Maxon TE-25DC User manual

© 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.

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•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.

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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.

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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 [phone] 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

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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

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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

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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”

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VEHICLE REQUIREMENTS - Continued
TE-25DC & TE-33 LOW BED CLEARANCES
(44” TO 38” BED HEIGHT)
FIG. 11-1
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”
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” 26-1/8”
22-5/16 TO 12-5/16”
36-5/8”
24-1/2” 12-5/8”
21” 9-1/4”
TEWR-25DC & TEWR-33 ONLY
54” MAX BED HEIGHT (ALL PLATFORMS)
46” MIN BED HEIGHT (52” X 84” PLATFORMS ONLY)
44” MIN BED HEIGHT (48” X 84” PLATFORMS ONLY)

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WALK RAMP BOX
CLEARANCE DIMENSIONS
(FOR REFERENCE ONLY)
FIG. 12-1B
2. Check for correct clearances between walk ramp, walk ramp box, and the extension
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” MIN.
32-1/2” MAX.
(RAMP WIDTH)
27-1/2”
20-1/2”
2-1/4”
1-1/2”
9-3/16” 8-1/2”
EXTENSION PLATE
HSILL
HRAMP
HRAMP = 8-3/8” - HSILL - 1/8” clearance
HSILL is the height of the vehicle body sill.
HRAMP is the height of the ramp (max).
NOTCH
(4 PLACES)

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VEHICLE REQUIREMENTS - Continued
• 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.
CAUTION
NOTE: The platform cutout area shown below applies to trucks. If the rear sill di-
mension is taller than 5” it may 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 of the body and frame.
NOTE: The dimensions, shown in the illustration below, are maximums except as
indicated.
3. Fit the Liftgate to vehicle body by cutting vehicle
frame as shown in FIGS. 13-1, 14-1, or 15-1.
VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE
(54” TO 42” BED HEIGHT)
FIG. 13-1
PLATFORM CLEARANCE
CUTOUT AREA
(WITHIN DASHED LINES)
TRUCK
FRAME
BODY FLOOR
BODY CROSS MEMBERS
TRUCK BODY REAR SILL
5”
12”
17-7/8” MIN

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VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE
(44” TO 38” BED HEIGHT)
FIG. 14-1
PLATFORM 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 applies to trucks. If the rear sill di-
mension is taller than 4” it may need to be modified. Check with body
manufacturer before modifying the rear sill.
4”

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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 modified. Check with body manufac-
turer before modifying the rear sill.
TRUCK BODY
VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE
(54” TO 44” BED HEIGHT WITH WALK RAMP)
FIG. 15-1
PLATFORM CLEARANCE
CUTOUT AREA
(WITHIN DASHED LINES)
TRUCK
FRAME
BODY CROSS MEMBERS
BODY FLOOR
REAR SILL
19” MIN
9”

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

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STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE
1. Mark and drill holes into rear sill as shown in FIGS. 17-1 and 18-1.
REAR SILL - HOLE LOCATIONS FOR 96” WIDE VEHICLE
FIG. 17-1
BOLT EXTENSION PLATE
USE 9/16” DRILL
(19 PLACES)
1-1/4”
3-1/8”
REAR
SILL
1-1/2”
19”
24”
14”
34”
41”
48”
55
62”
72”
77”
82”
94-1/2”
96”
6-1/2” 6-1/2”
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. MAXON recommends getting the optional extension plate hardware
kit listed in OPTIONS section. Vehicle body must be drilled according to
instructions. Extension plate may also be welded to vehicle body. Do the fol-
lowing bolting or welding instructions for the extension plate.
CAUTION
To preserve the corrosion-resistant properties of the galvanized finish,
MAXON recommends bolting the galvanized extension plate to vehicle.
CAUTION

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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”
REAR
SILL
USE 9/16” DRILL
(19 PLACES)
6-1/2” 6-1/2”
3-1/8”

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2. Bolt extension plate to vehicle as shown in FIG. 19-1. If necessary, reposition extension
plate so top surface is flush with top surface of sill. Then, torque bolts and lock nuts to
105 +/-20 lb-ft.
BOLTING EXTENSION PLATE (96” WIDE EXTENSION PLATE SHOWN)
FIG. 19-1
STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -
Continued
VEHICLE
BODY
EXTENSION
PLATE
BOLTS
(KIT ITEMS)
3/16” 3/16”
NOTE: An optional 102” wide extension kit is available for 102” wide vehicles.
WRAP WELD
HORIZONTAL
2” MIN/ 6” MAX
WRAP WELD
HORIZONTAL
2” MIN/ 6” MAX
TEARDROP
LOCK NUTS
(KIT ITEMS)
WRAP WELD AROUND END
OF EXTENSION PLATE
NOTE: Do not tighten extension plate bolts and lock nuts until:
• 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 between the bolt-on extension plate and vehicle rear sill
must be as flat as possible. Interference between the mating surfaces could
result in a distorted top surface of extension plate when all the bolts are
tightened. Distorted extension plate can also make the dual steps difficult to
install correctly. Remove interference or shim rear sill to eliminate or reduce
the possibility of a distorted extension plate.
CAUTION
NOTE: Weld the LH and RH ends of the extension plate to vehicle body as shown
in FIG. 19-1 if any of the following conditions apply.
• Bolt holes are not accessible on the corner posts of the vehicle body.
• Liftgate will be used for dock loading applications.
• As required by body/trailer manufacturer

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1. Center the extension plate on vehicle body. Before welding extension plate to vehicle
body, make sure top surface of extension plate is flush with floor of vehicle body.
Weld the extension plate to vehicle body sill as shown in FIGS. 20-1 and 21-1.
EXTENSION PLATE WELDS - VIEWED FROM ABOVE
FIG. 20-1
STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -
Continued
WELD LENGTH & SPACE:
2” - 11 3/4” (96” WIDE
VEHICLE)
2” - 12 1/2” (102” WIDE
VEHICLE)
3/16”
3/16”
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 vehicle body.
• Top surface of extension plate is level with the ground.
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.
CAUTION
To preserve the corrosion-resistant properties of the galvanized finish,
MAXON recommends bolting the galvanized extension plate to vehicle.
CAUTION
NOTE: For welding galvanized steel, refer to recommended practices as outlined in
AWS (American Welding Society) D19.0 Welding Zinc-Coated Steel.