Maxon TE-25DC, TEWR-33, TE-33, TEWR-25DC Installation Manual

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.

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

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) ................................................................... 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

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

9

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.

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

Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.

WARNINGS

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

• Keep fi ngers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.

• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.

• 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.

• 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 modifi cations on the Liftgate. Modifi cations may result in early failure

of the Liftgate and may create hazards for Liftgate operators and maintainers.

• 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.

!

WARNING

• Recommended practices for welding galvanized steel are contained in the current AWS (Ameri­can 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 [phone] FAX [phone]

5

SAFETY INSTRUCTIONS

• 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.

• 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.

• Do not allow untrained persons to operate 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.

• Be careful working by an automotive type battery. Make sure the work area is well ventilated and

there are no fl ames 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 fi rst 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.

SAFETY INSTRUCTIONS

• 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.

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.

• 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 [phone] FAX [phone]

6

STANDARD LIFTGATE COMPONENTS

!

CAUTION

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.

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 [e-mail]

EXTENSION PLATE

EXTENSION PLATE FOR WALK RAMP

DUAL STEP KIT

PARTS BOX B

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

PARTS BOX A OR C

TE-25DC OR TE-33 LIFTGATE

LIFTGATE COMPONENTS

FIG. 7-1

7

TE-25DC & TE-33 INSTALLATION PARTS BOXES

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX A 1 297502-01

1 SPRING CLIP 10 050079
2 PLASTIC TIE 2 206864
3 #10 LOOM CLAMP 2 801681
4 SCREW TAPPING #10 X 1/2” LG. 2 030458
5 CABLE ASSEMBLY, 2 GA, 48” LG. 1 251871-26
6 CABLE ASSEMBLY, 175 AMPS, 38’ LG. 1 264422

CONTENTS OF PARTS BOX A

TABLE 8-1

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX B 1 297049-01

1 TOGGLE SWITCH ASSEMBLY 1 296855-01
2 HEX NUT, 1/2”-13 2 901011-9
3 HEX HEAD CAP SCREW, 1/2”-13 X 1-1/2” LG. 2 900035-3
4 INSTALLATION BRACKET 2 269462-01
5 SCREW, SELF TAPPING, #10-24 X 1-1/2” LG. 2 900057-7
6 LUG, 2 GA COPPER 1 906497-02

CONTENTS OF PARTS BOX B

TABLE 8-2

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX C 1 297502-02

1 SPRING CLIP 20 050079
2 PLASTIC TIE 4 206864
3 GROMMET, 1” DIAMETER, 2 HOLES 1 266428-09
4 CABLE ASSEMBLY, 175 AMP 38’ LG. 1 264422
5 GROUND CABLE ASSEMBLY, 2 GA X 38’ LG. 1 269191-01
6 SCREW TAPPING #10 X 1/2” LG. 2 030458
7 #10 LOOM CLAMP 2 801681

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

CONTENTS OF PARTS BOX C

TABLE 8-3

8

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.

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

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

1 INSTALLATION MANUAL 1 M-17-10
2 OPERATION MANUAL 1 M-17-11

220382

299038-01

266013-02

3 DECALS (SEE DECAL PAGES IN THIS MANUAL) 1

282522-01

282847-02

265441-01

285800-01

TE-25DC STANDARD KIT

TABLE 9-1

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF TE-33 MANUAL & DECAL KIT 1 298270-01

1 INSTALLATION MANUAL 1 M-17-10
2 OPERATION MANUAL 1 M-17-11

220388-02

299038-01

266013-02

3 DECALS (SEE DECAL PAGES IN THIS MANUAL) 1

282522-01

282847-02

265441-01

285800-01

TE-33 STANDARD KIT

TABLE 9-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

9

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”
(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” (un­loaded). Minimum bed height varies with platform depth. See TEWR-25DC &
TEWR-33 CLEARANCES, FIG. 11-2.

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

on vehicle bodies equipped with swing open doors.

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

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

installing Liftgate.

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

vehicle to prevent interference between vehicle and Liftgate.

13”

54” MAX BED HEIGHT
42” MIN BED HEIGHT

23-1/2” TO 11-1/2”

on

32-11/16”

22-1/8”

24-1/2”

12-5/8”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

TE-25DC & TE-33 HIGH BED CLEARANCES

(54” TO 42” BED HEIGHT)

FIG. 10-1

10

VEHICLE REQUIREMENTS - Continued

35-1/2”

24-7/8”

13”

44” MAX BED HEIGHT (ALL PLATFORMS)
40” MIN BED HEIGHT (52” X 84” PLATFORMS ONLY)
38” MIN BED HEIGHT (48” X 84” PLATFORMS ONLY)

TE-25DC & TE-33 LOW BED CLEARANCES

(44” TO 38” BED HEIGHT)

FIG. 11-1

13-1/2”

21”

16-7/8” TO 10-7/8”

36-5/8”

26-1/8”

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)

TEWR-25DC & TEWR-33 (WALK RAMP) CLEARANCES

(44” TO 54” BED HEIGHT)

FIG. 11-2

24-1/2”

22-5/16 TO 12-5/16”

12-5/8”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

11

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.

1-1/2”

9-3/16”

27-1/2”

20-1/2”

2-1/4”

EXTENSION PLATE

8-1/2”

WALK RAMP

LATCH

WALK RAMP PAD

(2 PLACES)

25” MIN.
32-1/2” MAX.
(RAMP WIDTH)

WALK RAMP BOX

CLEARANCE DIMENSIONS

(FOR REFERENCE ONLY)

FIG. 12-1B

2-1/4”

NOTCH

(4 PLACES)

1-1/2”

H

SILL

H

RAMP

H

= 8-3/8” - H

RAMP

H

is the height of the vehicle body sill.

SILL

H

is the height of the ramp (max).

RAMP

- 1/8” clearance

SILL

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

TEWR-25DC OR TEWR-33 LIFTGATE

SHOWN WITH WALK RAMP BOX

FIG. 12-1A

12

VEHICLE REQUIREMENTS - Continued

CAUTION

• To prevent platform from being damaged, make sure vehicle frame is cut cor­rectly. 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.

NOTE: The dimensions, shown in the illustration below, are maximums except as

indicated.

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 modifi ed. Check with body man-
ufacturer before modifying the rear sill.

3. Fit the Liftgate to vehicle body by cutting vehicle
frame as shown in FIGS. 13-1, 14-1, or 15-1.

TRUCK BODY

5”

REAR SILL

PLATFORM CLEARANCE

CUTOUT AREA

(WITHIN DASHED LINES)

17-7/8” MIN

BODY FLOOR

BODY CROSS MEMBERS

TRUCK
FRAME

12”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE

(54” TO 42” BED HEIGHT)

FIG. 13-1

13

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.

TRUCK BODY

4”

REAR SILL

PLATFORM CLEARANCE

CUTOUT AREA

(WITHIN DASHED LINES)

19-1/2” MIN

BODY FLOOR

BODY CROSS MEMBERS

9-1/2”

TRUCK
FRAME

VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE

(44” TO 38” BED HEIGHT)

FIG. 14-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

14

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.

TRUCK BODY

9”

REAR SILL

BODY CROSS MEMBERS

PLATFORM CLEARANCE

CUTOUT AREA

(WITHIN DASHED LINES)

19” MIN

BODY FLOOR

TRUCK
FRAME

VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE

(54” TO 44” BED HEIGHT WITH WALK RAMP)

FIG. 15-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

15

17-9/32”

CENTER OF MASS

21-5/16”

TE-25DC & TE-33 CENTER OF MASS

(STOWED POSITION)

FIG. 16-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

16

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE

CAUTION

CAUTION

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 re­quired. 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 fol­lowing bolting or welding instructions for the extension plate.

BOLT EXTENSION PLATE

1. Mark and drill holes into rear sill as shown in FIGS. 17-1 and 18-1.

96”

94-1/2”

19”

14”

1-1/2”

24”

6-1/2”

34”

48”

41”

REAR

SILL

55

62”

72”

77”

82”

USE 9/16” DRILL

(19 PLACES)

1-1/4”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

3-1/8”

6-1/2”

REAR SILL - HOLE LOCATIONS FOR 96” WIDE VEHICLE

FIG. 17-1

17

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -

Continued

102”

100-1/2”

95-1/2”

85”

80”

75”

65”

58”

51”

44”

37”

1-1/2”

27”

22”

17”

6-1/2”

REAR

SILL

USE 9/16” DRILL

(19 PLACES)

REAR SILL - HOLE LOCATIONS FOR 102” WIDE VEHICLE

FIG. 18-1

1-1/4”

6-1/2”

3-1/8”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

18

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. Distorted extension plate can also make the dual steps diffi cult to
install correctly. Remove interference or shim rear sill to eliminate or reduce
the possibility of a distorted 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 fl at as possible.

• Top of extension plate is fl ush with top of rear sill.

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

2. Bolt extension plate to vehicle as shown in FIG. 19-1. If necessary, reposition extension

plate so top surface is fl ush with top surface of sill. Then, torque bolts and lock nuts to

105 +/-20 lb-ft.

VEHICLE

BODY

BOLTS

(KIT ITEMS)

3/16”

EXTENSION

PLATE

TEARDROP

LOCK NUTS

(KIT ITEMS)

WRAP WELD
HORIZONTAL
2” MIN/ 6” MAX

WRAP WELD AROUND END

OF EXTENSION PLATE

2” MIN/ 6” MAX

WRAP WELD

HORIZONTAL

3/16”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BOLTING EXTENSION PLATE (96” WIDE EXTENSION PLATE SHOWN)

NOTE: An optional 102” wide extension kit is available for 102” wide vehicles.

FIG. 19-1

19

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -

Continued

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.

NOTE: Before welding extension plate to vehicle body, make sure:

• Inboard edge of extension plate is fl ush with the top of sill on vehicle body.

• Top surface of extension plate is level with the ground.

NOTE: For welding galvanized steel, refer to recommended practices as outlined in

AWS (American Welding Society) D19.0 Welding Zinc-Coated Steel.

1. 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.

Weld the extension plate to vehicle body sill as shown in FIGS. 20-1 and 21-1.

3/16”

EXTENSION

PLATE

EXTENSION PLATE WELDS - VIEWED FROM ABOVE

VEHICLE

BODY

FIG. 20-1

3/16”

WELD LENGTH & SPACE:

2” - 11 3/4” (96” WIDE

VEHICLE)

2” - 12 1/2” (102” WIDE

VEHICLE)

3/16”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

20

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -

Continued

EXTENSION

PLATE

VEHICLE

BODY

3/16”

EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH

FIG. 21-1

NOTE: During installation of Liftgate, installation brackets keep the heel of the plat-

form level with extension plate and maintain a ¾” gap between extension
plate and heel of platform. The extension plate has bolt holes for bolting on
the installation brackets provided in parts box.

WELD LENGTH & SPACE:
2” - 11 3/4” (96” WIDE VEHICLE)
2” - 12 1/2” (102” WIDE VEHICLE)

2. Bolt 2 installation brackets (parts box items) on the

extension plate as shown in FIG. 21-2. Tighten hex

nuts securely.

CAP SCREW

1/2”-13 X 1-1/2” LG.

(2 PLACES)

BRACKET

(2 PLACES)

EXTENSION

PLATE

FLAT WASHER

1/2”-13

(2 PLACES)

HEX NUT

1/2”-13

(2 PLACES)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BOLTING ON INSTALLATION BRACKETS

FIG. 21-2

21

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.

NOTE:

BOLT & LOCK

NUT (6 PLACES)

If it’s necessary to unbolt mounting plates from main frame (FIG. 22-1
& FIG. 22-2), torque mounting plate nuts and bolts 220-240 lb-ft.

BOLT &

LOCK NUT

(6 PLACES)

34-1/4”

BOLT-ON MOUNTING PLATES 34-1/4”

FIG. 22-1

BOLT & LOCK

NUT (6 PLACES)

BOLT &

LOCK NUT

(6 PLACES)

33-3/4”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BOLT-ON MOUNTING PLATES 33-3/4”

FIG. 22-2

22

STEP 2 - WELD LIFTGATE TO VEHICLE - Continued

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)

BOLT &

LOCK NUT

FLIPOVER

(UNFOLDED)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

PLATFORM & FLIPOVER UNFOLDED

FIG. 23-2

23

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. Make sure hoist

is not being set
up the incorrect

way (FIG. 24-2).

Place a “C”­clamp on each
side of platform

as shown in FIG.
24-1. (Clamps prevent

hoist chain from slipping off
platform.) Place chain all

around platform (FIG. 24-1).

3. Hoist the Liftgate.

Then, place fl oor jack
under main frame

(FIG. 24-1). Jack the

Liftgate into position.
Make sure vehicle
fl oor is horizontal
and pins are lined up

(FIG. 24-1).

CORRECT WAY TO HOIST LIFTGATE

FIG. 24-1

FLIPOVER

HOIST CHAIN

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

INCORRECT WAY TO HOIST LIFTGATE

FIG. 24-2

24

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.

CAUTION

When using an electric welder, connect the welder ground to one of the parts
being welded, as close to the weld as possible. Failure to comply could result
in damage to cylinders and electrical parts.

NOTE: On some low bed trucks, wood spacer may interfere with having two 7”

vertical welds per mounting plate. If the spacer interferes with minimum 7”
welds, cut and weld the top of each mounting plate 1/2” below the top radius
of the truck frame.

NOTE: If main frame is galvanized, skip instructions 4 and 5. Go to instruction 6.

4. Unbolt mounting plate

from main frame. Reposi-

tion mounting plate against
vehicle frame. Tack weld as

shown in FIG. 25-1. Repeat

CUT LINE & TOP WELD

(IF NECESSARY)

for second mounting plate
(reposition and tack weld).

VEHICLE FRAME

(TYPICAL TRUCK

FRAME SHOWN)

MOUNTING PLATE

TACK

(TYPICAL - RH & LH

MOUNTING PLATES)

MAIN FRAME
(CUT-AWAY VIEW)

1/4”

REPOSITIONING PAINTED MOUNTING PLATE

(RH SIDE SHOWN)

FIG. 25-1

1/2”

MOUNTING
PLATE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

25

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.

26-1. Remove clamps.

6. If necessary, unbolt mount-

ing plate to cut at the top as

shown in FIG. 26-2. Repeat

for LH mounting plate. Then,
bolt mounting plates in correct

position (FIG. 26-2). Torque

mounting plate nuts and bolts

220 - 240 lb-ft.

VEHICLE FRAME

(TYPICAL TRUCK

FRAME SHOWN)

2” LG. 4 PLACES

(TYPICAL - RH & LH

MOUNTING

PLATES)

WELD TO VEHICLE FRAME AND MAIN FRAME

2” LG. 4 PLACES

(TYPICAL - RH & LH

MOUNTING PLATES)

1/4”

(RH SIDE SHOWN)

FIG. 26-1

1/4”

BED LEVEL

MOUNTING

PLATE

VEHICLE FRAME

(TYPICAL TRUCK FRAME SHOWN)

MOUNTING PLATE

7. Clamp both mounting plates to

vehicle frame. Weld the mount­ing plates to vehicle frame as

shown in FIGS. 26-2 or 27-1.

CUT LINE & TOP WELD

(IF NECESSARY)

1/2”

24-1/2” HIGH BED
21” LOW BED

MAIN FRAME

WELD TO VEHICLE FRAME (RH SIDE SHOWN)

FIG. 26-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

26

STEP 2 - WELD LIFTGATE TO VEHICLE - Continued

2” LG. 4 PLACES

(TYPICAL - RH & LH

MOUNTING PLATES)

1/4”

BED LEVEL

VEHICLE FRAME

(TYPICAL TRUCK FRAME SHOWN)

MOUNTING PLATE

MAIN FRAME

WELD TO VEHICLE FRAME - WALK RAMP

24-1/2”

(RH SIDE SHOWN)

FIG. 27-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

27

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. Liftgate and optional

battery box are typically
installed on trucks as

shown in FIG. 28-1. See

the following page for
battery and cable con­nections.

LIFTGATE

TRUCK BATTERIES,
TYPICAL LOCATION

150 AMP

CIRCUIT BREAKER

175 AMP

FUSED CABLE

LIFTGATE

POWER UNIT

OPTIONAL

BATTERY BOX,

TYPICAL LOCATION

CIRCUIT

BREAKER

RECOMMENDED LIFTGATE & BATTERY BOX

INSTALLATION ON TRUCK

FIG. 28-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

28

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

2. Select holes on top of battery box

frame to align mounting brackets
fl ush to cross members. Refer

to FIGS. 29-1A & 29-1B for trail­ers and FIG. 29-2 for trucks. Bolt

mounting brackets to battery box

frame as shown in FIG. 29-1C.

Torque each bolt and lock nut to

85-128 lb-ft.

TRAILER BODY

CROSS MEMBER

LOCK NUT

WASHER

MOUNTING
BRACKETS

LOCK

WASHER

CROSS

MEMBER

WASHER

CAP SCREW

BOLTING BRACKETS

(8 PLACES)

FIG. 29-1C

BATTERY BOX

FRAME

MOUNTING

BRACKETS

BATTERY BOX

FLUSH BRACKETS

FOR TRAILERS

(8 PLACES)

FIG. 29-1B

FRAME

TRUCK BODY

CROSS MEMBER

MOUNTING

BRACKETS

ALIGNING BATTERY

BOX FRAME

(TRAILER SHOWN)

FIG. 29-1A

BATTERY BOX

FRAME

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FLUSH BRACKETS FOR TRUCKS

(8 PLACES)

FIG. 29-2

29

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 members (FIG. 30-1). Bolt

mounting brackets to cross mem-

bers as shown in FIGS. 30-2A and
30-2B. Torque bolts and lock nuts
to 85-128 lb-ft.

CAP SCREWS

(2 PLACES)

MOUNTING

BRACKETS

WASHERS

(4 PLACES)

CROSS

MEMBER

1/2” HOLES

MARK AND DRILL

FIG. 30-1

LOCK WASHERS

(2 PLACES)

LOCK NUTS

(2 PLACES)

CROSS

MEMBERS

MOUNTING
BRACKETS

CROSS

MEMBER

BOLTING BRACKETS

(8 PLACES)

FIG. 30-2B

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BOLTING BATTERY BOX FRAME

FIG. 30-2A

30

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

!

WARNING

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.

CAUTION

To prevent pump box components from being damaged by electric current
from welding, connect welder grounding cable to the part being welded.

CAUTION

Cover pump box and optional battery box with fl ame-resistant covering before
welding pump box frame to vehicle.

4. Weld each bracket to cross
members as shown in FIGS.
31-1A and 31-1B. Weld top of

bracket if accessible.

MEMBERS

CROSS

IF ACCESSIBLE

3/16”

WELDING BRACKETS

3/16”

(8 PLACES)

FIG. 31-1B

CROSS

MEMBERS

3/16”

BRACKET

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BOLTING PUMP & BATTERY

BOX FRAME

FIG. 31-1A

31

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.

5. Connect battery cables, fused cables, and ground
cables for 12 volt power as shown in FIG. 32-1 or
24 volt power as shown in FIG. 33-1.

GROUND CABLE TO PUMP

BOX OR COMMON CHASSIS

GROUND, 74” LG.

(BATTERY BOX KIT ITEM)

FUSED CABLE TO PUMP BOX

(IN PARTS BOX)

10” LG.

BLACK CABLE

10” LG.

RED CABLE

(-) BATTERY

CABLE TO

COMMON
GROUND

FUSED CABLE

(SEE NOTE)

150 AMP
CIRCUIT

BREAKER

12” LG.

RED CABLE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

12 VOLT BATTERY CONNECTIONS

FOR 12 VOLT POWER

FIG. 32-1

32

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

FUSED CABLE TO PUMP

BOX, 42” LG.

(BATTERY BOX KIT ITEM)

CABLE
10” LG.

12 VOLT BATTERY CONNECTIONS

FOR 24 VOLT POWER

FIG. 33-1

CABLE
12” LG.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

33

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)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 34-1

34

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

175 AMP FUSED

CABLE TO

PUMP BOX

GROUND CABLE

TO PUMP BOX

HEX NUT

5/16”-18, GR8

(3 PLACES)

FLAT WASHER

5/16”

(3 PLACES)

LOCK NUT, 1/4”-20

PAN HEAD SCREW

1/4”-20 X 1” LG.

(2 PLACES)

(2 PLACES)

FLAT WASHER

1/4”

(4 PLACES)

1/2”-20 X 2 1/4” LG. GR8

CHARGE LINE FROM

VEHICLE BATTERY

150 AMP CIRCUIT

BREAKER

CAP SCREW

(4 PLACES)

J-BOLT

BATTERY

TIE DOWN

J-BOL T ANCHOR

(PART OF

BATTERY PLATE)

BATTERY

PLATE

BATTERY

STRAP

LOCK WASHER

9/16”

(4 PLACES)

FIG. 35-1

35

HEX NUT

1/2”-20

(4 PLACES)

FLAT WASHER

9/16”

(4 PLACES)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

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 is typically
installed on trucks as

shown in FIG. 36-1. See

the following page for
running the battery cable.

LIFTGATE

LIFTGATE

POWER UNIT

RECOMMENDED LIFTGATE & BATTERY BOX

INSTALLATION ON TRUCK

FIG. 36-1

TRUCK BATTERIES,
TYPICAL LOCATION

175 AMP

FUSED CABLE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

36

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 rst check behind the drilling surface so you do not
damage any fuel lines, vent lines, brake lines or wires.

2. Clip fused power cable to vehicle chassis with fuse nearest the vehicle battery, as

shown in FIG. 37-1. Keep enough cable near the battery to reach the positive terminal

without straining cable (after connection). Run cable to pump box on Liftgate.

VEHICLE FRAME

(TRUCK FRAME SHOWN)

18”- 24”

SPACING

175 AMP FUSE

SHORTEST

CABLE END

TERMINAL LUG

(TO VEHICLE BATTERY)

CABLE

CLIPS

CHARGE LINE

(TO PUMP BOX)

FRONT OF VEHICLE

REAR OF VEHICLE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 37-1

37

STEP 5 - CONNECT POWER CABLE

1. Unbolt and remove pump cover

(FIG. 38-1).

CAP SCREW,

5/16”-18

(2 PLACES)

HOLDER FLAT

(2 PLACES)

NYLON NUT,

5/16”-18

FLAT WASHER,

5/16”

(2 PLACES)

PUMP COVER

(2 PLACES)

POWER UNIT

(REF)

UNBOLTING PUMP COVER

FIG. 38-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

38

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

grommet on pump mounting plate

(FIG. 39-3).

3. On the bare wire end of fused power

cable, keep enough length to attach
copper terminal lug and reach starter
solenoid without putting tension on

cable (after connection) (FIG. 39-1).

Measure (if needed) and then cut
excess cable from bare wire end of
cable. Put heat shrink tubing (parts

box) (FIG. 39-1) on the end of the

cable (leave room for terminal lug).
Crimp copper terminal lug (from parts
box) on the fused power cable and

shrink the heat shrink tubing (FIG.

39-2).

CAUTION

Do not over-tighten the terminal
nuts on starter solenoid. For the
load terminals, torque nuts to 35
lb-in max. Torque the nuts on #10-32
control terminals 10-15 lb-in.

COPPER TERMINAL LUG

HEAT SHRINK TUBING

(P/N 253316-04)

FUSED POWER CABLE

(BARE WIRE END)

PLACING TERMINAL LUG & HEAT SHRINK

TUBING ON FUSED POWER CABLE

FIG. 39-1

TYPICAL FUSED POWER CABLE WITH

TERMINAL LUG INSTALLED

FIG. 39-2

STARTER

SOLENOID

PUMP MOUNTING PLATE

BATTERY

TERMINAL POST

BOTTOM

GROMMET

FUSED

POWER CABLE

4. Remove hex nut and lock wash-

er from battery terminal post on
the starter solenoid. Connect the
fused power cable to the starter

solenoid as shown in FIG. 39-3.

Reinstall and tighten lock washer
and hex nut. Torque hex nut to

30-35 lb-in maximum.

HEX
NUT

LOCK

COPPER

TERMINAL LUG

WASHER

DRIP

LOOP

TYPICAL FUSED POWER CABLE CONNECTION

(GRAVITY DOWN PUMP SHOWN)

FIG. 39-3

39

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

STEP 6 - CONNECT GROUND CABLE

TERMINAL LUG

(EXTERNAL 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. Unbolt pump ground cable from the

pump mounting bracket. Then, bolt and
tighten pump ground cable and external
ground cable (parts box) to mounting

bracket (FIG. 40-1).

TERMINAL LUG

(EXTERNAL GROUND

CABLE)

CONNECTING EXTERNAL GROUND CABLE

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.

PUMP MOUNTING

BRACKET

PUMP GROUND

CABLE

CAP

SCREW,

5/16” LG.

FIG. 40-1

VEHICLE CHASSIS

(TRUCK FRAME SHOWN)

2. Extend the ground cable to reach

vehicle frame (FIG. 40-2) without

putting tension on cable (after con­nection). Connect to an existing
grounding point if available.

3. If necessary, drill a 11/32” (0.343”)

hole in vehicle frame for bolting
the ground cable terminal lug

(FIG. 40-2).

4. To prevent corrosion, paint or

use galvanized spray on bare

metal area FIG. 40-2.

5. Bolt both ends of the ground

cable terminal lug as shown in

FIGS. 40-1 & 40-2.

TERMINAL LUG

(GROUND CABLE)

5/16"-18 X 1" LG

CAP SCREW

40

BARE

METAL

FIG. 40-2

5/16” FLAT

WASHER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

5/16”-18

LOCK NUT

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” hole on corner post and
down the vertical post and
under the vehicle body to

the pump assembly. (See

dashed line - FIG. 41-2).

DRILLING MOUNTING HOLES

FIG. 41-1

3. Push control switch and

cable back into the 3/4” hole
in the vertical post until con­trol switch touches the post

(FIG. 41-2). Attach control

switch to vertical post with
2 self-tapping screws (parts

box) (FIG. 41-2).

4. If necessary, use

clamps and self-tapping
screws (parts box) to
secure switch cable to
vehicle under-body and

frame (FIG. 41-2).

CONTROL SWITCH

3/4” HOLE

SELF-TAPPING

SCREW

(2 PLACES)

ROUTING CONTROL SWITCH WIRING

FIG. 41-2

VEHICLE BODY

VERTICAL POST

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

PUMP BOX

41

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 grom­met on pump mounting plate (FIGS.
42-1 & 42-2). Connect the switch

wiring to the pump assembly as

shown in (FIGS. 42-1 & 42-2).

WHITE

WIRE

STARTER

SOLENOID

CONTROL

SWITCH

FUSE

HOLDER

ASSEMBLY

GREEN

WIRE

WIRING

HARNESS

GROMMET

BLACK

WIRE

JUNCTION

BLOCK

TERMINAL 1

CONTROL SWITCH WIRING CONNECTIONS

(GRAVITY DOWN)

FIG. 42-1

POWER DOWN

MODULE

STARTER

SOLENOID

BLACK

WHITE

WIRE

WIRE

GREEN

WIRE

FUSE

HOLDER

ASSEMBLY

HARNESS

CONTROL

SWITCH

WIRING

GROMMET

CONTROL SWITCH WIRING CONNECTIONS

(POWER DOWN)

FIG. 42-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

42

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.

NOTE: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions.

+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606

See TABLES 44-1 & 44-2 for recommended brands of ISO 32 & ISO 15 oils.

1. Unbolt and remove pump cover
(FIG. 43-1).

2. Check the hydraulic fl uid level

CAP SCREW,

5/16”-18

(2 PLACES)

in reservoir as follows. With
Liftgate stowed, or platform at
vehicle bed height, level should

be as shown in FIG. 43-2.

3. If needed, add fl uid to the reservoir as fol-
lows. Pull out (no threads) fi ller cap (FIG.
43-2). Fill the reservoir with hydraulic fl uid to
level shown in FIG. 43-2. Reinstall fi ller cap

(FIG. 43-2).

FLAT WASHER,

(2 PLACES)

HOLDER FLAT

(2 PLACES)

PUMP COVER

UNBOLTING PUMP COVER

RESERVOIR

NYLON NUT,

5/16”-18

(2 PLACES)

5/16”

POWER UNIT

(REF)

FIG. 43-1

FILLER

CAP

CAUTION

Pump cover must be correctly
secured to prevent it from be­coming a hazard. To secure pump
cover, the long side of the holder
fl ats must butt against pump cov­er as shown in the illustration.

4. Bolt on the pump cover as shown

in FIG. 43-1. Torque the bolts (cap
screws) to 10-14 lb-in.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

3”(PD)

1-1/2”(GD)

POWER UNIT FLUID LEVEL

FIG. 43-2

43

STEP 8 - CHECKING HYDRAULIC FLUID - Continued

ISO 32 HYDRAULIC OIL

RECOMMENDED

BRANDS

CHEVRON HIPERSYN 32

KENDALL GOLDEN MV

SHELL TELLUS S2 VX 32

EXXONMOBIL UNIVIS N-32, DTE-24

PART NUMBER

TABLE 44-1

ISO 15 OR MIL-H-5606 HYDRAULIC OIL

RECOMMENDED

BRANDS

CHEVRON FLUID A, AW-MV-15

KENDALL GLACIAL BLU

SHELL TELLUS S2 VX 15

EXXONMOBIL UNIVIS HVI-13

ROSEMEAD THS FLUID 17111

PART NUMBER

TABLE 44-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

44

STEP 9 - CONNECT POWER CABLE TO BATTERY

NOTE: MAXON recommends using dielectric grease on all electrical connections.

1. Remove nut from negative (-) bat-

tery terminal. Disconnect negative

(-) battery cable (FIG. 45-1).

BATTERY CABLE

2. Remove nut from positive (+)
battery terminal (FIG. 45-1).

3. Connect fused positive (+) cable
to positive (+) battery terminal
(FIG. 45-2). Then, reinstall nut
on positive (+) battery terminal
(FIG. 45-3).

NEGATIVE (-)

DISCONNECTING (-) BATTERY CABLE

POSITIVE (+)

BATTERY CABLE

NUT

NUT

NUT

POSITIVE (+)

BATTERY TERMINAL

NEGATIVE (-)

BATTERY TERMINAL

FIG. 45-1

FUSED (+)

CABLE

POSITIVE (+)

BATTERY TERMINAL

4. Reconnect negative (-) battery

cable to negative (-) battery ter­minal (FIG. 45-2). Then, reinstall
nut on negative (-) battery termi­nal (FIG. 45-2).

CONNECTING FUSED (+) CABLE

FIG. 45-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

NEGATIVE (-)

BATTERY TERMINAL

NUT

NEGATIVE (-)

BATTERY CABLE

RECONNECTED BATTERY CABLES

FIG. 45-3

45

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. Release control switch. Hydraulic system is ready.

2. Remove fl oor jack and hoist
supporting Liftgate (FIG. 46-1).

FLOOR JACK

3. Lower platform to the ground.

Remove both installation brackets

from extension plate (FIG. 46-2).

FIG. 46-1

BRACKET & FASTENERS

(2 PLACES)

EXTENSION PLATE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 46-2

46

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).

LH

CYLINDER

LOCKING

BRACKETS

REMOVING LOCKING BRACKETS

FIG. 47-1

RH

CYLINDER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

47

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.

RAISING PLATFORM

FIG. 48-1

6. If the platform lowers with a “jerking” motion,

bleed air from the hydraulic system by doing
the following. Push the control switch to the

DOWN position until you hear air escaping
into the hydraulic fl uid reservoir. Then, raise
the platform (FIG. 48-1). Repeat this step

until there is no air left in the system

and platform lowers smoothly (FIG. 48-2).

LOWERING PLATFORM

FIG. 48-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

48

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. 49-1).

5/8”

(+/- 1/8”)

EXTENSION

PLATE

PLATFORM

5/8”

(+/- 1/8”)

CHECKING GAP BETWEEN PLATFORM

& EXTENSION PLATE

FIG. 49-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

49

STEP 10 - REMOVE LOCKING BRACKETS & CHECK

FOR INTERFERENCE - Continued

NOTE: Correct any fi t and in-

terference problems
before continuing
with installation.

8. Ensure top surface of platform

and extension plate are fl ush
at the RH & LH sides of plat-

form (FIGS. 50-1 and 50-2).

The allowable difference in
height is 1/8” maximum as
shown.

SURFACES FLUSH

PLATFORM

1/8” (MAX)

EXTENSION

PLATE

DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM

& EXTENSION PLATE (RH VIEW)

FIG. 50-1

SURFACES FLUSH

PLATFORM

1/8” (MAX)

EXTENSION

PLATE

DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM

& EXTENSION PLATE (LH VIEW)

FIG. 50-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

50

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.

SCREW

CAP

OPENER

BRACKET

OPENER

ASSEMBLY

HEX
NUT

REMOVING BOLT FROM OPENER BRACKET

FIG. 51-1

NOTE: Hole positions are ap-

proximate and may have
to be adjusted up 1 hole
or down 1 hole for best
opener function on your
vehicle.

TRUCK BED HEIGHT HOLE NUMBER

52” - 54” HOLE #6

51” - 53” HOLE #5

50” - 52” HOLE #4

49” - 51” HOLE #3

48” - 50” HOLE #2

42” - 49” HOLE #1

40” - 44”

(26”+26” PLATFORM)

38” - 40”

(24”+24” PLATFORM)

HOLE #3

HOLE #1

HOLE #6

HOLE #5

HOLE #4

HOLE #3

HOLE #2

HOLE #1

OPENER

BRACKET

OPENER

ASSEMBLY

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

42”- 54” OR
38”- 44”

BOLT HOLE CHART FOR 42”- 54”

& 38”- 44” BED HEIGHTS

(ALL PLATFORMS UNLESS NOTED)

TABLE 51-1

POSITIONING OPENER FOR

38”- 44” LOW BED HEIGHT OR

42”- 54” HIGH BED HEIGHT

FIG. 51-2

51

STEP 11 - ADJUST PLATFORM OPENER - Continued

HOLE #6

HOLE #5

HOLE #4

HOLE #3

HOLE #2

HOLE #1

(REF)

OPENER

BRACKET

BED HEIGHT

OPENER

ASSEMBLY

44” - 54”

POSITIONING OPENER FOR

44”- 54” BED HEIGHT WITH WALK RAMP

FIG. 52-1

TRUCK BED HEIGHT HOLE NUMBER

BOLT HOLE CHART FOR 44”- 54” BED
HEIGHT WITH WALK RAMP (26”+26” &

24”+24” PLATFORMS UNLESS NOTED)

52” - 54” HOLE #6

51” - 53” HOLE #5

50” - 52” HOLE #4

49” - 51” HOLE #3

46” - 50” HOLE #2

44” - 47”

(24” X 24” PLATFORM)

TABLE 52-1

52

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

HOLE #1

STEP 12 - ADJUST PLATFORM (IF REQUIRED)

NOTE: Before doing the following proce-

dure, 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 ipover must touch

the ground at the same time (FIG. 53-1). If the

shackles and the tip of fl ipover touch the ground

at the same time, RAISE platform to bed height.

Tip of fl ipover should be above bed level (FIG.

53-2). If indications are correct in both cases
(FIGS. 53-1 & 53-2), Liftgate is installed correctly

and no adjustment is needed. If indications are

incorrect, continue with instruction 2.

NOTE: If tip of fl ipover touches fi rst (FIG.
53-3), do instruction 2. If the shackle

touches fi rst (FIG. 54-1), skip instruc-
tion 2 and do 3.

TIP OF

FLIPOVER

PLATFORM & SHACKLES

TOUCH GROUND

FIG. 53-1

TIP OF FLIPOVER

LEVEL LINE

PLATFORM EDGE ABOVE

BED LEVEL

FIG. 53-2

2. Make sure platform is still at ground level. If

the shackle is not touching the ground, mea-

sure and compare distance “A” (FIG. 53-3)
with TABLE 53-1 to determine the correct
shim. Make shims as needed (FIG. 53-5).
Weld shim as shown in FIG. 53-4.

RAISE TIP OF

FLIPOVER

THIS DISTANCE “A”

7/8” 1/16” 1/16”

2” 1/8” 1/8”

3” 3/16” 3/16”

3-15/16” 1/4” 1/4”

REQUIRED

SHIM

THICKNESS

WELD SIZE

“W”

TABLE 53-1

2-1/4”

1-1/2”

SHACKLES DO NOT TOUCH

CENTERED

(TOP EDGES FLUSH)

SHIM

(TABLE 53-1)

“A”

(TABLE 53-1)

GROUND

FIG. 53-3

PLATFORM

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

SHACKLE

(REF)

SHIM MADE FROM STEEL FLAT

FIG. 53-5

“W”
“W”

(TABLE 53-1)

2 PLACES

WELDING SHIMS (CURBSIDE SHOWN)

FIG. 53-4

53

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. 54-3).

“B”

(TABLE 54-1)

TIP OF

FLIPOVER

LOWER TIP OF

FLIPOVER

THIS DISTANCE “B”

7/8” 1/16”

2” 1/8”

3” 3/16”

3-15/16” 1/4”

GRIND METAL FROM

PLATFORM STOP

TABLE 54-1

4. RAISE the platform to comfortable work

height. Fold fl ipover and platform for access

to platform stops (FIG. 54-2).

5. Grind correct amount of metal (TABLE 54-1)
from platform stop as shown in FIG. 54-3.

PLATFORM DOES NOT

TOUCH GROUND

FIG. 54-1

PLATFORM RAISED TO WORK HEIGHT

FIG. 54-2

PLATFORM

STOP

6. Unfold fl ipover and platform. LOWER plat-

form to the ground. As the platform fi rst
touches the ground, the tip of fl ipover and
shackle should touch at the same time as

shown in FIG. 54-1.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

GRIND HERE

(TABLE 54-1)

GRINDING PLATFORM STOPS

(CURBSIDE SHOWN)

FIG. 54-3

54

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.

Weld each of the two
mounting plates as shown

in FIGS. 55-1 or 55-2.

(TYPICAL TRUCK FRAME

2 X 7” MIN

VERTICAL WELDS

TYPICAL - BOTH

MOUNTING PLATES

LONG SILL

VEHICLE FRAME

SHOWN)

1/4”

MOUNTING PLATE

LONG SILL

VEHICLE FRAME

(TYPICAL TRUCK FRAME

2 X 7” MIN

VERTICAL WELDS

TYPICAL - BOTH

MOUNTING PLATES

SHOWN)

1/4”

MAIN FRAME

1/4”

MOUNTING PLATE (PAINTED) WELDED

TO TRUCK FRAME & MAIN FRAME

FIG. 55-1

MOUNTING PLATE

MAIN FRAME

MOUNTING PLATE (GALVANIZED) WELDED

TO TRUCK FRAME

FIG. 55-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

55

STEP 14 - BOLT OPTIONAL STEPS TO

EXTENSION PLATE

1. Lower platform to the ground
(FIG. 56-1).

!

WARNING

To prevent accidental personal injury
and equipment damage, disconnect
(-) battery cable and (+) cable from
battery.

2. Disconnect power to the pump by
disconnecting negative (-) and positive
(+) cables from battery (FIG. 56-2).

Reinstall nuts on negative (-) and posi­tive (+) battery terminals.

PLATFORM LOWERED TO GROUND

FIG. 56-1

POSITIVE (+)

NUT

NEGATIVE (-)

BATTERY CABLE

BATTERY CABLE

NEGATIVE (-)

BATTERY POST

POSITIVE (+)

BATTERY POST

DISCONNECTING BATTERY POWER

FIG. 56-2

56

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

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.

3. Line up the LH step (Kit item) on LH

side of the extension plate. Bolt step to

extension plate (FIG. 57-1). Tighten

bolts 1, 2, 3 and 4 in the numbered
order shown in FIG. 57-1. Then, torque
each bolt and lock nut to 105 lb-ft in

the same order.

FLAT WASHER

(2 PLACES)

FLANGE LOCK NUT

(2 PLACES)

PART OF

EXTENSION

PLATE

LOCK NUT

(2 PLACES)

1/2”-13

CARRIAGE BOLT

(2 PLACES)

1/2” X 1-1/2” LG

FRAME BOLT

(2 PLACES)

3

4

LH STEP

1

2

90°

BOLTING STEP TO EXTENSION PLATE

(LH DUAL STEP SHOWN)

FIG. 57-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

57

STEP 14 - BOLT OPTIONAL STEPS TO

EXTENSION PLATE - Continued

4. Bolt the step support (Kit item)

to mounting channel (Kit item)

(FIG. 58-1).

LH STEP

REAR SILL

1/2” X 3-1/2” LG.

FRAME BOLT

(2 PLACES)

I-BEAM

(VEHICLE BODY)

LOCK NUT

(3 PLACES)

FLAT WASHER

(3 PLACES)

MOUNTING

CHANNEL

STEP SUPPORT

BOLTING SUPPORT TO MOUNTING CHANNEL &

STEP (LH DUAL STEP & SUPPORT SHOWN)

5. Butt the fl at part of the mounting

channel against bottom of vehicle
rear sill and I-beams. Then, butt the
step support against back of the

step (FIG. 58-1).

6. Ensure slotted hole in the step sup-

port is lined up with the hole on the

step (FIG. 58-1). Then, bolt the sup­port to step (FIG. 58-1). Torque the
lock nuts (FIG. 58-1) to 105 lb-ft.

1/2” X 1-1/2” LG

FRAME BOLT

FIG. 58-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

58

STEP 14 - BOLT OPTIONAL STEPS TO

EXTENSION PLATE - Continued

NOTE: Before welding mounting channel to

vehicle body, ensure step is straight
and steps are in vertical position.

7. Weld the fl at part of the mounting

channel to vehicle body as shown

in FIG. 59-1.

I-BEAM

(VEHICLE BODY)

MOUNTING

CHANNEL

3/16”
3/16”

REAR SILL

WELD TO AS MUCH
I-BEAM FLANGE &
REAR SILL AS POSSIBLE

8. Repeat instructions 3 through 7

for RH step. Use the RH Step As­sembly (Kit item).

9. Reconnect power to the pump by
reconnecting positive (+) and nega­ tive (-) cables to battery (FIG. 59-2).

Reinstall and tighten nut when each
battery cable is reconnected.

WELDING FLAT OF MOUNTING CHANNEL TO

VEHICLE BODY (LH DUAL STEP SHOWN)

FIG. 59-1

POSITIVE (+)

BATTERY POST

NUT

NEGATIVE (-)

BATTERY CABLE

POSITIVE (+)

BATTERY CABLE

NEGATIVE (-)

BATTERY POST

RECONNECTING POWER

FIG. 59-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

59

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.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

60

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. Use good common sense when locating these decals on
vehicle.

NOTE: Ensure there is no residue, dirt or corrosion where decals are attached.

If necessary, clean surface before attaching decals.

UP DECAL

P/N 299038-01

WARNING DECAL

P/N 282847-02

DOWN DECAL

P/N 299038-01

INSTRUCTION

DECAL

P/N 285800-01

DECAL “C”

DECAL “F”

DECAL “B”

DECAL “A”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

CAPACITY DECAL

(REFER TO TABLE 62-1)

FIG. 61-1

61

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

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

62

PAINT DECAL

(PAINTED ONLY)

P/N 267338-01

DECALS & PLATES

MAXON NAME PLATE

P/N 280004-01

SERIAL PLATE

(REF)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 63-1

63

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. Use good common sense when locating these decals on
vehicle.

NOTE: Ensure there is no residue, dirt or corrosion where decals are attached.

If necessary, clean surface before attaching decals.

WARNING DECAL

P/N 282847-02

UP DECAL

P/N 299038-01

DOWN DECAL

P/N 299038-01

INSTRUCTION

DECAL

P/N 285800-01

FIG. 64-1

DECAL “F”

DECAL “A”

DECAL “C”

WARNING DECAL

P/N 265441-01

NOTICE DECAL

P/N 266013-02

DECAL “B”

CAPACITY DECAL

(REFER TO TABLE 65-1)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

64

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

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

65

PAINT DECAL

(PAINTED ONLY)

P/N 267338-01

DECALS & PLATES

MAXON NAME PLATE

P/N 280004-01

SERIAL PLATE

(REF)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 66-1

66

TOUCHUP PAINTED OR GALVANIZED FINISH

CAUTION

Damaged cylinder seals and contaminated hydraulic fl uid can result from
painting the polished portion of the cylinder rod. To prevent damage, protect
the exposed polished portion of the cylinder rod while painting.

• If bare metal or primer is exposed on the painted portions of the Liftgate, touch up the

paint. 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.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

67

PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN)

“S2” VALVE

DIRECTION OF

CONTROLLED

FLOW

SYSTEM DIAGRAMS

STARTER

SOLENOID

MOTOR

GRAVITY DOWN POWER UNIT

FIG. 68-1

POWER UNIT MOTOR & SOLENOID OPERATION

SOLENOID OPERATION

LIFTGATE
FUNCTION

RAISE A - -

LOWER VENT -

PORT

REFER TO VALVES SHOWN ON

HYDRAULIC SCHEMATIC

( MEANS ENERGIZED)

MOTOR

VALVE

“S2”

VALVE

LOCK

TABLE 68-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

68

HYDRAULIC SYSTEM DIAGRAMS

HYDRAULIC SCHEMATIC (GRAVITY DOWN)

HYDRAULIC CYLINDERS

HYDRAULIC

LOCK VALVE

3 GPM FLOW

CONTROL VALVE

PORT A - RAISE

PORT B - RETURN

(PLUGGED)

VENT
PORT

FILL HOLE

(PLUGGED)

AUX. HAND

PUMP PORT

(PLUGGED)

VALVE “S2”

RELIEF VALVE

(SET AT 3250 PSI)

PUMP

FILTER

CHECK VALVE

M

RESERVOIR

FIG. 69-1

MOTOR

(REF)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

DRAIN HOLE (PLUGGED)

69

ELECTRICAL SYSTEM DIAGRAMS

ELECTRICAL SCHEMATIC (GRAVITY DOWN)

CONTROL SWITCH

(DOWN)(UP)

BLACKGREEN

WHITE

FUSE HOLDER

WITH 10 AMP

FUSE

122

SOLENOID

VALVE “S2”

JUNCTION

BLOCK

RED

LOCK

VALVE

CYCLE

COUNTER

1

(IF

EQUIPPED)

STARTER

SOLENOID

MOTOR

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BATTERY

BLACK

FIG. 70-1

70

PUMP & MOTOR SOLENOID OPERATION (POWER DOWN)

“S2” VALVE

“S1” VALVE

SYSTEM DIAGRAMS

STARTER

SOLENOID

MOTOR

DIRECTION OF

CONTROLLED

FLOW

POWER DOWN POWER UNIT

FIG. 71-1

POWER UNIT MOTOR & SOLENOID OPERATION

SOLENOID OPERATION

LIFTGATE
FUNCTION

RAISE A - -

LOWER B -

PORT

MOTOR

REFER TO VALVES SHOWN ON

HYDRAULIC SCHEMATIC

( MEANS ENERGIZED)

VALVE

“S2”

VALVE

“S1”

LOCK

VALVE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

TABLE 71-1

71

HYDRAULIC SYSTEM DIAGRAMS

HYDRAULIC SCHEMATIC (POWER DOWN)

HYDRAULIC CYLINDERS

HYDRAULIC

LOCK VALVE

PORT B ­POWER DOWN

3 GPM FLOW
CONTROL VALVE

PORT A - RAISE

VALVE “S2”

VALVE “S1”

MOTOR

(REF)

FILTER

FILTER

RELIEF VALVE 2

(SET AT 1100 PSI)

RELIEF VALVE 1

(SET AT 2750 PSI)

PUMP

RESERVOIR

AUX. HAND

PUMP PORT

(PLUGGED)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

DRAIN HOLE (PLUGGED)

FIG. 72-1

72

ELECTRICAL SYSTEM DIAGRAMS

ELECTRICAL SCHEMATIC (POWER DOWN)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 73-1

73

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

S2 Coil Resistance: 7.5Ω @ 70ºF ±15% 30.8Ω @ 70ºF ±15%

S2 Ampere: 1.6A 0.78A

Coil terminal torque: 15-45 lb-in max.
Valve cartridge torque: 25-30 lb-ft max.
Coil nut torque: 15-45 lb-in

12V 24V

Digital Cycle Counter

Operation Voltage: 7V - 30V

Ampere: <2mA

Solenoid Lock Valve

Coil Resistance: 8.0Ω @ 70ºF ±15% 30Ω @ 70ºF ±15%

Ampere: 1.5A 0.8A

Coil terminal torque: 3-4.5 lb-ft max.
Valve cartridge torque: 18.5-22 lb-ft max.

Ground Cable

Cap Screw Torque: 24 lb-ft max.

TABLE 74-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

74

OPTIONS

OPTIONAL LIFTGATE COMPONENTS

MECHANICAL KITS PART NO. GD PD

EXTENSION KIT 102”, 13” EXTENSION PLATE 287095-03 X X

EXTENSION KIT 102”, 13” EXTENSION PLATE, GALVANIZED 287095-03G X X

ELECTRICAL KITS PART NO. GD PD

IN CAB ON-OFF SWITCH 250477 X X

TUK-A-WAY DUAL CONTROL KIT 297115-01 X X

TUK-A-WAY DUAL CONTROL KIT, STREET SIDE 297116-01 X X

HAND HELD CONTROL ASSEMBLY, INSIDE 280570-07 X

HAND HELD CONTROL ASSEMBLY, 120” LG. 263260-13 X X

HAND HELD CONTROL ASSEMBLY, 240” LG. 263260-14 X X

OVAL, 2 LIGHT MOUNTING FRAME BRACKET 282372-01 X X

OVAL, 2 LIGHT MOUNTING FRAME BRACKET, GALVANIZED 282372-01G X X

CYCLE COUNTER 297620-01 X X

HAND PUMP OPTIONS PART NO. GD PD

HAND PUMP KIT, TE-33/GPTLR, POWER DOWN 287389-01 X

HAND PUMP KIT, TE-33/GPTLR, GRAVITY DOWN 287369-01 X

MISCELLANEOUS KITS PART NO. GD PD

TRAFFIC CONES 268893-01 X X

EXTENSION PLATE HARDWARE KIT (96” & 102” W VEH) 283257-02 X X

HIGH BED STEP OPTIONS (42” TO 54” BED HEIGHT, 30” OVERALL STEP HEIGHT)

PAINTED DUAL STEP KITS WITH BUMPER PART NO. GD PD

DUAL STEPS, 14” RUBBER BUMPERS 288705-01 X X

DUAL STEPS, 13.5” RUBBER BUMPERS 288705-02 X X

DUAL FLEX STEPS 14” RBR BUMPERS WITH FLEXIBLE WIRE ROPE LOWER
STEP & 14” LG. RUBBER BUMPER

DUAL FLEX STEPS WITH FLEXIBLE WIRE ROPE LOWER STEP & 13.5” LG.
RUBBER BUMPER

DUAL STEPS W/ BRACKET FOR LIGHT AND 14” RUBBER BUMPERS 288705-31 X X

DUAL STEPS W/ BRACKET FOR LIGHT AND 13.5” PLASTIC BUMPERS 288705-32 X X

PAINTED DUAL STEPS WITH BUMPERS AND NO STEPS ON STREET SIDE PART NO. GD PD

DUAL STEPS, STREET SIDE, NO STEPS, 14” BUMPER 288705-03 X X

DUAL STEPS, STREET SIDE, NO STEPS, 13.5” BUMPER 288705-04 X X

DUAL FLEX STEPS, STREET SIDE, NO STEPS, 14” BUMPER 288705-23 X X

DUAL FLEX STEPS, STREET SIDE, NO STEPS, 13.5” BUMPER 288705-24 X X

DUAL STEPS, W/LIGHT STREET SIDE, NO STEPS, 14” BUMPER 288705-33 X X

DUAL STEPS, W/LIGHT STREET SIDE, NO STEPS, 13.5” BUMPER 288705-34 X X

288705-21 X X

288705-22 X X

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

75

OPTIONS

OPTIONAL LIFTGATE COMPONENTS - CONTINUED

PAINTED DUAL STEPS WITHOUT BUMPERS PART NO. GD PD

DUAL STEPS, NO BUMPERS 288705-05 X X

DUAL STEPS, STREET SIDE NO STEPS, NO BUMPERS 288705-06 X X

DUAL FLEX STEPS, NO BUMPERS 288705-25 X X

DUAL FLEX STEPS, STREET SIDE, NO STEPS, NO BUMPERS 288705-26 X X

DUAL STEPS W/LIGHT, NO BUMPERS 288705-35 X X

DUAL STEPS W/LIGHT, STREET SIDE, NO STEPS, NO BUMPER 288705-36 X X

GALVANIZED DUAL STEP KITS WITH BUMPERS PART NO. GD PD

DUAL STEPS, 14” RUBBER BUMPERS 288705-01G X X

DUAL STEPS, 13.5” PLASTIC BUMPERS 288705-02G X X

DUAL FLEX STEPS 14” RUBBER BUMPERS 288705-21G X X

DUAL FLEX STEPS 13.5” PLASTIC BUMPERS 288705-22G X X

DUAL FLEX STEPS W/LIGHT, 14” RUBBER BUMPERS 288705-31G X X

DUAL FLEX STEPS W/LIGHT, 13.5” PLASTIC BUMPERS 288705-32G X X

GALVANIZED DUAL STEPS WITH BUMPERS AND NO STEPS STREET SIDE PART NO. GD PD

DUAL STEP KIT, STREET SIDE, NO STEPS, 14” RUBBER BUMPER 288705-03G X X

DUAL STEP KIT, STREET SIDE, NO STEPS, 13.5” BUMPER 288705-04G X X

DUAL FLEX STEP KIT, STREET SIDE, NO STEPS, 14” RUBBER BUMPERS 288705-23G X X

DUAL FLEX STEP KIT, STREET SIDE, NO STEPS, 13.5” RUBBER BUMPERS 288705-24G X X

DUAL STEPS W/LIGHT, STREET SIDE, NO STEPS, 14” RUBBER BUMPERS 288705-33G X X

DUAL STEPS W/LIGHT, STREET SIDE, NO STEPS,13.5” RUBBER BUMPERS 288705-34G X X

GALVANIZED DUAL STEPS WITHOUT BUMPERS PART NO. GD PD

DUAL STEPS, NO BUMPERS 288705-05G X X

DUAL STEPS, STREET SIDE, NO STEPS, NO BUMPERS 288705-06G X X

DUAL FLEX STEPS, NO BUMPERS, GALVANIZED 288705-25G X X

DUAL FLEX STEPS, STREET SIDE, NO STEPS, NO BUMPERS 288705-26G X X

DUAL STEPS W/LIGHT, NO BUMPERS 288705-35G X X

DUAL STEPS W/LIGHT, STREET SIDE, NO STEPS, NO BUMPER, GALVANIZED 288705-36G X X

BUMPERS KIT PART NO. GD PD

RUBBER BUMPER KIT, 14” BUMPERS (2.5”W X 3”H X 14” LG) 288706-01 X X

RUBBER BUMPER KIT, 13.5” PLASTIC BUMPERS (2.9”W X 1.5”H X 13.5” LG) 288707-01 X X

LOW BED STEP OPTIONS (38” TO 44” BED HEIGHT, 21” OVERALL STEP HEIGHT)

PAINTED SINGLE STEPS WITH BUMPERS PART NO. GD PD

SINGLE STEPS, 14” RUBBER BUMPERS 288705-11 X X

SINGLE STEPS, 13.5” PLASTIC BUMPERS 288705-12 X X

PAINTED SINGLE STEPS WITH BUMPERS NO STEPS ON STREET SIDE PART NO. GD PD

SINGLE STEPS, STREET SIDE NO STEPS, 14” RUBBER BUMPERS 288705-13 X X

SINGLE STEPS, STREET SIDE NO STEPS,13.5” PE BUMPERS 288705-14 X X

PAINTED SINGLE STEPS WITHOUT BUMPERS PART NO. GD PD

SINGLE STEP KIT, NO BUMPERS 288705-15 X X

SINGLE STEP KIT, STREET SIDE, NO STEPS, NO BUMPERS 288705-16 X X

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

76

OPTIONS

OPTIONAL LIFTGATE COMPONENTS - CONTINUED

GALVANIZED SINGLE STEPS W/BUMPERS PART NO. GD PD

SINGLE STEP KIT, 14” RUBBER BUMPERS 288705-11G X X

SINGLE STEP KIT, 13.5” PE BUMPERS 288705-12G X X

GALVANIZED SINGLE STEPS WITH BUMPERS NO STEPS ON STREET SIDE PART NO. GD PD

SINGLE STEP KIT, STREET SIDE, NO STEPS, 14” RUBBER BUMPERS 288705-13G X X

SINGLE STEP KIT, STREET SIDE, NO STEPS, 13.5” PE BUMPERS 288705-14G X X

GALVANIZED SINGLE STEPS WITHOUT BUMPERS PART NO. GD PD

SINGLE STEPS WITH NO BUMPERS 288705-15G X X

SINGLE STEPS, STREET SIDE, NO STEPS, NO BUMPERS 288705-16G X X

PAINTED STEPS WITHOUT BUMPERS - WELD-ON STEP PART NO. GD PD

DOCK BUMPER, DUAL STEP 251416 X X

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

77