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Maxon TE-15 Installation Manual

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To fi nd maintenance & parts information for your TE-15, TE-20, TE-25 or TE-30 Liftgate, go to
www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-15/TE-20 or TE-25/TE-30 buttons.
Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the
PARTS PORTAL, TUK-A-WAY & TE-15/TE-20 or TE-25/TE-30 buttons.
©
2019 MAXON LIFT CORP.
M-16-33
REV C
MARCH 2019

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Summary of Contents for Maxon TE-15

  • Page 1 REV C MARCH 2019 To fi nd maintenance & parts information for your TE-15, TE-20, TE-25 or TE-30 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-15/TE-20 or TE-25/TE-30 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

    NOTICE ..........................6 TE-SERIES LIFTGATE COMPONENTS ................7 PARTS BOXES FOR TE-SERIES ..................8 MANUALS & DECALS KITS, TE-15 & TE-20 ............... 9 MANUALS & DECALS KITS, TE-25 & TE-30 ..............10 VEHICLE REQUIREMENTS ....................11 CENTER OF MASS ......................16 STEP 1 - INSTALL EXTENSION PLATES ................
  • Page 3 STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE ............. 61 STEP 14 - BOLT STEPS TO EXTENSION PLATE ............63 STEP 15 - VEHICLE TAILLIGHT POSITIONING ..............67 ATTACH DECALS ......................68 TOUCHUP PAINTED OR GALVANIZED FINISH ............... 71 SYSTEM DIAGRAMS ......................72 PUMP, MOTOR &...

  • Page 4: Summary Of Changes: M-16-33, Revision C

    Parts Box B. Added new UP/DOWN decals for control switch, OPERATING INSTRUCTIONS decal with QR code, parts portal decal with QR code, and MAXON 24/7 support decal. QR 9-10,67-69 codes are linked to operation manuals or videos on the MAXON website, and parts explosions on the MAXON Parts Portal.

  • Page 5: Warnings

    Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates. See Operation Manual for operating safety requirements. WARNING Installing and maintaining a liftgate can expose you to chemicals, including lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To mini- mize exposure, install and maintain liftgate in a well-ventilated area and wear proper Personal protective equipment (PPE).

  • 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: Te-Series 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 closed in each box. If parts and components are missing or incorrect, call: Maxon Customer Service Call (800) 227-4116 or Send e-mail to customersupport@maxonlift.com...

  • Page 8: Parts Boxes For Te-Series

    PARTS BOXES FOR TE-SERIES 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 GROUND CABLE ASSEMBLY, 2GA, 48” LG 251871-26 CABLE ASSEMBLY, 2GA, 49-3/4” LG. (GROUND) 268226-11 CAP SCREW, 5/16”-18 X 3/4”...

  • Page 9: Manuals & Decals Kits, Te-15 & Te-20

    MANUALS & DECALS KITS, TE-15 & TE-20 To fi nd maintenance & parts information for your TE-15, TE-20, TE-25 or TE-30 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-15/TE-20 or TE-25/TE-30 but- tons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A-WAY &...

  • Page 10: Manuals & Decals Kits, Te-25 & Te-30

    MANUALS & DECALS KITS, TE-25 & TE-30 To fi nd maintenance & parts information for your TE-15, TE-20, TE-25 or TE-30 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY and TE-15/TE-20 or TE-25/TE-30 but- tons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A-WAY &...

  • Page 11: Vehicle Requirements

    • See TE-15 and TE-20 low bed installation dimensions in FIG. 12-2. • See TE-15 and TE-20 high bed truck frame cut-out dimensions in FIG. 13-1. • See TE-15 and TE-20 low bed truck frame cut-out dimensions in FIG. 13-2.
  • Page 12 TE-15 & TE-20 34” 22” 12-7/8” 25” 30-3/8” 54” MAX. (UNLOADED) 42” MIN. (LOADED) 24” MAX. 14” MIN. CLEARANCES FOR TE-15 & TE-20 HIGH BED INSTALLATION (PAINTED) FIG. 12-1 37-1/2” 25-1/4” 9-3/8” 21” 27” 44” MAX. (UNLOADED) 36” MIN. (LOADED) 18” MAX.
  • Page 13 VEHICLE REQUIREMENTS TE-15 & TE-20 - Continued REAR SILL BODY FLOOR BODY CROSS MEMBERS 6-1/8” BODY FRAME 13” SPACER TRUCK FRAME PLATFORM CLEARANCE CUTOUT AREA (WITHIN DASHED LINES) 16-1/2” VEHICLE FRAME CUT-OUT (42” TO 54” BED HEIGHTS) FIG. 13-1 REAR SILL...
  • Page 14 VEHICLE REQUIREMENTS TE-25 & TE-30 34” 26” 21-3/8” 11-3/4” 25” 30-3/8” 54” MAX. (UNLOADED) 42” MIN. (LOADED) 24” MAX. 14” MIN. CLEARANCES FOR TE-25 & TE-30 HIGH BED INSTALLATION FIG. 14-1 37-1/2” 29-5/16” 24-7/8” 8-1/4” 21” 27” 44” MAX. (UNLOADED) 36”...
  • Page 15 VEHICLE REQUIREMENTS TE-25 & TE-30 - Continued REAR SILL BODY FLOOR BODY CROSS MEMBERS 6-1/8” BODY FRAME 13-3/4” SPACER PLATFORM CLEARANCE TRUCK FRAME CUTOUT AREA (WITHIN DASHED LINES) 20-1/4” VEHICLE FRAME CUT-OUT (42” TO 54” BED HEIGHTS) FIG. 15-1 REAR SILL BODY FLOOR BODY CROSS MEMBERS 6-1/8”...

  • Page 16: Center Of Mass

    13-7/8” 24”+24” STEEL & ALUM 5-3/4” 14” TE-25/TE-30 24”+24” ALUM 5-3/8” 13-5/8” 26”+26” STEEL & ALUM 6” 14.1” 26”+26” ALUM 5-5/8” 13-7/8” 22”+14” STEEL 5-3/4” 14-1/4” TE-15/TE-20 24”+18” ALUM 5-5/8” 13-7/8” CENTER OF MASS DIMENSIONS FOR TE-SERIES LIFTGATES TABLE 16-1...

  • Page 17: Step 1 - Install Extension Plates

    STEP 1 - INSTALL EXTENSION PLATES NOTE: TE-15, TE-20, TE-25 & TE-30 Liftgates may be equipped with two types of extensions plates. The weld-on extension plate is shown in FIG. 17-1. The bolt-on extension plate (FIG. 17-2) has bolt holes so it can be bolted to vehicle body.

  • Page 18: Weld Extension Plate To Vehicle

    STEP 1 - INSTALL EXTENSION PLATES - Continued WELD EXTENSION PLATE TO VEHICLE 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. NOTE: Before welding extension plate to vehicle body, make sure: •...

  • Page 19: Weld A Bolt-On Extension Plate To Vehicle

    CAUTION To preserve the corrosion resistance properties of the galvanized fi nish, MAXON recommends bolting the galvanized extension plate to vehicle. Center the extension plate on vehicle body. Before welding extension plate to vehicle body, make sure top surface of extension plate is fl ush with fl oor of vehicle body.

  • Page 20: Bolt Extension Plate To Vehicle

    MAXON recommends bolting the extension plate to vehicle. NOTE: The extension plate has bolt holes so it can be bolted to vehicle body. Grade 8 bolts are required. MAXON recommends getting the optional extension plate hardware kit listed in OPTIONS section. Vehicle body must be drilled according to instructions.
  • Page 21 STEP 1 - INSTALL EXTENSION PLATES - 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 22 STEP 1 - INSTALL EXTENSION PLATES - Continued BOLT EXTENSION PLATE TO VEHICLE - Continued 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 23: Bolt Installation Brackets To Extension Plate

    STEP 1 - INSTALL EXTENSION PLATES - Continued BOLT INSTALLATION BRACKETS TO EXTENSION PLATE NOTE: During installation of liftgate, installation brackets keep the heel of the platform level with extension plate and maintain a ¾” gap between ex- tension plate and heel of platform. The extension plate has bolt holes for bolting on the installation brackets provided in parts box.

  • Page 24: Step 2 - Weld Liftgate To Vehicle

    STEP 2 - WELD LIFTGATE TO VEHICLE NOTE: TE- Series Liftgates are equipped with 2 types of mounting plates. • Mounting plates on painted Liftgates are temporarily bolted to the main frame for shipping (FIG. 25-2). These mounting plates must be unbolted, repositioned, and welded to main frame and truck frame as shown in these instructions.
  • Page 25 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued 42-1/4” BOLT & BOLT & LOCK NUT LOCK NUT (4 PLACES) (4 PLACES) BOLT-ON MOUNTING PLATES 42-1/4” (GALVANIZED) FIG. 25-1 BOLT & BOLT & LOCK NUT LOCK NUT (4 PLACES) (4 PLACES) WELD-ON MOUNTING PLATES (PAINTED) TEMPORARILY BOLTED AS SHOWN FIG.
  • Page 26 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued WARNING Do not remove lock angle except when instructed to do so in this manual. NOTE: Liftgates are shipped with a locking angle that positions Liftgate cor- rectly for high bed or low bed installation.
  • Page 27 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued WARNING 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 28 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued 4. Unbolt mounting plate from main frame. Reposi- tion mounting plate against vehicle frame. Tack weld as shown in FIGS. 28-1 or CUT LINE & TOP WELD 28-2. Repeat for second (IF NECESSARY) mounting plate (reposition and tack weld).
  • Page 29 FRAME SHOWN) 2” LG. 4 PLACES (TYPICAL - RH & LH 1/4” MOUNTING MOUNTING PLATE PLATES) TE-15 & TE-20 WELD TO VEHICLE FRAME (RH SIDE SHOWN) FIG. 29-1 VEHICLE FRAME (TYPICAL TRUCK FRAME SHOWN) 2” LG. 4 PLACES (TYPICAL - RH & LH 1/4”...
  • Page 30 1/4” MOUNTING MOUNTING PLATES) PLATE BOLTS (4 PLACES) TE-15 & TE-20 WELD TO VEHICLE FRAME (RH SIDE SHOWN) FIG. 30-1 7. Clamp both mounting plates to vehicle frame. Weld the mount- CUT LINE & TOP WELD (IF NECESSARY) ing plates to vehicle frame as shown in FIGS.

  • Page 31: 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 32 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 33 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- plate mark and drill holes through CROSS MEMBER cross members (FIG.
  • Page 34 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 35 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 36 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 37 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 38 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) (2 PLACES) CHARGE LINE FROM VEHICLE BATTERY GROUND CABLE...

  • Page 39: 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 40 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 41: Step 5 - Connect Power Cable

    STEP 5 - CONNECT POWER CABLE 1. Unbolt the pump cover as shown in FIG. 41-1. UNBOLTING PUMP COVER FIG. 41-1...
  • Page 42 STEP 5 - CONNECT POWER CABLE - Continued NOTE: Hydraulic lines and electrical lines must be run into pump box through seal- ing grommets (FIG. 42-3). To ensure a good seal on hydraulic & electrical lines, never cut the sealing grommets. 2.

  • Page 43: Step 6 - Connect Ground Cable

    STEP 6 - CONNECT GROUND CABLE NOTE: Electrical lines must be run into pump box through sealing grommets (FIG. 43-1A). To ensure a good seal on the electrical lines, never cut the sealing grommets. NOTE: To ensure power unit is correctly grounded, connect 2 gauge ground cable to grounding connection on pump.
  • Page 44 STEP 6 - CONNECT GROUND CABLE - Continued NOTE: If there is a grounding point on the frame, use it to connect ground cable. Then, skip the step for drilling a hole. NOTE: Clean the ground cable connection point on the frame down to bare metal. 4.

  • Page 45: 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. 45-1. VEHICLE BODY VERTICAL POST (CURB SIDE) 2. Insert control switch wiring (parts box) into the 3/4”...
  • Page 46 STEP 7 - INSTALL CONTROL SWITCH - Continued CAUTION CAUTION Do not over-tighten the terminal nuts. For the 5/16” load terminals, torque nuts to 35 lb-in. Torque the nuts on #10-32 control terminals to 15 lb-in. NOTE: Hydraulic lines and electrical lines run into pump box through sealing grom- mets (FIG.
  • Page 47 STEP 7 - INSTALL CONTROL SWITCH - Continued POWER DOWN MODULE WHITE WIRE BLACK WIRE STARTER TERMINAL-1 SOLENOID TERMINAL-2 GREEN WIRE FUSE HOLDER CONTROL SWITCH CONNECTED TO PD PUMP ASSEMBLY FIG. 47-1...

  • Page 48: Step 8 - Checking Hydraulic Oil

    STEP 8 - CHECKING HYDRAULIC OIL 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 49 STEP 8 - ADD 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 49-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON...

  • Page 50: Step 9 - Connect Power Cable To Battery

    STEP 9 - CONNECT POWER CABLE TO BATTERY 1. Remove nut from negative (-) bat- POSITIVE (+) tery terminal. Disconnect negative BATTERY CABLE (-) battery cable (FIG. 50-1). POSITIVE (+) BATTERY TERMINAL NEGATIVE (-) BATTERY CABLE NEGATIVE (-) BATTERY TERMINAL DISCONNECTING (-) BATTERY CABLE 2.

  • Page 51: Step 10 - Remove Locking Angle And Check For Interference

    STEP 10 - REMOVE LOCKING ANGLE AND 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 52 STEP 10 - REMOVE LOCKING ANGLE AND CHECK FOR INTERFERENCE - Continued 3. Remove fl oor jack and hoist supporting Liftgate (FIG. 52-1). FLOOR JACK FIG. 52-1 4. Lower platform to the ground (FIG. 52-2). Look for any interference between liftgate and vehicle as platform is lowered.
  • Page 53 STEP 10 - REMOVE LOCKING ANGLE AND CHECK FOR INTERFERENCE - Continued NOTE: Correct any fi t and interference problems before continuing with installation. 7. Raise platform to bed height (FIG. 53-1). There should be a 5/8” gap between the heel of platform and the extension plate (FIG.
  • Page 54 STEP 10 - REMOVE LOCKING ANGLE AND CHECK FOR INTERFERENCE - Continued NOTE: Correct any fi t and interference problems before continuing with installation. 8. Ensure top surface of platform and extension plate are fl ush at the RH and LH sides of platform (FIG. 54-1).

  • Page 55: Step 11 - Bolt Platform Opener To Liftgate

    STEP 11 - BOLT PLATFORM OPENER TO LIFTGATE 1. Start with platform unfolded at ground level (FIG. 55-1). OPENER WITH 10 HOLES TO POSITION & BOLT TO BRACKET BRACKET WITH 3 (REFER TO TABLE 56-1) HOLES TO POSITION OPENER FLAT WASHER, 1/2”...
  • Page 56 26”+26” STEEL & ALUM, OR ALUM & ALUM 48” TO 52” 52” TO 54” 42” TO 50” 22”+14” STEEL & STEEL 50” TO 54” TE-15/TE-20 42” TO 48” (HIGH BED) 22”+18” ALUM & ALUM 48” TO 52” 52” TO 54”...
  • Page 57 STEP 11 - BOLT PLATFORM OPENER TO LIFTGATE - Continued CAUTION If there is any interference with the platform while stowing Liftgate, check for damage on bottom of platform, fl ipover, and the hinge in between. A damaged platform or fl ipover may result in personal injury and additional damage to Liftgate.

  • Page 58: Step 12 - Platform Adjustment (If Required)

    STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED) NOTE: Before doing the following procedure, make sure vehicle is parked on level ground. 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 59 STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED) - Continued 3. Make shims as needed (FIG. 59-1). Position 2-1/4” bottom edge of shim to line up with mark on shackle (FIG. 59-2). Then, weld the shim to shackle as shown in FIG. 59-2. 1-1/2”...
  • Page 60 STEP 12 - PLATFORM ADJUSTMENT (IF REQUIRED) - Continued 4. 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. 60-1) with TABLE 60-1 to determine how much to grind from the TIP OF platform stops (FIG.

  • Page 61: Step 13 - Finish Welding Liftgate To Vehicle

    LONG SILL VEHICLE FRAME (TYPICAL TRUCK FRAME MOUNTING SHOWN) PLATE 2 X 7” MIN 1/4” VERTICAL WELDS TYPICAL - BOTH MOUNTING PLATES MAIN FRAME TE-15 & TE-20 MOUNTING PLATE WELDED TO TRUCK FRAME & BOLTED TO MAIN FRAME FIG. 61-2...
  • Page 62 STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE - Continued LONG SILL VEHICLE FRAME (TYPICAL TRUCK FRAME SHOWN) 2 X 7” MIN 1/4” VERTICAL WELDS TYPICAL - BOTH MOUNTING PLATES MOUNTING PLATE MAIN FRAME 1/4” TE-25 & TE-30 MOUNTING PLATE WELDED TO TRUCK FRAME &...

  • Page 63: Step 14 - Bolt Steps To Extension Plate

    STEP 14 - BOLT STEPS TO EXTENSION PLATE 1. Lower platform to the ground (FIG. 63-1). PLATFORM LOWERED TO GROUND FIG. 63-1 WARNING To prevent accidental personal injury and equipment damage, disconnect (-) battery cable and (+) cable from POSITIVE (+) BATTERY CABLE battery.
  • Page 64 STEP 14 - BOLT 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 65 STEP 14 - BOLT STEPS TO EXTENSION PLATE - Continued 4. Bolt the step support (Kit item) to mounting channel (Kit item) REAR SILL I-BEAM (FIG. 65-1). (VEHICLE BODY) LOCK NUT (3 PLACES) FLAT WASHER (3 PLACES) MOUNTING 1/2” X 3-1/2” LG. CHANNEL LH STEP FRAME BOLT...
  • Page 66 STEP 14 - BOLT 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 67: 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 68: Attach Decals

    ATTACH DECALS 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 69 ATTACH DECALS - Continued PARTS QR CODE DECAL PARTS QR CODE DECAL P/N 299348-01 (TE-15,TE-20) P/N 299348-01 (TE-15,TE-20) P/N 299348-02 (TE-25,TE-30) P/N 299348-02 (TE-25,TE-30) SERIAL PLATE (REF) SERIAL PLATE (REF) MAXON 24/7 MAXON 24/7 SUPPORT DECAL SUPPORT DECAL P/N 298634-01 P/N 298634-01 DECAL “F”...
  • Page 70 ATTACH DECALS - Continued DECAL SHEET P/N 282522-01 FIG. 70-1 MODEL DECAL P/N CAPACITY TE-15 220386 1500 POUNDS [680 KG] TE-20 220387 2000 POUNDS [907 KG] TE-25 220382 2500 POUNDS [1134 KG] TE-30 220388 3000 POUNDS [1360 KG] CAPACITY DECALS...

  • Page 71: 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 72: System Diagrams

    SYSTEM DIAGRAMS PUMP, MOTOR & SOLENOID OPERATION - GRAVITY DOWN MOTOR JUNCTION BLOCK PRESSURE SOLENOID SWITCH VENT SOLENOID VALVE GRAVITY DOWN PUMP MOTOR & SOLENOID SWITCH OPERATION SOLENOID SWITCH OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION LOCK MOTOR SOLENOID VALVE A VALVE RAISE PRESSURE...

  • Page 73: Pump, Motor & Solenoid Operation - Power Down

    SYSTEM DIAGRAMS PUMP, MOTOR & SOLENOID OPERATION - POWER DOWN MOTOR POWER DOWN MODULE PORT A “S2” VALVE SOLENOID SWITCH “S1” VALVE PORT B POWER DOWN PUMP MOTOR & SOLENOID SWITCH OPERATION SOLENOID SWITCH OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE VALVE LOCK...

  • Page 74: Hydraulic System Diagrams

    HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC (GRAVITY DOWN) HYDRAULIC CYLINDER LOCK VALVE 2 GPM FLOW CONTROL VALVE RETURN PORT FILLER HOLE (PLUGGED) (PLUGGED) PRESSURE PORT VENT PORT VALVE A CHECK VALVE AUX. HAND RELIEF VALVE PUMP PORT (SET AT 3250 PSI) (PLUGGED) MOTOR PUMP...

  • Page 75: Hydraulic Schematic (Power Down)

    HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDER LOCK VALVE 2 GPM FLOW PORT B - LOWER CONTROL VALVE (POWER DOWN) PORT A - RAISE VALVE S2 RELIEF VALVE 2 (SET AT 1100 PSI) VALVE S1 RELIEF VALVE 1 (SET AT 3200 PSI) AUX.

  • Page 76: Electrical System Diagrams

    ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC (GRAVITY DOWN) CONTROL SWITCH (UP) (DOWN) GREEN BLACK JUNCTION BLOCK WHITE CYCLE BLACK COUNTER BLACK EQUIPPED) FUSE HOLDER WITH 10 AMP FUSE SOLENOID VALVE STARTER SOLENOID LOCK VALVE CABLE WITH 175 A FUSE MOTOR BATTERY BLACK FIG.

  • Page 77: Electrical Schematic (Power Down)

    ELECTRICAL SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC (POWER DOWN) WHITE CONTROL SWITCH (UP) (DOWN) POWER DOWN MODULE BLACK WHITE (CABLE) GREEN BLACK (CABLE) BLACK FUSE HOLDER WITH 10 AMP BLACK FUSE LOCK SOLENOID, SOLENOID, VALVE VALVE S2 VALVE S1 STARTER SOLENOID CYCLE COUNTER CABLE WITH MOTOR 175 A FUSE...
  • Page 78 SYSTEM DIAGRAMS 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 79: Options

    OPTIONS OPTIONAL LIFTGATE COMPONENTS MISCELLANEOUS KITS PART NO. TRAFFIC CONES 268893-01 RELOCATE PUMP MTG KIT, GD TUK-A-WAY 297619-01 RELOCATE PUMP MTG KIT, GD TUK-A-WAY, GALVANIZED 297619-01G RELOCATE PUMP MTG KIT, PD TUK-A-WAY 297619-02 RELOCATE PUMP MTG KIT, PD TUK-A-WAY, GALVANIZED 297619-02G EXTENSION PLATE HARDWARE, 96”...
  • Page 80 OPTIONS OPTIONAL LIFTGATE COMPONENTS - Continued HIGH BED STEP OPTIONS (42” TO 54” BED HEIGHT, 30” OVERALL STEP HEIGHT) PAINTED DUAL STEP KITS WITH BUMPER PART NO. DUAL STEPS, 14” RUBBER BUMPERS 288705-01 DUAL STEPS, 13.5” RUBBER BUMPERS 288705-02 DUAL FLEX STEPS 14” RUBBER BUMPERS WITH FLEXIBLE WIRE ROPE LOWER 288705-21 STEP &...
  • Page 81 OPTIONS OPTIONAL LIFTGATE COMPONENTS - Continued LOW BED SINGLE STEPS OPTIONS (36” TO 44” BED HEIGHT, 21” OVERALL STEP HEIGHT) PAINTED SINGLE STEP KITS WITH BUMPERS SINGLE STEP, 14” RUBBER BUMPERS 288705-11 SINGLE STEP, 13.5” PLASTIC BUMPERS 288705-12 PAINTED SINGLE STEP KITS WITH BUMPERS, NO STEPS ON STREET SIDE SINGLE STEPS, STREETSIDE NO STEPS, 14”...
  • Page 82 OPTIONS OPTIONAL LIFTGATE COMPONENTS - Continued LOW BED DUAL STEPS OPTIONS (36” TO 44” BED HEIGHT, 21” OVERALL STEP HEIGHT) PAINTED DUAL STEPS WITH BUMPERS (WITH LIGHTS) DUAL STEPS WITH LIGHT (2.5”W X 3”H X 14” LG RUBBER BUMPERS) 288705-41 DUAL STEPS WITH LIGHT (2.9”W X 1.5”H X 13.5”...

  • Page 83: Pre-Delivery Inspection Form

    Important! This pre-delivery checklist is to aid the installer in confi rming the proper installation of this Maxon product. It is not a comprehensive list and does not replace the use of the installation manual. The installer is responsible for following all instructions in the installation manual.

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