Maxon TE-25DC Installation Manual Download Page 9

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1921 Slauson

ve. Santa Fe Springs, CA. 90670 (800) 227-41

16 F

AX (888) 771-7713

TE-25DC & TE-33 MANUALS & DECALS

ITEM

NOMENCLATURE OR DESCRIPTION

QTY.

PART NUMBER

REF

TE-25DC MANUAL & DECAL KIT

298270-02

INSTALLATION MANUAL

M-17-10

OPERATION MANUAL

M-17-11

DECALS (SEE DECAL PAGES IN THIS MANUAL)

220382
299038-01
266013-02
282522-01
282847-02
265441-01
285800-01

TE-25DC STANDARD KIT

TABLE 9-1

nd maintenance & parts information for your

TE-25DC or TE-33 Liftgate

, go to

www.maxonlift.com. Click the

PRODUCTS

TUK-A-WAY

TE-25DC/TE-33

buttons.

Open the

Maintenance Manual

in the

PRODUCT DOCUMENTATION

window. For

parts, click on the

PARTS PORTAL

TUK-A-WAY

TE-25DC/TE-33

buttons.

ITEM

NOMENCLATURE OR DESCRIPTION

QTY.

PART NUMBER

REF

TE-33 MANUAL & DECAL KIT

298270-01

INSTALLATION MANUAL

M-17-10

OPERATION MANUAL

M-17-11

DECALS (SEE DECAL PAGES IN THIS MANUAL)

220388-02
299038-01
266013-02
282522-01
282847-02
265441-01
285800-01

TE-33 STANDARD KIT

TABLE 9-2

Summary of Contents for TE-25DC

Page 1: ...ce parts information for your TE 25DC or TE 33 Liftgate go to www maxonlift com Click the PRODUCTS TUK A WAY TE 25DC TE 33 buttons Open the Maintenance Manual in the PRODUCT DOCUMENTATION window For p...

Page 2: ...TO VEHICLE 22 STEP 3 ATTACH OPTIONAL BATTERY BOX FRAME TO VEHICLE IF EQUIPPED 28 STEP 4 RUN POWER CABLE 36 STEP 5 CONNECT POWER CABLE 38 STEP 6 CONNECT GROUND CABLE 40 STEP 7 INSTALL CONTROL SWITCH 41...

Page 3: ...8 PUMP MOTOR SOLENOID OPERATION GRAVITY DOWN 68 HYDRAULIC SCHEMATIC GRAVITY DOWN 69 ELECTRICAL SCHEMATIC GRAVITY DOWN 70 PUMP MOTOR SOLENOID OPERATION POWER DOWN 71 HYDRAULIC SCHEMATIC POWER DOWN 72 E...

Page 4: ...new manual decal kit for TE 25DC Old decals P N 264507 were removed New bilingual decals P N 299038 01 were added 41 FIG 41 2 shows new control switch 57 FIG 57 1 shows new carriage bolts for bolting...

Page 5: ...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 modifications...

Page 6: ...id gets in your eyes immediately seek first 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...

Page 7: ...ll Maxon Customer Service Call 800 227 4116 or Send e mail to cservice maxonlift com Unpacking the Liftgate on unlevel surface may allow heavy components to slide off when shipping bands are cut Injur...

Page 8: ...PART NUMBER REF PARTS BOX C 1 297502 02 1 SPRING CLIP 20 050079 2 PLASTIC TIE 4 206864 3 GROMMET 1 DIAMETER 2 HOLES 1 266428 09 4 CABLE ASSEMBLY 175 AMP 38 LG 1 264422 5 GROUND CABLE ASSEMBLY 2 GA X 3...

Page 9: ...IT TABLE 9 1 To find maintenance parts information for your TE 25DC or TE 33 Liftgate go to www maxonlift com Click the PRODUCTS TUK A WAY TE 25DC TE 33 buttons Open the Maintenance Manual in the PROD...

Page 10: ...iftgates on high bed vehicles is 54 unloaded Minimum bed height is 42 loaded Maximum bed height for TE 25DC TE 33 Liftgates on low bed vehicles is 44 unloaded Minimum bed height varies with platform d...

Page 11: ...LATFORMS 40 MIN BED HEIGHT 52 X 84 PLATFORMS ONLY 38 MIN BED HEIGHT 48 X 84 PLATFORMS ONLY 16 7 8 TO 10 7 8 24 7 8 35 1 2 13 TEWR 25DC TEWR 33 WALK RAMP CLEARANCES 44 TO 54 BED HEIGHT FIG 11 2 13 1 2...

Page 12: ...plate FIGS 12 1A and 12 1B to prevent interference VEHICLE REQUIREMENTS Continued TEWR 25DC OR TEWR 33 LIFTGATE SHOWN WITH WALK RAMP BOX FIG 12 1A 1 1 2 WALK RAMP PAD 2 PLACES WALK RAMP LATCH 2 1 4 25...

Page 13: ...y need to be modified Check with body man ufacturer before modifying the rear sill Installer is responsible for ensuring that vehicle body and frame modifications do not adversely affect the integrity...

Page 14: ...TFORM CLEARANCE CUTOUT AREA WITHIN DASHED LINES TRUCK FRAME TRUCK BODY BODY CROSS MEMBERS BODY FLOOR 9 1 2 REAR SILL 19 1 2 MIN VEHICLE REQUIREMENTS Continued NOTE The platform cutout area shown below...

Page 15: ...s to trucks If the rear sill dimen sion is taller than 9 it may need to be modified Check with body manufac turer before modifying the rear sill TRUCK BODY VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE...

Page 16: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 16 CENTER OF MASS TE 25DC TE 33 CENTER OF MASS STOWED POSITION FIG 16 1 17 9 32 21 5 16...

Page 17: ...TE 25DC TE 33 Liftgate extension plate comes with bolt holes so it can be bolted to vehicle body with optional bolt kit GRADE 8 bolts are re quired MAXON recommends getting the optional extension plat...

Page 18: ...7 4116 FAX 888 771 7713 18 REAR SILL HOLE LOCATIONS FOR 102 WIDE VEHICLE FIG 18 1 STEP 1 ATTACH EXTENSION PLATE TO VEHICLE Continued 1 1 4 1 1 2 27 37 44 51 58 65 75 80 85 95 1 2 100 1 2 102 22 17 REA...

Page 19: ...All the bolts and lock nuts are in place Mating surfaces of extension plate and rear sill are made flat as possible Top of extension plate is flush with top of rear sill CAUTION The mating surface bet...

Page 20: ...6 EXTENSION PLATE VEHICLE BODY WELD EXTENSION PLATE ALTERNATE METHOD 3 16 NOTE Before welding extension plate to vehicle body make sure Inboard edge of extension plate is flush with the top of sill on...

Page 21: ...13 2 PLACES HEX NUT 1 2 13 2 PLACES NOTE During installation of Liftgate installation brackets keep the heel of the plat form level with extension plate and maintain a gap between extension plate and...

Page 22: ...E TO VEHICLE NOTE TE 25DC TE 33 Liftgates are equipped with mounting plates in stalled at the factory Mounting plate widths are shown based upon truck or trailer frame widths Ensure you have the corre...

Page 23: ...71 7713 23 1 Unfold the platform and flipover FIG 23 2 PLATFORM FLIPOVER UNFOLDED FIG 23 2 FLIPOVER UNFOLDED PLATFORM UNFOLDED STEP 2 WELD LIFTGATE TO VEHICLE Continued WELD ON MOUNTING PLATES PAINTED...

Page 24: ...NCORRECT WAY TO HOIST LIFTGATE FIG 24 2 To prevent damage to the flipover NEVER hoist the Liftgate by the flipover as shown in the NO illustration Hoist the Liftgate by the platform only as shown in t...

Page 25: ...paint must be removed from all sides of the weld area before welding CAUTION CAUTION When using an electric welder connect the welder ground to one of the parts being welded as close to the weld as p...

Page 26: ...le frame Weld the mounting plates to vehicle frame as shown in FIG 26 1 Remove clamps 6 If necessary unbolt mount ing plate to cut at the top as shown in FIG 26 2 Repeat for LH mounting plate Then bol...

Page 27: ...4116 FAX 888 771 7713 27 STEP 2 WELD LIFTGATE TO VEHICLE Continued WELD TO VEHICLE FRAME WALK RAMP RH SIDE SHOWN FIG 27 1 VEHICLE FRAME TYPICAL TRUCK FRAME SHOWN MOUNTING PLATE MAIN FRAME 2 LG 4 PLACE...

Page 28: ...ollowing page for battery and cable con nections LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE BATTERY BOX INSTALLATION ON TRUCK FIG 28 1 CIRCUIT BREAKER RECOMMENDED CONFIGURATION NOTE Make sure t...

Page 29: ...FRAME BATTERY BOX FRAME MOUNTING BRACKETS MOUNTING BRACKETS BOLTING BRACKETS 8 PLACES FIG 29 1C FLUSH BRACKETS FOR TRAILERS 8 PLACES FIG 29 1B FLUSH BRACKETS FOR TRUCKS 8 PLACES FIG 29 2 ALIGNING BATT...

Page 30: ...olt mounting brackets to cross mem bers as shown in FIGS 30 2A and 30 2B Torque bolts and lock nuts to 85 128 lb ft NOTE If welding mounting brackets to cross members skip instruction 3 MARK AND DRILL...

Page 31: ...ct welder grounding cable to the part being welded CAUTION Recommended practices for welding on steel parts are contained in the cur rent AWS American Welding Society D1 1 Structural Welding Code Stee...

Page 32: ...it Remove all rings watches and jewelry before doing any electrical work WARNING 5 Connect battery cables fused cables and ground cables for 12 volt power as shown in FIG 32 1 or 24 volt power as show...

Page 33: ...TO VEHICLE IF EQUIPPED Continued FUSED CABLE SEE NOTE BATTERY CABLE TO COMMON GROUND FUSED CABLE TO PUMP BOX 42 LG BATTERY BOX KIT ITEM 150 AMP CIRCUIT BREAKER CABLE 12 LG CABLE 10 LG GROUND CABLE TO...

Page 34: ...VEHICLE IF EQUIPPED Continued 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...

Page 35: ...S HEX NUT 1 2 20 4 PLACES LOCK WASHER 9 16 4 PLACES FLAT WASHER 9 16 4 PLACES J BOLT ANCHOR PART OF BATTERY PLATE FLAT WASHER 1 4 4 PLACES PAN HEAD SCREW 1 4 20 X 1 LG 2 PLACES CAP SCREW 1 2 20 X 2 1...

Page 36: ...n in FIG 36 1 See the following page for running the battery cable LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE BATTERY BOX INSTALLATION ON TRUCK FIG 36 1 NOTE Make sure the Liftgate power unit a...

Page 37: ...ABLE END TERMINAL LUG TO VEHICLE BATTERY VEHICLE FRAME TRUCK FRAME SHOWN 18 24 SPACING CHARGE LINE TO PUMP BOX FRONT OF VEHICLE REAR OF VEHICLE CABLE CLIPS Never route an energized wire Make sure the...

Page 38: ...7 4116 FAX 888 771 7713 38 STEP 5 CONNECT POWER CABLE 1 Unbolt and remove pump cover FIG 38 1 UNBOLTING PUMP COVER FIG 38 1 CAP SCREW 5 16 18 2 PLACES HOLDER FLAT 2 PLACES FLAT WASHER 5 16 2 PLACES NY...

Page 39: ...39 2 4 Remove hex nut and lock wash er from battery terminal post on the starter solenoid Connect the fused power cable to the starter solenoid as shown in FIG 39 3 Reinstall and tighten lock washer a...

Page 40: ...UG EXTERNAL GROUND EXTERNAL GROUND CABLE CABLE NOTE If there is a grounding point on the frame use it to connect ground cable Then skip the step for drilling a hole 2 Extend the ground cable to reach...

Page 41: ...n corner post and down the vertical post and under the vehicle body to the pump assembly See dashed line FIG 41 2 ROUTING CONTROL SWITCH WIRING FIG 41 2 3 Push control switch and cable back into the 3...

Page 42: ...nes must be run into pump box through sealing grommets FIGS 42 1 42 2 To ensure a good seal on the electrical lines never cut the sealing grommets 5 Insert switch wiring through grom met on pump mount...

Page 43: ...1 UNBOLTING PUMP COVER FIG 43 1 3 If needed add fluid to the reservoir as fol lows Pull out no threads filler cap FIG 43 2 Fill the reservoir with hydraulic fluid to level shown in FIG 43 2 Reinstall...

Page 44: ...32 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 EXXONMOBIL UNIVIS N 32 DTE 24 ISO 15 OR MIL H 5606 HYDRAULIC OIL RECOMMENDED BRANDS PART NU...

Page 45: ...VE BATTERY CABLE RECONNECTED BATTERY CABLES FIG 45 3 POSITIVE BATTERY TERMINAL POSITIVE BATTERY CABLE NUT NUT 2 Remove nut from positive battery terminal FIG 45 1 3 Connect fused positive cable to pos...

Page 46: ...IG 46 1 FIG 46 2 FLOOR JACK BRACKET FASTENERS 2 PLACES EXTENSION PLATE 1 Push control switch to UP position and hold just enough time to pressurize hydraulic system Release control switch Hydraulic sy...

Page 47: ...7 4 Remove locking brackets from LH and RH cylinder FIG 47 1 NOTE To operate Liftgate locking brackets must be removed from cylinders REMOVING LOCKING BRACKETS FIG 47 1 LOCKING BRACKETS RH CYLINDER LH...

Page 48: ...FIG 48 1 NOTE Correct any interference problems before continuing with installation 6 If the platform lowers with a jerking motion bleed air from the hydraulic system by doing the following Push the...

Page 49: ...for 5 8 1 8 gap between heel of platform and edge of ex tension plate FIG 49 1 5 8 1 8 PLATFORM EXTENSION PLATE NOTE Correct any fit and interference problems before continuing with installation CHECK...

Page 50: ...ight is 1 8 maximum as shown SURFACES FLUSH 1 8 MAX 1 8 MAX SURFACES FLUSH EXTENSION PLATE EXTENSION PLATE PLATFORM PLATFORM DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM EXTENSION PLATE RH VIEW FIG 50 1 D...

Page 51: ...nut from opener bracket FIG 51 1 Rotate opener assembly to the correct hole position FIG 51 2 and TABLE 51 1 FIG 52 1 and TABLE 52 1 Reinstall cap screw and nut REMOVING BOLT FROM OPENER BRACKET FIG...

Page 52: ...D HEIGHT WITH WALK RAMP FIG 52 1 BOLT HOLE CHART FOR 44 54 BED HEIGHT WITH WALK RAMP 26 26 24 24 PLATFORMS UNLESS NOTED TABLE 52 1 HOLE 6 HOLE 5 HOLE 4 HOLE 3 HOLE 2 HOLE 1 REF OPENER ASSEMBLY OPENER...

Page 53: ...tgate is installed correctly and no adjustment is needed If indications are incorrect continue with instruction 2 TABLE 53 1 2 Make sure platform is still at ground level If the shackle is not touchin...

Page 54: ...STOP 7 8 1 16 2 1 8 3 3 16 3 15 16 1 4 PLATFORM DOES NOT TOUCH GROUND FIG 54 1 4 RAISE the platform to comfortable work height Fold flipover and platform for access to platform stops FIG 54 2 GRINDIN...

Page 55: ...must be removed from all sides of the weld area before welding CAUTION MOUNTING PLATE MOUNTING PLATE PAINTED WELDED TO TRUCK FRAME MAIN FRAME FIG 55 1 2 X 7 MIN VERTICAL WELDS TYPICAL BOTH MOUNTING P...

Page 56: ...SITIVE BATTERY POST NEGATIVE BATTERY CABLE NEGATIVE BATTERY POST NUT POSITIVE BATTERY CABLE WARNING To prevent accidental personal injury and equipment damage disconnect battery cable and cable from b...

Page 57: ...r shown in FIG 57 1 Then torque each bolt and lock nut to 105 lb ft in the same order BOLTING STEP TO EXTENSION PLATE LH DUAL STEP SHOWN FIG 57 1 1 2 X 1 1 2 LG FRAME BOLT 2 PLACES PART OF EXTENSION P...

Page 58: ...l against bottom of vehicle rear sill and I beams Then butt the step support against back of the step FIG 58 1 LH STEP STEP SUPPORT MOUNTING CHANNEL LOCK NUT 3 PLACES FLAT WASHER 3 PLACES REAR SILL 6...

Page 59: ...ng channel to vehicle body ensure step is straight and steps are in vertical position REAR SILL 8 Repeat instructions 3 through 7 for RH step Use the RH Step As sembly Kit item 3 16 MOUNTING CHANNEL R...

Page 60: ...60 STEP 15 VEHICLE TAILLIGHT POSITIONING NOTE Taillights may interfere with Liftgate Taillights and attaching hardware are not provided with the Liftgate If needed install vehicle taillights to compl...

Page 61: ...t must be applied so that they are easily visible when approaching vehicle to operate Liftgate Use good common sense when locating these decals on vehicle NOTE Ensure there is no residue dirt or corro...

Page 62: ...rings CA 90670 800 227 4116 FAX 888 771 7713 62 ATTACH DECALS Continued DECAL SHEET P N 282522 01 FIG 62 1 CAPACITY DECALS TABLE 62 1 MODEL DECAL P N CAPACITY TE 25DC 220382 2500 POUNDS 1134 KG TE 33...

Page 63: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 63 DECALS PLATES FIG 63 1 MAXON NAME PLATE P N 280004 01 SERIAL PLATE REF PAINT DECAL PAINTED ONLY P N 267338 01...

Page 64: ...they are easily visible when approaching vehicle to operate Liftgate Use good common sense when locating these decals on vehicle NOTE Ensure there is no residue dirt or corrosion where decals are atta...

Page 65: ...670 800 227 4116 FAX 888 771 7713 65 ATTACH DECALS TEWR 25DC TEWR 33 Continued FIG 65 1 DECAL SHEET P N 282522 01 CAPACITY DECALS TABLE 65 1 MODEL DECAL P N CAPACITY TEWR 25DC 220382 2500 POUNDS 1134...

Page 66: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 66 DECALS PLATES FIG 66 1 MAXON NAME PLATE P N 280004 01 SERIAL PLATE REF PAINT DECAL PAINTED ONLY P N 267338 01...

Page 67: ...od while painting CAUTION TOUCHUP PAINTED OR GALVANIZED FINISH 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...

Page 68: ...TY DOWN SYSTEM DIAGRAMS GRAVITY DOWN POWER UNIT FIG 68 1 TABLE 68 1 POWER UNIT MOTOR SOLENOID OPERATION LIFTGATE FUNCTION PORT SOLENOID OPERATION MEANS ENERGIZED MOTOR VALVE S2 LOCK VALVE RAISE A LOWE...

Page 69: ...HYDRAULIC SCHEMATIC GRAVITY DOWN FIG 69 1 M 3 GPM FLOW CONTROL VALVE RELIEF VALVE SET AT 3250 PSI PUMP MOTOR REF RESERVOIR CHECK VALVE FILTER DRAIN HOLE PLUGGED HYDRAULIC CYLINDERS FILL HOLE PLUGGED...

Page 70: ...7713 70 ELECTRICAL SCHEMATIC GRAVITY DOWN ELECTRICAL SYSTEM DIAGRAMS FIG 70 1 DOWN UP CONTROL SWITCH STARTER SOLENOID MOTOR FUSE HOLDER WITH 10 AMP FUSE JUNCTION BLOCK WHITE BLACK GREEN 1 2 2 1 CYCLE...

Page 71: ...SYSTEM DIAGRAMS POWER DOWN POWER UNIT FIG 71 1 TABLE 71 1 POWER UNIT MOTOR SOLENOID OPERATION LIFTGATE FUNCTION PORT SOLENOID OPERATION MEANS ENERGIZED MOTOR VALVE S2 VALVE S1 LOCK VALVE RAISE A LOWER...

Page 72: ...FIG 72 1 HYDRAULIC SCHEMATIC POWER DOWN HYDRAULIC CYLINDERS PORT B POWER DOWN PORT A RAISE RELIEF VALVE 2 SET AT 1100 PSI PUMP AUX HAND PUMP PORT PLUGGED VALVE S2 RESERVOIR DRAIN HOLE PLUGGED FILTER...

Page 73: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 73 ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC POWER DOWN FIG 73 1...

Page 74: ...Valves S1 S2 S1 Coil Resistance 6 6 70 F 15 26 7 70 F 15 S1 Ampere 1 8A 0 9A S2 Coil Resistance 7 5 70 F 15 30 8 70 F 15 S2 Ampere 1 6A 0 78A Coil terminal torque 15 45 lb in max Valve cartridge torqu...

Page 75: ...D PD TRAFFIC CONES 268893 01 X X EXTENSION PLATE HARDWARE KIT 96 102 W VEH 283257 02 X X HIGH BED STEP OPTIONS 42 TO 54 BED HEIGHT 30 OVERALL STEP HEIGHT PAINTED DUAL STEP KITS WITH BUMPER PART NO GD...

Page 76: ...STEP KIT STREET SIDE NO STEPS 13 5 RUBBER BUMPERS 288705 24G X X DUAL STEPS W LIGHT STREET SIDE NO STEPS 14 RUBBER BUMPERS 288705 33G X X DUAL STEPS W LIGHT STREET SIDE NO STEPS 13 5 RUBBER BUMPERS 2...

Page 77: ...PS ON STREET SIDE PART NO GD PD SINGLE STEP KIT STREET SIDE NO STEPS 14 RUBBER BUMPERS 288705 13G X X SINGLE STEP KIT STREET SIDE NO STEPS 13 5 PE BUMPERS 288705 14G X X GALVANIZED SINGLE STEPS WITHOU...

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