Maxon TE-250C Maintenance Manual
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Maxon TE-250C Maintenance Manual

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M-17-12
REV. B
APRIL 2020
© 2020 MAXON Lift Corp.

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Summary of Contents for Maxon TE-250C

  • Page 1 M-17-12 REV. B APRIL 2020 © 2020 MAXON Lift Corp.
  • Page 3 MAXON agrees to replace any components which are found to be defective during the fi rst 2 years of service, and will reimburse for labor based on MAXON’s Liftgate Warranty Flat Rate Schedule.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SUMMARY OF CHANGES: M-17-12, REVISION B ............. 6 WARNINGS ........................... 8 SAFETY INSTRUCTIONS ....................9 LIFTGATE TERMINOLOGY ....................10 PERIODIC MAINTENANCE ....................11 PERIODIC MAINTENANCE CHECKS .................11 PERIODIC MAINTENANCE CHECKLIST ................12 CHECKING HYDRAULIC FLUID ..................14 CHANGING HYDRAULIC FLUID ..................
  • Page 5 PLATFORM RAISES BUT LEAKS DOWN ................40 PLATFORM RAISES PARTIALLY AND STOPS ..............42 LIFTGATE WILL NOT LIFT RATED CAPACITY ..............44 PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY ....46...

  • Page 6: Summary Of Changes: M-17-12, Revision B

    SUMMARY OF CHANGES: M-17-12, REVISION B PAGE DESCRIPTION OF CHANGE Cover Updated REV and date of release. Added California Proposition 65 WARNING. Added Phillips 66 Arctic Low Pour oil to table of recommended ISO-15 oils. Added instructions for installing torsion springs correctly to assist with unfolding and folding different combinations of platforms and fl...
  • Page 7 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 8: Warnings

    Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining Liftgates. See Operation Manual for operating safety requirements. WARNING Installing and maintaining a liftgate can expose you to chemicals, including lead, which are knowto the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, install and maintain liftgate in a well-ventilated area and wear proper Per- sonal protective equipment (PPE).

  • Page 9: Safety Instructions

    Listen for scraping, grat- ing and binding noises and correct the problem before continuing to operate Liftgate. • Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial num- ber information with your parts order. Order replacement parts from: MAXON LIFT CORP.

  • Page 10: Liftgate Terminology

    LIFTGATE TERMINOLOGY EXTENSION PLATE CONTROL SWITCH MAIN FRAME LIFT CYLINDER PARALLEL PLATFORM PUMP ASSEMBLY (COVER IS BUMPER SHOWN) LIFT ARM PLATFORM OPENER WEDGE TORSION FLIPOVER SPRING...

  • Page 11: Periodic Maintenance

    Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it off. Touch up the paint where bare metal is showing. MAXON recommends using aluminum primer touchup paint.

  • Page 12: Periodic Maintenance Checklist

    PERIODIC MAINTENANCE CHECKLIST NOTE: Make sure vehicle is parked on level ground while performing maintenance checks. Quarterly or 1250 Cycles (whichever occurs fi rst) Check the level and condition of the hydraulic fl uid. Visually check all hoses and fi ttings for chafi ng and fl uid leaks. Tighten loose fi ttings or replace parts as required.
  • Page 13 PERIODIC MAINTENANCE CHECKLIST NOTE: Lube fi ttings are shown for the RH cylinder, lift arm, parallel arm, and opener. There are also lube fi ttings at the same places on the LH cylin- der, lift arm, and parallel arm. Refer to the PERIODIC MAINTENANCE CHECKS and PERIODIC MAINTENANCE CHECKLIST for the recom- mended grease and maintenance interval.

  • Page 14: Checking Hydraulic Fluid

    PERIODIC MAINTENANCE 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.
  • Page 15 ISO 32 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 EXXONMOBIL UNIVIS N-32, DTE-24 TABLE 15-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON FLUID A, AW-MV-15 KENDALL GLACIAL BLU SHELL TELLUS S2 VX 15...

  • Page 16: Changing Hydraulic Fluid

    PERIODIC MAINTENANCE CHANGING 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.
  • Page 17 3. Lower the platform all the way to the ground while draining the remaining hydraulic fl uid. 4. Reinstall drain plug (FIG. 16-2). 5. Pull out (no threads) fi ller cap (FIG. 16-2). Add 1 gallon of hydraulic fl uid to reservoir. Re-install fi...

  • Page 18: Replacing Platform Torsion Spring

    PERIODIC MAINTENANCE REPLACING PLATFORM TORSION SPRING NOTE: The following procedure shows how to replace torsion spring on RH side of platform. Use this procedure for replacing torsion spring on the LH side. 1. If platform is on the ground, manually fold fl...
  • Page 19 CAUTION Incorrect selection of torsion spring bracket holes can result in unnecessary strain or injury to operator. Selecting the correct bracket hole will reduce the force needed for operator to unfold and fold the platform. 5. Install the new torsion spring and bushing as shown in (FIGS.
  • Page 20 REPLACING PLATFORM TORSION SPRING - Continued 6. Drive platform hinge pin inboard to correct position through the platform hinge bracket ( FIG. 20-1). Line up the hole in the platform hinge pin with the hole in the pin collar. Install the roll pin through the pin collar until roll pin protrudes equally from both sides of the collar (FIG.
  • Page 21 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 22 PERIODIC MAINTENANCE PLATFORM ADJUSTMENT NOTE: Before doing the following procedure, make sure vehicle is parked on level ground. TIP OF FLIPOVER 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...
  • Page 23 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. 23-1) with TABLE 23-1 to determine how much to grind from the TIP OF platform stops (FIG.

  • Page 24: Decals: Te-25Dc & Te-33

    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 MAXON 24/7 MAXON 24/7 UP DECAL SUPPORT DECAL SUPPORT DECAL P/N 299038-01...
  • Page 25 DECAL SHEET P/N 282522-01 FIG. 25-1 MODEL DECAL P/N CAPACITY TE-25DC 220382 2500 POUNDS [1134 KG] TE-33 220388-02 3300 POUNDS [1500 KG] CAPACITY DECALS TABLE 25-1...

  • Page 26: Decals & Plates

    DECALS & PLATES PAINT DECAL (PAINTED ONLY) MAXON NAME PLATE P/N 267338-01 P/N 280004-01 SERIAL PLATE (REF) FIG. 26-1...
  • Page 27 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 28: Decals: Tewr-25Dc & Tewr-33

    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 MAXON 24/7 MAXON 24/7 SUPPORT DECAL SUPPORT DECAL UP DECAL P/N 298634-01...
  • Page 29 DECAL “F” DECAL “B” DECAL “A” DECAL “C” FIG. 29-1 DECAL SHEET P/N 282522-01 FIG. 29-2 MODEL DECAL P/N CAPACITY TEWR-25DC 220382 2500 POUNDS [1134 KG] TEWR-33 220388-02 3300 POUNDS [1500 KG] CAPACITY DECALS TABLE 29-1...

  • Page 30: Decals & Plates

    DECALS & PLATES PAINT DECAL (PAINTED ONLY) P/N 267338-01 MAXON NAME PLATE P/N 280004-01 SERIAL PLATE (REF) FIG. 30-1...

  • Page 31: System Diagrams

    SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) STARTER SOLENOID “S2” VALVE MOTOR DIRECTION OF CONTROLLED FLOW GRAVITY DOWN POWER UNIT FIG. 31-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE LOCK MOTOR “S2”...

  • Page 32: Hydraulic Schematic (Gravity Down)

    SYSTEM DIAGRAMS - Continued HYDRAULIC SCHEMATIC (GRAVITY DOWN) HYDRAULIC CYLINDERS HYDRAULIC LOCK VALVE 3 GPM FLOW CONTROL VALVE FILL HOLE PORT B - RETURN VENT (PLUGGED) (PLUGGED) PORT PORT A - RAISE VALVE “S2” RELIEF VALVE CHECK VALVE (SET AT 3250 PSI) AUX.

  • Page 33: Electrical Schematic (Gravity Down)

    ELECTRICAL SCHEMATIC (GRAVITY DOWN) CONTROL SWITCH (UP) (DOWN) GREEN BLACK JUNCTION BLOCK WHITE CYCLE COUNTER SOLENOID LOCK VALVE “S2” VALVE EQUIPPED) FUSE HOLDER WITH 10 AMP FUSE STARTER SOLENOID MOTOR BATTERY BLACK FIG. 33-1...

  • Page 34: Pump & Motor Solenoid Operation (Power Down)

    SYSTEM DIAGRAMS - Continued PUMP & MOTOR SOLENOID OPERATION (POWER DOWN) STARTER SOLENOID MOTOR “S2” VALVE “S1” VALVE DIRECTION OF CONTROLLED FLOW POWER DOWN POWER UNIT FIG. 34-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE VALVE...

  • Page 35: Hydraulic Schematic (Power Down)

    HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDERS HYDRAULIC LOCK VALVE 3 GPM FLOW CONTROL VALVE PORT B - POWER DOWN PORT A - RAISE VALVE “S2” FILTER RELIEF VALVE 2 (SET AT 1100 PSI) VALVE “S1” RELIEF VALVE 1 (SET AT 2750 PSI) AUX.

  • Page 36: Electrical Schematic (Power Down)

    SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC (POWER DOWN) FIG. 36-1...

  • Page 37: Electrical Values

    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...

  • Page 38: Troubleshooting

    TROUBLESHOOTING PLATFORM WILL NOT RAISE & MOTOR WILL NOT RUN 1. Connect voltmeter between motor solenoid terminal “B” and ground STARTER TERMINAL “A” SOLENOID wires connection on pump (FIG. 38-1). LOAD Verify that full battery voltage is at “B”. Recharge the battery if TERMINAL “D”...

  • Page 39: Platform Will Not Raise, But Motor Runs

    PLATFORM WILL NOT RAISE, BUT MOTOR RUNS 1. Do the CHECKING HYDRAULIC FLUID procedure in this manual. If necessary, add hydraulic fl uid. RESERVOIR 2. Check for structural damage and replace worn parts. CAUTION Keep dirt, water and other contaminants from entering the hydraulic system.

  • Page 40: Platform Raises But Leaks Down

    TROUBLESHOOTING PLATFORM RAISES BUT LEAKS DOWN 1. Check if the “A” (lowering) solenoid valve is constantly STARTER SOLENOID energized. Connect voltmeter TERMINAL “A” LOAD negative (-) lead to ground (-) wires connection on pump and TERMINAL “D” TERMINAL “B” SWITCHED BATTERY positive (+) lead to (+) terminal BATTERY (+) on the “A”...
  • Page 41 VALVE CAUTION CARTRIDGE Keep dirt, water and other contaminants from entering the hydraulic system. Be- fore opening the hydraulic fl uid reservoir COIL fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.

  • Page 42: Platform Raises Partially And Stops

    TROUBLESHOOTING PLATFORM RAISES PARTIALLY AND STOPS 1. Lower the opened platform to the ground. Do the CHECKING HYDRAULIC FLUID procedure in this manual. If necessary, add hydraulic fl uid. RESERVOIR 2. Use voltmeter to verify the battery voltage is 12.6 volts or more under load from pump motor. 3.
  • Page 43 5. Check the hydraulic cylinder. With the plat- LOWER PORT form at vehicle fl oor level, remove the hy- draulic line from the LOWER port on the cyl- RAISE PORT inder (FIG. 43-1). Hold the control switch in the “RAISE” position for two seconds while you watch for hydraulic fl...

  • Page 44: Liftgate Will Not Lift Rated Capacity

    TROUBLESHOOTING LIFTGATE WILL NOT LIFT RATED CAPACITY 1. Use voltmeter to verify the battery voltage is 12.6 volts or more under load from pump motor. 2. Check for structural damage or lack of lubrica- tion. Replace worn parts. RELIEF VALVE ADJUST SCREW CAUTION Keep dirt, water and other contaminants...
  • Page 45 5. Check the hydraulic cylinder. With the platform at vehicle fl oor level, remove the hydraulic line from the LOWER port on the cylinder (FIG. 45-1). Hold the control switch in the “RAISE” position for two LOWER PORT seconds while you watch for hydraulic fl uid at the LOWER port.

  • Page 46: Platform Will Not Lower, Lowers Too Slowly, Or Too Quickly

    TROUBLESHOOTING PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY 1. Connect voltmeter (+) lead to STARTER TERMINAL “A” SOLENOID motor solenoid terminal “B” and TERMINAL “D” LOAD the (-) lead to the ground wires SWITCHED BATTERY connection on pump (FIG. 46-1). TERMINAL “B”...
  • Page 47 FLOW CAUTION CONTROL VALVE Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the open- ings. Also, protect the openings from acci- dental contamination during maintenance.

This manual is also suitable for:

Te-33Tewr-25dcTewr-33

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