Maxon TE-25DC Manual de usuario
© 2018 MAXON Lift Corp.
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
5
•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
6
NOTICE NOTICE
SAFETY INSTRUCTIONS
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
7
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
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
8
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
9
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
10
1. Check for correct clearances (FIGS. 10-1, 11-1, and 11-2)
on
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”
Este manual sirve para los siguientes modelos
3
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