Maxon DMD-22 User Maintenance Manual
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Maxon DMD-22 User Maintenance Manual

Dmd series
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M-16-40
AUGUST 2018
© MAXON Lift Corp. 2018

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Summary of Contents for Maxon DMD-22

  • Page 1 M-16-40 AUGUST 2018 © MAXON Lift Corp. 2018...
  • 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 WARNINGS ........................... 6 SAFETY INSTRUCTIONS ....................7 LIFTGATE TERMINOLOGY ....................8 PERIODIC MAINTENANCE ....................9 PERIODIC MAINTENANCE CHECKS .................. 9 PREVENTATIVE MAINTENANCE (PM) CHECKLIST ............10 CHECKING HYDRAULIC FLUID ..................11 CHANGING HYDRAULIC FLUID ..................13 PRESSURIZING HYDRAULIC SYSTEM ................15 TORSION BAR REPLACEMENT &...
  • Page 5 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 6: Warnings

    Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining Liftgates. See Operation Manual for operating safety requirements. WARNINGS WARNING • Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your feet are clear of the Liftgate. •...

  • Page 7: 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 8: Liftgate Terminology

    LIFTGATE TERMINOLOGY COLUMN MAIN FRAME RUNNER PLATFORM...

  • Page 9: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHECKS WARNING Never operate the Liftgate with parts loose or missing. NOTE: Photocopy the PM CHECKLIST on the next page to help keep track of periodic maintenance on the Liftgate. Keep completed form with maintenance records. Annually Visually check the entire Liftgate for excessively worn parts and broken welds, especially the hinge pins.

  • Page 10: Preventative Maintenance (Pm) Checklist

    Quarter Liftgate Preventative Maintenance (PM). Note: Includes steps 1-16 Satisfactory Repair Required Corrected Change hydraulic fl uid. Satisfactory Repair Required Corrected Inspect wear on slide pads. For more detailed information, please refer to the product maintenance manuals. Use only genuine Maxon replacement parts for all repairs. TABLE 10-1...

  • Page 11: 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 hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
  • Page 12 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 12-1 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 13: 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 hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
  • Page 14 6. Raise platform to bed height (FIG. 14-1). Continue to hold UP/DOWN control switch for 30 - 60 seconds to circulate hydraulic fl uid through slave cylinder and reservoir (FIG. 14-2). Release UP/ UP/DOWN DOWN control switch. CONTROL SWITCH NOTE: Three cycles of draining, fi lling, and circulating hydraulic fl...

  • Page 15: Pressurizing Hydraulic System

    PERIODIC MAINTENANCE PRESSURIZING HYDRAULIC SYSTEM CAUTION Operating Liftgate, under certain conditions, with air in system could result in damage to lift and load as well as personal injury. If lines are opened & closed or replaced, and if power unit or cylinders are replaced, pressurize hydraulic system before operating Liftgate with a passenger or load.

  • Page 16: Torsion Bar Replacement & Adjustment

    TORSION BAR REPLACEMENT & ADJUSTMENT REPLACE LH TORSION BAR WARNING Ensure platform is latched securely in stowed position to release most tension from torsion bar(s) and keep platform from suddenly un- folding. Injury could result from unbolting the torsion bar(s) under tension. When all tension is released from torsion bar(s), platform can PLATFORM unfold suddenly.
  • Page 17 PERIODIC MAINTENANCE TORSION BAR REPLACEMENT & ADJUSTMENT - Continued 4. With platform securely supported, remove cover plate (FIG. 17-1). PLATFORM TAPPING SCREWS (8 PLACES) COVER PLATE REMOVING COVER PLATE FIG. 17-1 5. Loosen locking screw from LH torsion bar housing (FIG. 17-2). LH TORSION BAR HOUSING LH TORSION...
  • Page 18 TORSION BAR REPLACEMENT & ADJUSTMENT - Continued 6. Remove LH torsion bar pin (FIG. 18-1). LOCK WASHER FLAT WASHER (2 PLACES) CAP SCREW, 1/2” TORSION BAR REMOVING LH TORSION BAR PIN FIG. 18-1 7. Remove LH torsion bar (FIG. 18-2). REMOVING LH TORSION BAR FIG.
  • Page 19 ADJUST LH TORSION BAR WARNING Platform can unfold suddenly with no tension on torsion bar. Stay out of the path of unfolding platform when adjusting the torsion bar. Get second person to help unlatch platform. 1. Stow platform. Refer to Operation Manual for detailed operating TORSION instructions.
  • Page 20 TORSION BAR REPLACEMENT & ADJUSTMENT - Continued 3. Unlatch platform (FIG. 20-1). Platform should just escape the latch as shown in FIG. 20-1, position 1. 4. Unfold platform until latch pin is 2”-3” from latch (FIG. 20-1, position 2). Release hold on platform.
  • Page 21 TORSION BAR REPLACEMENT & ADJUSTMENT - Continued 7. With platform securely supported, remove cover plate (FIG. 21-1). PLATFORM TAPPING SCREWS (8 PLACES) COVER PLATE REMOVING COVER PLATE FIG. 21-1 8. Loosen locking screw from LH torsion bar housing (FIG. 21-2). LH TORSION BAR HOUSING LH TORSION...
  • Page 22 TORSION BAR REPLACEMENT & ADJUSTMENT - Continued 9. Increase LH torsion bar tension by moving LH torsion bar housing inboard towards center of vehicle (FIG. 22-1). Approximate adjustment travel should be no more than 10”. STOP BLOCK LH TORSION BAR HOUSING INCREASING LH TORSION BAR TENSION FIG.
  • Page 23 PERIODIC MAINTENANCE TORSION BAR REPLACEMENT & ADJUSTMENT - Continued REPLACE RH TORSION BAR (IF EQUIPPED) 1. Stow platform. Refer to Operation Manual for detailed operating instructions. 2. Support platform and fl ipover evenly by placing supports under the RH and LH runners (FIG. 23-1). SUPPORT (2 PLACES) FIG.
  • Page 24 TORSION BAR REPLACEMENT & ADJUSTMENT - Continued 4. Loosen locking screw from RH torsion bar housing (FIG. 24-1). RH TORSION BAR HOUSING LOCKING SCREW RH TORSION FIG. 24-1 5. On RH runner, unbolt the platform and runner pin from RH runner (FIG. 24-2). Next, remove platform and runner pin, and platform PLATFORM &...
  • Page 25 TORSION BAR REPLACEMENT & ADJUSTMENT - Continued PLATFORM & 7. With platform in vertical RUNNER PIN position, insert the torsion bar LOCK into the RH platform and WASHERS runner pin, through RH runner, platform spacer and engage with RH torsion bar housing (FIG.

  • Page 26: Decals

    DECALS NOTE: Decals are preinstalled at factory. Decal location shown for reference. NOTE: Ensure there is no residue, dirt or DMD-22 ONLY corrosion where decals are attached. CAPACITY DECAL If necessary, clean surface before P/N 220388-03 replacing decals. DMD-33 ONLY...
  • Page 27 DECAL SHEET P/N 289192-01 WARNING DECAL WARNING DECAL P/N 298373-01 P/N 299274-01...

  • Page 28: System Diagrams

    SYSTEM DIAGRAMS PUMP MOTOR & VALVE OPERATION (MANUAL CLOSE) LOWERING VALVE STARTER SWITCH MOTOR POWER UNIT FIG. 28-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE MOTOR FUNCTION LOWERING STARTER VALVE SWITCH RAISE LOWER REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC TABLE 28-1...

  • Page 29: Pump Motor & Valve Operation (Equipped With Hydraulic Closer)

    PUMP MOTOR & VALVE OPERATION (EQUIPPED WITH HYDRAULIC CLOSER) FOLD/UNFOLD VALVE LOWERING STARTER ASSEMBLY VALVE SWITCH MOTOR POWER UNIT FIG. 29-1 POWER UNIT MOTOR & VALVE OPERATION REMOTE VALVE OPERATION MEANS ENERGIZED) LIFTGATE FUNCTION LOWERING FOLD/UNFOLD MOTOR VALVE VALVE RAISE LOWER UNFOLD FOLD...

  • Page 30: Hydraulic Schematic (Manual Close)

    HYDRAULIC SCHEMATIC (MANUAL CLOSE) FIG. 30-1...

  • Page 31: Hydraulic Schematic (Equipped With Hydraulic Closer)

    HYDRAULIC SCHEMATIC (EQUIPPED WITH HYDRAULIC CLOSER) FIG. 31-1...

  • Page 32: Electrical Schematic (Manual Close)

    ELECTRICAL SCHEMATIC (MANUAL CLOSE) FIG. 32-1...

  • Page 33: Electrical Schematic (Equipped With Hydraulic Closer)

    ELECTRICAL SCHEMATIC (EQUIPPED WITH HYDRAULIC CLOSER) FIG. 33-1...

  • Page 34: Electrical Schematic - Jumper Harness Assembly

    ELECTRICAL SCHEMATIC - JUMPER HARNESS ASSEMBLY CONNECT TERMINALS TO VEHICLE HARNESS ORANGE GREEN BLACK YELLOW WHITE TERMINAL “A” GROUND TERMINAL “F” LH STOP/TURN TERMINAL “B” TAIL TERMINAL “E” RH STOP/TURN TERMINAL “C” REVERSE TERMINAL “D” STOP CONNECT MALE TERMINAL TO COVER LIGHTS HARNESS FOREIGN/DOMESTIC FIG.

  • Page 35: Electrical Schematic - Housing Cover Assembly (Without Lights)

    SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY (WITHOUT LIGHTS) CONNECT TO WIRING HARNESS LICENSE PLATE LIGHT LH LICENSE PLATE RH LICENSE PLATE LIGHT LIGHT FIG. 35-1...

  • Page 36: Electrical Schematic - Housing Cover Assembly (With Four Lights)

    ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY (WITH FOUR LIGHTS)

  • Page 37: Electrical Schematic - Housing Cover Assembly, Foreign Vehicle

    SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY, FOREIGN VEHICLE (WITH 6 LIGHTS )

  • Page 38: Dmd Electrical Values

    SYSTEM DIAGRAMS DMD ELECTRICAL VALUES SOLENOID SWITCH 5.4Ω @70ºF. ±15% 20.1Ω @70ºF. ±15% Coil Resistance: 2.2A 1.2A Ampere: Coil terminal torque: 10-15 lb-in max. Contact terminal torque: 30-35 lb-in max. LOWERING VALVE 6.6Ω @ 70ºF. ±15% 26.7Ω @ 70ºF. ±15% Coil Resistance: 1.8A 0.9A...

  • Page 39: Recommended Bolt Torques

    RECOMMENDED BOLT TORQUES CAUTION The torque values in the following table are provided for torquing grade 8 bolts on Liftgate mechanical parts. To prevent damage, never use the infor- mation in this table for torquing electrical or hydraulic hose connections on the pump assembly.

This manual is also suitable for:

Dmd-33

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