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JUNE 04, 2025

Maxon RC Rail Liftgate Power System Guide: Battery Box, Electrical, and Hydraulic Setup Explained

The Maxon RC Series is a heavy-duty rail-style liftgate designed for demanding fleet applications. With its high power requirements and advanced hydraulic components, installing the RC Series correctly is crucial to long-term performance and reliability. This guide walks through verified Maxon installation steps for the battery box, electrical connections, hydraulic lines, and final setup, ensuring safety and optimal operation from day one.

• Documentation Resources from Maxon
• Battery Box Mounting and Frame Positioning
• Electrical Wiring and Cable Routing
• Hydraulic Pipe and Hose Connections
• Hydraulic Fluid Type and Fill Process
• Final System Adjustments and Safety Checks
• Conclusion

Documentation Resources from Maxon

Information in this article is sourced from Maxon’s RC series manuals and technical guides. Always refer to your specific liftgate’s manuals for complete procedures and serial number, model, and year-specific details.

Reference PDFs used:

• RC Series Sales Document (RC-23456-M100)
• RC Series Maintenance Manual (M-90-3M, Rev. M)
• RC Series Operation Manual (M-90-2D, Rev. D)
• RC Series Installation Manual (M-90-1H, Rev. H)
• RC Series Maintenance Checklist (M-94-16)
• RC Series Technical Bulletin (TB-02-01, Rev. A)

Battery Box Mounting and Frame Positioning

For many trailer installations—and select truck configurations—Maxon provides an optional battery box that houses the dedicated power supply for the RC Series liftgate. The positioning and secure attachment of this battery box are vital to prevent vibration issues, electrical hazards, or premature component failure.

Key Installation Steps

• When it’s used: The battery box is typically required on trailers, especially when the tractor’s battery is inaccessible or insufficient to support the liftgate.
• Mounting options: Brackets may be either bolted (FIG. 13-1C) or welded to the truck or trailer's crossmembers. Trailer flush mount and truck-specific bracket layouts are shown in FIG. 13-1A and 13-2, respectively.
• Torque specifications: All bolts attaching the mounting brackets to the frame must be torqued to 85–128 lb-ft (FIG. 14-2B).
• Ventilation requirements: The battery box includes three critical ventilation holes to prevent hydrogen gas buildup during charging (FIG. 17-1). These must remain unblocked at all times.
• Truck vs. Trailer setup: Maxon illustrates recommended layouts in FIG. 34-1 for trailers and FIG. 34-2 for trucks, including battery box and power unit placement.

Properly securing the battery box and allowing adequate ventilation ensures safe operation and extends the life of your liftgate’s electrical components.

Electrical Wiring and Cable Routing

Because this Maxon liftgate gate draws significant electrical current, proper wiring is essential to avoid system failure or fire hazards. Maxon provides explicit guidelines for cable gauge, grounding, and protective routing.

Wiring Best Practices for the RC Series

• Cable types: The standard power cable provided is a 32 ft. fused cable. Optional extensions include a 40-ft cable with fuse (P/N 264848) and a 10-ft extension (P/N 264849).
• Fuse placement: Always connect the fused end of the power cable to the positive battery terminal to protect against overcurrent (FIG. 16-1).
• Connection method: Maxon strongly recommends using soldered terminals with shrink tubing for vibration protection. Crimp connections can fail over time if done improperly.
• Grounding: Use a designated chassis ground or connect to the pump box’s ground stud. A 150-amp circuit breaker is typically installed inline (FIG. 35-1).
• Cable routing: Secure power cables with frame clips and keep clear of exhaust components or sharp edges.
• Safety tip: Always remove rings, watches, and metal jewelry before handling electrical cables to prevent arc flash or short circuits.
• Dielectric grease: Apply to all electrical contact points to prevent corrosion and moisture intrusion.

Following these guidelines minimizes the risk of premature electrical failure and ensures the system can handle the RC’s heavy draw.

Hydraulic Pipe and Hose Connections

This Maxon rail lift gate’s lifting power is driven by hydraulic pressure. Clean and secure pipe and hose connections are vital to reliable gate operation.

Connection Requirements

• Steel pipe installation: Each lift includes a 7-ft welded steel hydraulic pipe (two for hydraulic closer models). These must be welded beneath the body crossmembers, ending roughly 24 inches from the truck’s rear.
• Hose connections: A 4-ft hydraulic hose connects each pipe to the hydraulic power unit. Blow compressed air through pipes and hoses before making connections to remove metal shavings or contaminants.
• Cord routing: Run a 3-conductor control cord (or two for hydraulic closer setups) through the power unit box. Tie off all lines securely to prevent movement during transit.

Clean and well-routed hydraulic lines reduce system strain, prevent leaks, and ensure consistent pressure delivery during operation.

Hydraulic Fluid Type and Fill Process

Using the correct lift gate hydraulic fluid is key to temperature-specific performance and long-term durability of the liftgate’s hydraulic pump.

Recommended Fluids and Fill Tips

• Fluid types by climate:
• ISO 32: For +50°F to +120°F ambient temperatures.
• ISO 15 or MIL-H-5606: For cold weather performance below +70°F.
• Initial fill: Add 4 quarts to the reservoir, then lower the platform and ensure fluid reaches the “Gravity Down” line on the decal (FIG. 25-2).
• Cleanliness matters: Before removing the filler cap, clean the reservoir cap area to prevent contamination.
• Brand recommendations: Compatible brands include:
• Shell: Tellus S2 V32, V15
• Mobil: DTE-13M, DTE-24, DTE-11M
• Chevron: HYPERSYN 32, AW-MV-15
• Exxon: Univis N-32, HVI-13
• AMSOIL: AWH-05, AWF-05

Using the wrong fluid—or introducing dirt—can damage seals and reduce system responsiveness.

Final System Adjustments and Safety Checks

With wiring and hydraulics complete, the final step is to test and fine-tune system performance for safe field use.

Required Adjustments

• Flow control valve: Adjust so platform opens from the stowed position in 4–6 seconds in moderate climates (FIG. 28-1). Faster than 4 seconds may cause a dangerous “bang” when opening.
• Runner brake test:
• Raise the lift.
• Support one runner on a jack.
• Lower the jack.
• If the runner stays up, the brake is holding. If it drops, inspection is needed.
• Visual checks:
• Remove platform hold-down chains.
• Inspect for loose wires, blocked vents, ungrounded terminals, or obstructed hydraulic hoses.
• Platform leveling: If the gate rises unevenly, consult the Maxon RC Maintenance Manual for platform alignment.

These final steps are vital to ensure safe operation and compliance with Maxon’s liftgate warranty policies.

Conclusion

Installing the Maxon RC railgate requires careful attention to electrical, hydraulic, and structural details. This guide outlines the official, step-by-step Maxon-recommended methods for battery box installation, wiring configuration, pipe routing, and fluid maintenance.

Proper setup is not just about performance—it’s about safety, longevity, and maximizing ROI. If you need help sourcing compatible components such as ISO hydraulic fluid, fused power kits, or battery boxes, reach out to LiftGateMe. Our team can verify parts against your serial number and ensure you’re matched with the exact equipment needed for your RC Series liftgate.