessary.
2)Cutand shape the bodyand chassis to fit thetailgate.
3)Fixingthemountingdeviceonthetruckbody.
4)Removethepinfromplatform bearing
5)Positionthemainframeunderthetruck.Then displace the power pack.
6)Fixthemountingbracketsontothetruckmainframe.
7)Mountthepowerpack again.
8)Energizethe power pack.
9)Removethemountingdevicesandlowerthehoistingunitforapproximately40cm.
10) Position the platform and install the joint plate, the spring, the tube and the pin at the
platformbearing.
11)Liftuptheleverarmandtheclosingcylinderandinstallthe pinsforleverarm-jointplate
12)RemovethetiltingLock.
13)Adjusttheplatformlevel.
14)Installingthe platformlock.
2

UNPACKING THE TAILGATE LOADER
A complete unit will be shipped on one pallet consisting of two main units:
(1)Platform
(2)Mainframewithliftingarms,cylinders,
powerpack,mountingbrackets,2
button-remote-controland
installationmanual.
CAUTION: Never lift the Main Frame with the hoisting
unit at the stabilizer.
(Lift cylinder will be damaged)
Always lift the complete unit evenly, as shown in the
picture,being carefultoraisetheliftarmsat thesame
time. Be sure the lift arms and the lever arms are
secured.
3
Power Pack
Pallet
Platform
MainFrame
MountingBracket
LiftingArms
FORBIDDEN!!!

PREPARING FOR INSTALLATION
Removerearlights,bumper, tool boxandsparewheel,if
necessary.
Disconnect the battery cable to prevent damage to the
batterywhilewelding.
Remove any obstruction attached to the frame of the
vehicle that would interfere with the installation. The
mountingbracketswillcoverthemainframe and subframe.
Installing on a truck body with roll-up doors or
without rear doors.
Cutouttherearoftheframe,ifnecessary, as shown in the
installationdrawings.
Reinforce the cut outs.
Truck bodies with rear doors.
Refrigeratedbodies with swing doors need an end profile,
madefromstainlesssteel, welded to the body asshowninthe
drawing,ontheright.
Subframe Tie-down
Mounting bracket
4

INSTALLATION INSTRUCTIONS
Installing the Mounting Device
- Fixing the mounting device
Centerthemountingdeviceon
thetruckbody floor.
Bothmountingdevicesmust
makeacontactwiththetruck
floorend.Clampbothmounting
devicesonthetruckbodyfloor.
- Platform Preparation
Beforeyoucaninstallthemainframeyouhavetoremovethe2pins,thespring and the
tubefromthe platform.
1) Removethe pin from platformbearingonbothsides.
2) Removethe spring on the rightside.
Removethetubeontheleftside.
5

INSTALLATION INSTRUCTIONS
Position the tailgate unit
- Position the main frame
- Installthemountingbracketson the main frame, but donotfixit.
- Placethemainframeunderthevehiclewith lift arms attached using a floor jack, and
raise main frame to its approximate final position.
-Be sure to lubricate all pin surfaces before installing the pins.
- Raise the hoisting unit to the mounting device, remembering that the lift cylinders will
comeapartifraisedtoohigh.(Ifnecessary,raisethemainframeclosertothevehiclechassis.)
- Installpins(Liftarm- platform) between
mountingdeviceandhoisting unit.
- The main frame must be parallel with the
body.
- IMPORTANT: SEE “TAILGATE KINEMATICS” THE
MAXIMUM AND MINIMUM MEASUREMENTS MUST BE
KEPT.
- Displace the power pack
- Beforeyoucanfixthemountingbrackets,youhaveto
displace the power pack.
6
Loosenthe 4 screws
M10x25onthepower
pack
Now displace the power pack
It is not necessarry to remove any hydraulic hoses, fittings
and electric wirings.

INSTALLATION INSTRUCTIONS
Position the tailgate unit
- Install mounting brackets
- Placethemountingbrackets to its exact final position.
- Clampthemountingbracketsonthetruck frame.
- Fixthemountingbracketsonthemainframe.
- Drill16mm(5/8”)holesintothechassisand mounting bracket.
ScrewM16 (5/8”) is 8.8 Strength(Grade8)
Max.Torque195Nm(145ftlbs.)
Drilltwo holesineach bracket,puta boltineach oneandsecure.Thendrilltheotherholes.
NUMBER OF SCREWS PER MOUNTING BRACKET: 4 pieces
M16x50
- MOUNT THE POWER PACK AGAIN. FASTEN THE 4 SCREWS
M10x25
TruckMainFrame
Screw Clamp
MountingBracket
TruckMainFrame
Screw Clamp
MountingBracket
4 HOLES
ø16mm(5/8“)
7
Check the
right-angled

8
INSTALLATION INSTRUCTIONS
Energize the power pack
CAUTION: REMOVE TRANSPORT FILLER CAP AND INSERT DIPSTICK:
(There is no air hole in filler cap and the pump or reservoir will be destroyed)
Besurethe vehicle and the liftgateareof the same current (12Vor 24V).
Fuse is in the power pack. (12V = 25Amp and 24V = 16Amp).
Connectthepositive cable, directlyfrom thebattery, to thestartersolenoid. (min. 16mm²)
Connectthenegativecable,directly fromthe battery, tothe motorground.(min. 16mm²)
Completeallotherelectricalwork.(Connectallcontrolswitches)
CAUTION: REMOVE TRANSPORT FILLER CAP AND INSERT DIPSTICK:
(Thereisno air hole intransportfiller cap and thepump or reservoir will bedestroyed)
- BuildinbetweenBattery(+)and (+)-Cable the Main Fuse
MAIN FUSE
12V = 125 Ampere
24V = 80 Ampere
to Power
Pack
FUSE BOX

INSTALLATION INSTRUCTIONS
Correct wiring of the Power Pack
NOTE: Allbattery powerleadsmusthave acoreareanot lessthan16mm²and bedouble
insulated.
Connectbothbatterycables(+and-)directly from the battery to the power pack.
ATTENTION: Byfixingthebatterycableonthestarterswitch, you must hold upthe
locknut.
* Energizethepowerpackand actuatethevalvetobe sure they are operating properly.
* Pleasechecktheoperatingtemperatureregularly. It should not increase by morethan
-20°C to +70°C.
* Checkanewpower packforleakageaftera short periodoftime.Tightenanyfittingsthat
maybeleaking.
TURNING
HOLD UP
StarterSwitch
LockNut
BatteryCable
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10
INSTALLATION INSTRUCTIONS
Installing the platform
- Remove mounting device
- Press the “UP”-Button to energize the hydraulic system until the pins for the mounting
devicesmovesslightly.
- Removepinsbetweenmountingdeviceandliftarm.
- Removescrewclampsandmountingdevices.
- Installing the platform
- Pressthe“DOWN”-Buttonandpush
thehoistingunitmanuallydownward
in one time, to lower the hoisting
unitapproximately40cm.
- Positiontheplatform
- Removethejointplate(onbothsides)
“DOWN”-Button
1) Remove pin between lever arm and
jointplate
2)Removethejointplate
pin:leverarm-jointplate
jointplate
leverarm

INSTALLATION INSTRUCTIONS
Installing the platform
- Placethejoint plate to the platformbearing (1) (on left side)
- Installthepin(liftarm - platform) from inside at the platformbearing.(2) (onleftside)
Movethepinonlyuptothejointplate.(3)
- Placethejoint plate to theplatformbearing (1) (on right side)
- Installthepin(liftarm - platform) from inside at the platformbearing.(2) (onrightside)
Movethepinonlyuptothejointplate.(3)
11

INSTALLATION INSTRUCTIONS
Installing the platform
- Installthetorsionspring (only on right side)
- Putoneendof the spring in the bearingofthejoint plate and the other endinthe
bearingoftheplatform.
- Movethepin(liftarm- platform)toitsfinalpositionandinstallthelockingscrew.
- Installthetube (onlyonleftside)
- Movethepin(liftarm- platform)toitsfinalpositionandinstallthelockingscrew.
- If bothpins (liftarm -platform) areinstalled andsecured, manually closethe platform(30°).
12

13
INSTALLATION INSTRUCTIONS
Installing the platform
- Nowliftuptheleverarmontherightsideandtheplatformclosingcylinderontheleft
sidetothe joint plate.
- Installthepinontherightside(leverarm-jointplate)andsecureit.
- Installthepinontheleftside(leverarm-jointplate)andsecureit.
Liftuptheleverarmstothe
jointplate
jointplate
leverarm
pin(leverarm-jointplate)
jointplate
platformclosingcylinder
pin(leverarm-jointplate)

14
INSTALLATION INSTRUCTIONS
Remove tilting lock
- Theplatforminstallationisnow complete. Open the platform.
- RemoveTiltingLock
Thetiltinglockpreventsthe automatic leveling from working untiltheinstallationis
complete.Itisthelastthingtoremove.
- RemovethescrewM6x70on both sides.
(BeforeremovingthescrewM6x70theplatformmustbe
raisedfromground)
Tilting lock
Tiltingbracket
Mainframe
ScrewM6x70

INSTALLATION INSTRUCTIONS
How to adjust the platform level
- Lowertheplatformtogroundlevel.(Donottilt the platform to ground)
- Loosenthelockingnut.
(onbothsides)
- Turn the adjusting screw clockwise for
lowertheplatformtip
(onbothsides)
- Turntheadjustingscrewanticlockwisefor
raisetheplatform tip
(onbothsides)
- Checkthecorrectadjustementoftheadjustingscrews
Onlowerposition,thebothadjusting screws must have contact with thejointplate.
OK WRONG
- Iftheplatformleveliscorrect,fasten the locking nut. (on both sides)
Adjusting
screwM16
Lockingnut
Jointplate
contact
contact contact
nocontact
15

16
INSTALLATION INSTRUCTIONS
Installing the platform lock
- Installing the platform lock
- Besurethe platform is initsuppermost position (at vehiclebedlevel) and closed.
- Weldor boltthelock hook to the vehicle body.
Platform
Lock hook
Platformlock

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