Maxon TE-25DC Manuale utente

M-17-10

REV. A

JULY 2018

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 PRODUCT DOCUMENTATION window. For parts, click on the

PARTS PORTAL, TUK-A-WAY & TE-25DC/TE-33 buttons.

TABLE OF CONTENTS

SUMMARY OF CHANGES: M-17-10, REVISION A............................................................. 4

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 ....................................................... 17

BOLT EXTENSION PLATE.................................................................................. 17

WELD EXTENSION PLATE (ALTERNATE METHOD) ........................................ 20

STEP 2 - WELD LIFTGATE 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

STEP 8 - CHECKING HYDRAULIC FLUID......................................................................... 43

STEP 9 - CONNECT POWER CABLE TO BATTERY......................................................... 45

STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE ............... 46

STEP 11 - ADJUST PLATFORM OPENER ......................................................................... 51

STEP 12 - ADJUST PLATFORM (IF REQUIRED) .............................................................. 53

STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE ..................................................... 55

STEP 14 - BOLT OPTIONAL STEPS TO EXTENSION PLATE ......................................... 56

STEP 15 - VEHICLE TAILLIGHT POSITIONING ............................................................... 60

ATTACH DECALS: TE-25DC & TE-33............................................................................... 61

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)................................................................... 69

ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 70

PUMP & MOTOR SOLENOID OPERATION (POWER DOWN).......................................... 71

HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 72

ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 73

ELECTRICAL VALUES........................................................................................................ 74

OPTIONS ........................................................................................................................... 75

OPTIONAL LIFTGATE COMPONENTS.............................................................................. 75

TABLE OF CONTENTS - Continued

SUMMARY OF CHANGES: M-17-10, REVISION A

PAGE DESCRIPTION OF CHANGE

Cover Updated REV, date of release, and models. TE-25DC & TEWR-25DC were added.

Various Added TE-25DC and TEWR-25DC throughout the manual with topics & instructions

about TE-33 & TEWR-33 liftgates.

9Table 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.

41 FIG. 41-2 shows new control switch.

57 FIG. 57-1 shows new carriage bolts for bolting on dual steps.

60 Updated taillights installation instructions.

61,64 Added new bilingual UP/DOWN decals and removed old UP & DOWN decal.

62,65 Added table for 2500 lb and 3300 lb capacity decals.

74 Updated electrical values table to include cycle counter operation voltage.

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

•Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your

feet are clear of the Liftgate.

• Keep ﬁngers, 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 modiﬁcations on the Liftgate. Modiﬁcations 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

WARNINGS

•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.

•Recommended practices for welding galvanized steel are contained in the current AWS (Ameri-

can Welding Society) D19.0 Welding Zinc-Coated Steel. Damage to Liftgate and/or vehicle,

and personal injury can result from welds that are done incorrectly.

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

NOTICE NOTICE

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 ﬂames 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 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, 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.

•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. Refer to Technology Maintenance Council (TMC) RP 1428: Entry

and Egress Guidelines for Vehicles With Fold-Under Type Liftgates.

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

STANDARD LIFTGATE COMPONENTS

CAUTION

LIFTGATE COMPONENTS

FIG. 7-1

NOTE: Make sure you have all components and parts before you start installing Liftgate.

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]

Unpacking the Liftgate on unlevel surface may allow heavy components to slide off

when shipping bands are cut. Injury and equipment damage could result. Before

the shipping bands are cut, put Liftgate on level asphalt, concrete or compacted

dirt surface that will support 1500 lb. When unpacking the Liftgate, remove heavy

components carefully to avoid injury and damage.

EXTENSION PLATE

TE-25DC OR TE-33 LIFTGATE

EXTENSION PLATE FOR WALK RAMP

DUAL STEP KIT

PARTS BOX B

PARTS BOX A OR C

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

TE-25DC & TE-33 INSTALLATION PARTS BOXES

CONTENTS OF PARTS BOX A

TABLE 8-1

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX A 1 297502-01

1SPRING CLIP 10 050079

2PLASTIC TIE 2 206864

3#10 LOOM CLAMP 2 801681

4SCREW TAPPING #10 X 1/2” LG. 2 030458

5CABLE ASSEMBLY, 2 GA, 48” LG. 1 251871-26

6CABLE ASSEMBLY, 175 AMPS, 38’ LG. 1 264422

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX C 1 297502-02

1SPRING CLIP 20 050079

2PLASTIC TIE 4 206864

3GROMMET, 1” DIAMETER, 2 HOLES 1 266428-09

4CABLE ASSEMBLY, 175 AMP 38’ LG. 1 264422

5GROUND CABLE ASSEMBLY, 2 GA X 38’ LG. 1 269191-01

6SCREW TAPPING #10 X 1/2” LG. 2 030458

7#10 LOOM CLAMP 2 801681

CONTENTS OF PARTS BOX B

TABLE 8-2

CONTENTS OF PARTS BOX C

TABLE 8-3

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX B 1 297049-01

1TOGGLE SWITCH ASSEMBLY 1 296855-01

2HEX NUT, 1/2”-13 2 901011-9

3HEX HEAD CAP SCREW, 1/2”-13 X 1-1/2” LG. 2 900035-3

4INSTALLATION BRACKET 2 269462-01

5SCREW, SELF TAPPING, #10-24 X 1-1/2” LG. 2 900057-7

6LUG, 2 GA COPPER 1 906497-02

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

TE-25DC & TE-33 MANUALS & DECALS

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF TE-25DC MANUAL & DECAL KIT 1 298270-02

1INSTALLATION MANUAL 1 M-17-10

2OPERATION MANUAL 1 M-17-11

3DECALS (SEE DECAL PAGES IN THIS MANUAL) 1

220382

299038-01

266013-02

282522-01

282847-02

265441-01

285800-01

TE-25DC STANDARD KIT

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 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 1 298270-01

1INSTALLATION MANUAL 1 M-17-10

2OPERATION MANUAL 1 M-17-11

3DECALS (SEE DECAL PAGES IN THIS MANUAL) 1

220388-02

299038-01

266013-02

282522-01

282847-02

265441-01

285800-01

TE-33 STANDARD KIT

TABLE 9-2

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

1. Check for correct clearances (FIGS. 10-1, 11-1, and 11-2)

vehicle to prevent interference between vehicle and Liftgate.

VEHICLE REQUIREMENTS

NOTE: Make sure vehicle is parked on level ground while preparing vehicle and

installing Liftgate.

NOTE: Dimensions are provided as reference for ﬁtting Liftgate to vehicle body.

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”

(unloaded). Minimum bed height varies with platform depth. See TE-25DC & TE-33

LOW BED CLEARANCES, FIG. 11-1.

• Maximum bed height for TEWR-25 & TEWR-33 walk ramp Liftgates is 54” (un-

loaded). Minimum bed height varies with platform depth. See TEWR-25DC &

TEWR-33 CLEARANCES, FIG. 11-2.

If swing door latches interfere with ﬁt of extension plate, do not install this Liftgate

on vehicle bodies equipped with swing open doors.

TE-25DC & TE-33 HIGH BED CLEARANCES

(54” TO 42” BED HEIGHT)

FIG. 10-1

54” MAX BED HEIGHT

42” MIN BED HEIGHT

13”

22-1/8”

23-1/2” TO 11-1/2”

32-11/16”

24-1/2” 12-5/8”

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