Maxon TE-25DC Installation Manual
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Maxon TE-25DC Installation Manual

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M-17-10
REV. A
JULY 2018
To fi 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.
© 2018 MAXON Lift Corp.

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Summary of Contents for Maxon TE-25DC

  • Page 1 REV. A JULY 2018 To fi 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 &...

  • Page 2: Table Of Contents

    WARNINGS ........................... 5 SAFETY INSTRUCTIONS ....................6 NOTICE ..........................6 STANDARD LIFTGATE COMPONENTS ................7 TE-25DC & TE-33 INSTALLATION PARTS BOXES ............. 8 TE-25DC & TE-33 MANUALS & DECALS ................9 VEHICLE REQUIREMENTS ....................10 CENTER OF MASS ......................16 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE ............
  • Page 3 TABLE OF CONTENTS - Continued DECALS & PLATES ......................63 ATTACH DECALS: TEWR-25DC & TEWR-33 ..............64 DECALS & PLATES ......................66 TOUCHUP PAINTED OR GALVANIZED FINISH ............... 67 SYSTEM DIAGRAMS ......................68 PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) ........68 HYDRAULIC SCHEMATIC (GRAVITY DOWN) ..............

  • Page 4: Summary Of Changes: M-17-10, Revision A

    Added TE-25DC and TEWR-25DC throughout the manual with topics & instructions Various about TE-33 & TEWR-33 liftgates. Table added with new manual & decal kit for TE-25DC. Old decals P/N 264507 were removed. New bilingual decals P/N 299038-01 were added. FIG. 41-2 shows new control switch.

  • Page 5: Warnings

    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. •...

  • Page 6: Safety Instructions

    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.

  • Page 7: Standard Liftgate Components

    If parts and components are missing or incorrect, call: Maxon Customer Service Call (800) 227-4116 or Send e-mail to cservice@maxonlift.com EXTENSION PLATE DUAL STEP KIT EXTENSION PLATE FOR WALK RAMP PARTS BOX B PARTS BOX A OR C TE-25DC OR TE-33 LIFTGATE LIFTGATE COMPONENTS FIG. 7-1...

  • Page 8: Te-25Dc & Te-33 Installation Parts Boxes

    TE-25DC & TE-33 INSTALLATION PARTS BOXES ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER PARTS BOX A 297502-01 SPRING CLIP 050079 PLASTIC TIE 206864 #10 LOOM CLAMP 801681 SCREW TAPPING #10 X 1/2” LG. 030458 CABLE ASSEMBLY, 2 GA, 48” LG.

  • Page 9: Te-25Dc & Te-33 Manuals & Decals

    TE-25DC & TE-33 MANUALS & DECALS To fi 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.

  • Page 10: Vehicle Requirements

    VEHICLE REQUIREMENTS NOTE: Maximum and Minimum Operating Bed Height for Standard Platforms: • Maximum bed height for TE-25DC & TE-33 Liftgates 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”...
  • Page 11 44” MAX BED HEIGHT (ALL PLATFORMS) 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” TE-25DC & TE-33 LOW BED CLEARANCES (44” TO 38” BED HEIGHT) FIG. 11-1 36-5/8”...
  • Page 12 VEHICLE REQUIREMENTS - Continued 2. Check for correct clearances between walk ramp, walk ramp box, and the extension plate (FIGS. 12-1A and 12-1B) to prevent interference. 27-1/2” NOTCH (4 PLACES) 20-1/2” 2-1/4” 2-1/4” EXTENSION PLATE 1-1/2” 1-1/2” SILL RAMP 8-1/2” 9-3/16”...
  • Page 13 VEHICLE REQUIREMENTS - Continued CAUTION • To prevent platform from being damaged, make sure vehicle frame is cut cor- rectly. If the cutouts are incorrect, platform may hit vehicle frame or underbody when stowing the Liftgate. • Installer is responsible for ensuring that vehicle body and frame modifi cations do not adversely affect the integrity of the body and frame.
  • Page 14 VEHICLE REQUIREMENTS - Continued NOTE: The platform cutout area shown below applies to trucks. If the rear sill di- mension is taller than 4” it may need to be modifi ed. Check with body manufacturer before modifying the rear sill. REAR SILL BODY FLOOR TRUCK BODY...
  • Page 15 VEHICLE REQUIREMENTS - Continued NOTE: The platform cutout area shown below applies to trucks. If the rear sill dimen- sion is taller than 9” it may need to be modifi ed. Check with body manufac- turer before modifying the rear sill. REAR SILL BODY FLOOR TRUCK BODY...

  • Page 16: Center Of Mass

    CENTER OF MASS 17-9/32” 21-5/16” TE-25DC & TE-33 CENTER OF MASS (STOWED POSITION) FIG. 16-1...

  • Page 17: Step 1 - Attach Extension Plate To Vehicle

    To preserve the corrosion-resistant properties of the galvanized fi nish, MAXON recommends bolting the galvanized extension plate to vehicle. NOTE: 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.
  • Page 18 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued 102” 100-1/2” 95-1/2” 85” 80” 75” 65” 58” 51” 44” 37” 27” 22” 17” 1-1/4” 1-1/2” 6-1/2” 6-1/2” USE 9/16” DRILL REAR (19 PLACES) SILL 3-1/8” REAR SILL - HOLE LOCATIONS FOR 102” WIDE VEHICLE FIG.
  • Page 19 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued CAUTION CAUTION The mating surface between the bolt-on extension plate and vehicle rear sill must be as fl at as possible. Interference between the mating surfaces could result in a distorted top surface of extension plate when all the bolts are tightened.

  • Page 20: Weld Extension Plate (Alternate Method)

    WELD EXTENSION PLATE (ALTERNATE METHOD) CAUTION To preserve the corrosion-resistant properties of the galvanized fi nish, MAXON recommends bolting the galvanized extension plate to vehicle. 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 21 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued EXTENSION PLATE VEHICLE BODY WELD LENGTH & SPACE: 3/16” 2” - 11 3/4” (96” WIDE VEHICLE) 2” - 12 1/2” (102” WIDE VEHICLE) EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH FIG.

  • Page 22: Step 2 - Weld Liftgate To Vehicle

    STEP 2 - WELD LIFTGATE 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 correct mounting plate kit for your application.
  • Page 23 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued BOLT & LOCK NUT BOLT & LOCK NUT WELD-ON MOUNTING PLATES (PAINTED) TEMPORARILY BOLTED AS SHOWN FIG. 23-1 1. Unfold the platform and fl ipover (FIG. 23-2). PLATFORM (UNFOLDED) FLIPOVER (UNFOLDED) PLATFORM &...
  • Page 24 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued CAUTION To prevent damage to the fl ipover, NEVER hoist the Liftgate by the fl ipover as shown in the NO illustration. Hoist the Liftgate by the platform only as shown in the YES illustration. 2.
  • Page 25 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued CAUTION Prevent damage to hydraulic hoses. If welding next to hydraulic hoses, use a protective cover such as a welding blanket to cover the hoses. 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 NOTE: For painted Liftgates, weld both mounting plates to vehicle frame before fully welding mounting plates to painted main frame. 5. Clamp both mounting plates to vehicle frame. Weld the mounting plates to vehicle frame as shown in FIG.
  • Page 27 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued 2” LG. 4 PLACES BED LEVEL (TYPICAL - RH & LH 1/4” MOUNTING PLATES) 24-1/2” VEHICLE FRAME (TYPICAL TRUCK FRAME SHOWN) MOUNTING PLATE MAIN FRAME WELD TO VEHICLE FRAME - WALK RAMP (RH SIDE SHOWN) FIG.

  • Page 28: Step 3 - Attach Optional Battery Box & Frame To Vehicle (If Equipped)

    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 29 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued 2. Select holes on top of battery box LOCK LOCK NUT frame to align mounting brackets WASHER fl ush to cross members. Refer WASHER CROSS to FIGS.
  • Page 30 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- CROSS plate mark and drill holes through MEMBER cross members (FIG.
  • Page 31 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 32 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued WARNING Remove all rings, watches and jewelry before doing any electrical work. NOTE: Always connect fused end of power cable to battery positive (+) terminal. NOTE: To connect charge lines, refer to instructions provided with each charge line kit.
  • Page 33 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 34 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 35 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...

  • Page 36: Step 4 - Run Power 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, TYPICAL LOCATION truck batteries is typically installed on trucks as 175 AMP...
  • Page 37 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, fi...

  • Page 38: Step 5 - Connect Power Cable

    STEP 5 - CONNECT POWER CABLE Unbolt and remove pump cover (FIG. 38-1). UNBOLTING PUMP COVER FIG. 38-1...
  • Page 39 STEP 5 - CONNECT POWER CABLE - Continued NOTE: Electrical lines must be run into pump box through sealing grom- mets (FIG. 39-3). To ensure a good seal on hydraulic & electrical lines, never cut the sealing grommets. 2. Run fused power cable through bottom COPPER TERMINAL LUG grommet on pump mounting plate (FIG.

  • Page 40: Step 6 - Connect Ground Cable

    STEP 6 - CONNECT GROUND CABLE NOTE: To ensure power unit is correctly grounded, connect 2 gauge ground cable from grounding connection on pump mounting plate to a grounding point on the frame, or negative battery terminal in the optional battery box. 1.

  • Page 41: Step 7 - Install Control Switch

    STEP 7 - INSTALL CONTROL SWITCH 1. Measure, mark and drill one 3/4” hole and two #21–size holes in the vertical post on curb side of vehicle body as shown in FIG. 41-1. VEHICLE BODY VERTICAL POST (CURB SIDE) 2. Insert control switch wir- ing harness (parts box) into 3/4”...
  • Page 42 STEP 7 - INSTALL CONTROL SWITCH - Continued NOTE: Electrical lines 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- CONTROL met on pump mounting plate (FIGS.

  • Page 43: Step 8 - Checking Hydraulic Fluid

    STEP 8 - CHECKING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller 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 - CHECKING HYDRAULIC FLUID - Continued ISO 32 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 EXXONMOBIL UNIVIS N-32, DTE-24 TABLE 44-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON...

  • Page 45: Step 9 - Connect Power Cable To Battery

    STEP 9 - CONNECT POWER CABLE TO BATTERY NOTE: MAXON recommends using dielectric grease on all electrical connections. 1. Remove nut from negative (-) bat- POSITIVE (+) tery terminal. Disconnect negative BATTERY CABLE (-) battery cable (FIG. 45-1). POSITIVE (+)

  • Page 46: Step 10 - Remove Locking Brackets & Check For Interference

    STEP 10 - REMOVE LOCKING BRACKETS & 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 BRACKETS & CHECK FOR INTERFERENCE - Continued NOTE: To operate Liftgate, locking brackets must be removed from cylinders. 4. Remove locking brackets from LH and RH cylinder (FIG. 47-1). CYLINDER LOCKING BRACKETS CYLINDER REMOVING LOCKING BRACKETS FIG.
  • Page 48 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued NOTE: Correct any interference problems before continuing with installation. 5. Raise platform to bed height (FIG. 48-1). Then, lower platform to the ground (FIG. 48-2). Look for any interference be- tween liftgate and vehicle as platform is raised and lowered.
  • Page 49 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued NOTE: Correct any fi t and interference problems before continuing with installation. 7. Raise platform to bed height (FIG. 49-1). Check for 5/8” (+/- 1/8”) gap between heel of platform and edge of ex- tension plate (FIG.
  • Page 50 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued NOTE: Correct any fi t and in- SURFACES FLUSH terference problems before continuing with installation. 8. Ensure top surface of platform PLATFORM and extension plate are fl ush 1/8”...

  • Page 51: Step 11 - Adjust Platform Opener

    STEP 11 - ADJUST PLATFORM OPENER To adjust openers, remove cap screw and hex 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.
  • Page 52 STEP 11 - ADJUST PLATFORM OPENER - Continued HOLE #6 HOLE #5 HOLE #4 HOLE #3 HOLE #2 HOLE #1 (REF) OPENER OPENER BRACKET ASSEMBLY 44” - 54” BED HEIGHT POSITIONING OPENER FOR 44”- 54” BED HEIGHT WITH WALK RAMP FIG.

  • Page 53: Step 12 - Adjust Platform (If Required)

    STEP 12 - ADJUST PLATFORM (IF REQUIRED) NOTE: Before doing the following proce- dure, make sure vehicle is parked on level ground. TIP OF FLIPOVER 1. Make sure platform is at ground level. Unfold the platform and fl ipover. As the platform fi rst touches the ground, shackles and tip of fl...
  • Page 54 STEP 12 - ADJUST PLATFORM (IF REQUIRED) - Continued 3. Make sure platform is still at ground level. If the tip of fl ipover is not touching the ground, measure and compare dis- tance “B” (FIG. 54-1) with TABLE 54-1 to determine how much to grind from the platform stops (FIG.

  • Page 55: Step 13 - Finish Welding Liftgate To Vehicle

    STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE 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. 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.

  • Page 56: Step 14 - Bolt Optional Steps To Extension Plate

    STEP 14 - BOLT OPTIONAL STEPS TO EXTENSION PLATE 1. Lower platform to the ground (FIG. 56-1). PLATFORM LOWERED TO GROUND FIG. 56-1 WARNING To prevent accidental personal injury and equipment damage, disconnect (-) battery cable and (+) cable from battery.
  • Page 57 STEP 14 - BOLT OPTIONAL STEPS TO EXTENSION PLATE - Continued CAUTION To prevent interference with Liftgate and possible damage, maintain 90º angle between steps and extension plate. Tighten bolts only in the order shown in illustration. NOTE: If 102” extension kit is to be installed for 102” wide vehicle, install the exten- sion kit before installing the steps.
  • Page 58 STEP 14 - BOLT OPTIONAL STEPS TO EXTENSION PLATE - Continued 4. Bolt the step support (Kit item) to mounting channel (Kit item) (FIG. 58-1). REAR SILL I-BEAM (VEHICLE BODY) LOCK NUT (3 PLACES) FLAT WASHER (3 PLACES) MOUNTING 1/2” X 3-1/2” LG. CHANNEL LH STEP FRAME BOLT...
  • Page 59 STEP 14 - BOLT OPTIONAL STEPS TO EXTENSION PLATE - Continued NOTE: Before welding mounting channel to vehicle body, ensure step is straight WELD TO AS MUCH 3/16” and steps are in vertical position. I-BEAM FLANGE & 3/16” REAR SILL AS POSSIBLE 7.

  • Page 60: Step 15 - Vehicle Taillight Positioning

    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 comply with state and federal vehicle lighting requirements, such as FMVSS 108.

  • Page 61: Attach Decals: Te-25Dc & Te-33

    ATTACH DECALS: TE-25DC & TE-33 NOTE: Preferred decal layout is shown. Decals on the Liftgate are attached at the factory. If vehicle does not permit this layout, decals in the manual and decal kit must be applied so that they are easily visible when approaching vehicle to operate Liftgate.
  • Page 62 ATTACH DECALS - Continued DECAL SHEET P/N 282522-01 FIG. 62-1 MODEL DECAL P/N CAPACITY TE-25DC 220382 2500 POUNDS [1134 KG] TE-33 220388-02 3300 POUNDS [1500 KG] CAPACITY DECALS TABLE 62-1...

  • Page 63: Decals & Plates

    DECALS & PLATES PAINT DECAL (PAINTED ONLY) P/N 267338-01 MAXON NAME PLATE P/N 280004-01 SERIAL PLATE (REF) FIG. 63-1...

  • Page 64: Attach Decals: Tewr-25Dc & Tewr-33

    ATTACH DECALS: TEWR-25DC & TEWR-33 NOTE: Preferred decal layout is shown. Decals on the Liftgate are attached at the factory. If vehicle does not permit this layout, decals in the manual and decal kit must be applied so that they are easily visible when approaching vehicle to operate Liftgate.
  • Page 65 ATTACH DECALS: TEWR-25DC & TEWR-33 - Continued DECAL SHEET P/N 282522-01 FIG. 65-1 MODEL DECAL P/N CAPACITY TEWR-25DC 220382 2500 POUNDS [1134 KG] TEWR-33 220388-02 3300 POUNDS [1500 KG] CAPACITY DECALS TABLE 65-1...

  • Page 66: Decals & Plates

    DECALS & PLATES PAINT DECAL (PAINTED ONLY) P/N 267338-01 MAXON NAME PLATE P/N 280004-01 SERIAL PLATE (REF) FIG. 66-1...

  • Page 67: Touchup Painted Or Galvanized Finish

    To maintain the protection provided by the original paint system, MAXON recommends aluminum primer touchup paint. • If bare metal is exposed on galvanized portions of the Liftgate, touch up the galvanized fi nish. To maintain the protection provided by the original galvanized fi nish, MAXON recommends cold galvanize spray.

  • Page 68: System Diagrams

    SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) STARTER SOLENOID “S2” VALVE MOTOR DIRECTION OF CONTROLLED FLOW GRAVITY DOWN POWER UNIT FIG. 68-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE LOCK MOTOR “S2”...

  • Page 69: Hydraulic Schematic (Gravity Down)

    HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC (GRAVITY DOWN) HYDRAULIC CYLINDERS HYDRAULIC LOCK VALVE 3 GPM FLOW CONTROL VALVE PORT B - RETURN FILL HOLE VENT (PLUGGED) (PLUGGED) PORT PORT A - RAISE VALVE “S2” RELIEF VALVE CHECK VALVE (SET AT 3250 PSI) AUX.

  • Page 70: Electrical Schematic (Gravity Down)

    ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC (GRAVITY DOWN) CONTROL SWITCH (UP) (DOWN) GREEN BLACK JUNCTION BLOCK WHITE CYCLE COUNTER SOLENOID LOCK VALVE “S2” VALVE EQUIPPED) FUSE HOLDER WITH 10 AMP FUSE STARTER SOLENOID MOTOR BATTERY BLACK FIG. 70-1...

  • Page 71: Pump & Motor Solenoid Operation (Power Down)

    SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION (POWER DOWN) STARTER SOLENOID MOTOR “S2” VALVE “S1” VALVE DIRECTION OF CONTROLLED FLOW POWER DOWN POWER UNIT FIG. 71-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE VALVE LOCK MOTOR...

  • Page 72: Hydraulic Schematic (Power Down)

    HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDERS HYDRAULIC LOCK VALVE 3 GPM FLOW CONTROL VALVE PORT B - POWER DOWN PORT A - RAISE VALVE “S2” FILTER RELIEF VALVE 2 (SET AT 1100 PSI) VALVE “S1” RELIEF VALVE 1 (SET AT 2750 PSI) AUX.

  • Page 73: Electrical Schematic (Power Down)

    ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC (POWER DOWN) FIG. 73-1...

  • Page 74: Electrical Values

    ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL VALUES Solenoid Switch Coil Resistance: 5.4Ω @70ºF ±15% 20.1Ω @70ºF ±15% Ampere: 2.2A 1.2A Coil terminal torque: 10-15 lb-in max. Contact terminal torque: 30-35 lb-in max. Solenoid Valves (S1 & S2) S1 Coil Resistance: 6.6Ω @ 70ºF ±15% 26.7Ω @ 70ºF ±15% S1 Ampere: 1.8A 0.9A...

  • Page 75: Options

    OPTIONS OPTIONAL LIFTGATE COMPONENTS MECHANICAL KITS PART NO. EXTENSION KIT 102”, 13” EXTENSION PLATE 287095-03 EXTENSION KIT 102”, 13” EXTENSION PLATE, GALVANIZED 287095-03G ELECTRICAL KITS PART NO. IN CAB ON-OFF SWITCH 250477 TUK-A-WAY DUAL CONTROL KIT 297115-01 TUK-A-WAY DUAL CONTROL KIT, STREET SIDE 297116-01 HAND HELD CONTROL ASSEMBLY, INSIDE 280570-07...
  • Page 76 OPTIONS OPTIONAL LIFTGATE COMPONENTS - CONTINUED PAINTED DUAL STEPS WITHOUT BUMPERS PART NO. DUAL STEPS, NO BUMPERS 288705-05 DUAL STEPS, STREET SIDE NO STEPS, NO BUMPERS 288705-06 DUAL FLEX STEPS, NO BUMPERS 288705-25 DUAL FLEX STEPS, STREET SIDE, NO STEPS, NO BUMPERS 288705-26 DUAL STEPS W/LIGHT, NO BUMPERS 288705-35...
  • Page 77 OPTIONS OPTIONAL LIFTGATE COMPONENTS - CONTINUED GALVANIZED SINGLE STEPS W/BUMPERS PART NO. SINGLE STEP KIT, 14” RUBBER BUMPERS 288705-11G SINGLE STEP KIT, 13.5” PE BUMPERS 288705-12G GALVANIZED SINGLE STEPS WITH BUMPERS NO STEPS ON STREET SIDE PART NO. SINGLE STEP KIT, STREET SIDE, NO STEPS, 14” RUBBER BUMPERS 288705-13G SINGLE STEP KIT, STREET SIDE, NO STEPS, 13.5”...

This manual is also suitable for:

Tewr-33Te-33Tewr-25dc

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