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Maxon DMD Series Maintenance Manual

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M-16-40
REV. C
SEPTEMBER 2022
© MAXON Lift Corp. 2022

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Summary of Contents for Maxon DMD Series

  • Page 1 M-16-40 REV. C SEPTEMBER 2022 © MAXON Lift Corp. 2022...
  • 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-16-40 REVISION C .............. 6 WARNINGS ........................... 7 SAFETY INSTRUCTIONS ....................8 LIFTGATE TERMINOLOGY ....................9 PERIODIC MAINTENANCE ....................10 PERIODIC MAINTENANCE CHECKS ................10 PREVENTATIVE MAINTENANCE (PM) CHECKLIST ............11 CHECKING HYDRAULIC FLUID ..................12 CHANGING HYDRAULIC FLUID ..................
  • Page 5 DMD ELECTRICAL VALUES & TORQUE SPECIFICATIONS .......... 49 BOLT TORQUES ........................ 50...

  • Page 6: Summary Of Changes: M-16-40 Revision C

    SUMMARY OF CHANGES: M-16-40 REVISION C PAGE DESCRIPTION OF CHANGE COVER Updated REV. and date of release. Transit hook with handle tab on the bottom is shown throughout manual. Added Quarterly/1250 Cycles PM CHECK to measure and adjust clearance be- 10, 11 tween main housing and bottom of stowed platform and fl...

  • Page 7: 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 known to the State of California to cause cancer and birth defects or other reproductive harm. To mini- mize exposure, install and maintain liftgate in a well-ventilated area and wear proper Personal protective equipment (PPE).

  • Page 8: 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 9: Liftgate Terminology

    LIFTGATE TERMINOLOGY LH COLUMN RH COLUMN MAIN FRAME HOUSING RUNNER PLATFORM...

  • Page 10: Periodic Maintenance

    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. NOTE: When replacing parts, refer to the Parts Portal on the Maxon website for genuine MAXON replacement parts.

  • Page 11: Preventative Maintenance (Pm) Checklist

    Change hydraulic fl uid. Satisfactory Repair required Corrected □ □ □ Inspect wear on slide pads. Satisfactory Repair required Corrected For more detailed information, refer to the Parts Portal on the Maxon website for genuine MAXON TABLE 11-1 replacement parts.

  • Page 12: 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 13 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 EXXONMOBIL UNIVIS HVI-13 ROSEMEAD THS FLUID 17111 TABLE 13-1...

  • Page 14: 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 15 5. Raise platform to bed height (FIG. 15-1). Continue to hold UP/DOWN control switch for 30 - 60 seconds to circulate hydraulic fl uid through slave cylinder and reservoir (FIG. 15-2). Release UP/ UP/DOWN DOWN control switch. CONTROL SWITCH NOTE: One cycle of draining, fi lling, and circulating hydraulic fl...

  • Page 16: Torsion Bar Adjustment

    PERIODIC MAINTENANCE TORSION BAR ADJUSTMENT NOTE: This procedure applies to platforms equipped with manual closer or hy- draulic closer. Platforms with manual closer use LH and RH torsion bars to assist with folding and unfolding. Platforms with hydraulic closer use a LH torsion bar to assist hydraulic cylinder with unfolding the platform.
  • Page 17 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 unfold suddenly.
  • Page 18 PERIODIC MAINTENANCE TORSION BAR ADJUSTMENT - Continued 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. ADJUST LH TORSION BAR (ALL PLATFORMS) 1.
  • Page 19 2. Lower the platform until arrow decals are lined up on column and runner (FIG. 19-1). Refer to Operation Manual for detailed operating instructions. 3. If platform is equipped with manual close, unlock the platform. Platform should open as shown in FIG. 19-1, position 1. Pull platform to unfold.
  • Page 20 PERIODIC MAINTENANCE TORSION BAR ADJUSTMENT - Continued NOTE: Tension can be increased (or decreased) with more precision by changing the position of the LH torsion bar housing. 4. Stow platform (FIG. 20-1). Refer to Operation Manual for detailed operating instructions. PLATFORM 5.
  • Page 21 7. Tighten locking screw securely LOCKING LH TORSION to hold LH torsion bar housing SCREW in position (FIG. 21-1). LH HOUSING FIG. 21-1...
  • Page 22 PERIODIC MAINTENANCE TORSION BAR ADJUSTMENT - Continued 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. NOTE: Tension can be increased (or decreased) with more precision LOCKING by changing the position of the...
  • Page 23 3. Tighten locking screw securely to hold RH torsion bar housing RH HOUSING in position (FIG. 23-1). LOCKING SCREW RH TORSION FIG. 23-1 4. Unfold and fold platform (FIGS. 23-2 and 23-3). Refer to Operation Manual for detailed operating instructions. Ensure platform unfolds and folds correctly.
  • Page 24 PERIODIC MAINTENANCE TORSION BAR ADJUSTMENT - Continued 5. Reinstall and bolt on torsion bar cover (FIG. 25-1). TAPPING SCREWS (8 PLACES) PLATFORM REATTACH TORSION BAR COVER PLATE FIG. 24-2 6. Platform can be stowed or returned to operation after adjustment.

  • Page 25: Torsion Bar Replacement

    TORSION BAR REPLACEMENT 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 unfold suddenly.
  • Page 26 PERIODIC MAINTENANCE TORSION BAR REPLACEMENT - Continued 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. 3. Support platform and fl ipover evenly by attaching chain hoist to the chain u-bolts on the platform, and place supports under the platform (FIG.
  • Page 27 5. Remove LH torsion bar pin (FIGS. 27-1 and 27-1A). TORSION BAR PIN REMOVING LH TORSION BAR PIN FIG. 27-1A FIG. 27-1 6. Loosen locking screw on LH torsion bar housing (FIGS. 27-2 and 27-2A). RH TORSION BAR PIN (REF) LOCKING LH HOUSING SCREW...
  • Page 28 PERIODIC MAINTENANCE TORSION BAR REPLACEMENT - Continued 7. Remove LH torsion bar (FIGS. 28-1 and 28-1A). REMOVING LH TORSION BAR FIG. 28-1A FIG. 28-1 8. With platform in vertical position, insert the replacement torsion bar into the LH platform and runner pin, through LH runner, platform spacer and engage with LH torsion bar housing (FIGS.
  • Page 29 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. REPLACE RH TORSION BAR 1. Lower platform to align arrows. Refer to Operation Manual for detailed HOIST CHAIN operating instructions.
  • Page 30 PERIODIC MAINTENANCE TORSION BAR REPLACEMENT - Continued 3. On RH runner, use large wrench or gripping pliers to hold RH torsion bar pin in vertical position (FIG. 30-1A). Unbolt the pin from RH runner (FIG. 30-1B). Next, remove platform pin, and thrust bearing (FIG.
  • Page 31 5. Remove RH torsion bar (FIGS. 31-1 and 31-1A). FIG. 31-1A REMOVING RH TORSION BAR FIG. 31-1 6. Insert the replacement torsion bar through RH runner, thrust bearing, and RH torsion bar housing (FIGS. 31-2 and 31-2A). FIG. 31-2A REPLACING RH TORSION BAR FIG.
  • Page 32 PERIODIC MAINTENANCE TORSION BAR REPLACEMENT - Continued 7. Insert the RH torsion bar pin. Use a large wrench to rotate the RH pin counterclockwise to line up the pin holes with the threaded holes in the RH runner (FIGS. 32-1 and 32-1A).

  • Page 33: Measure & Adjust Clearance For Platform With Flipover

    MEASURE & ADJUST CLEARANCE FOR PLATFORM WITH FLIPOVER NOTE: This procedure only applies to platforms equipped with a fl ipover section. The platform and fl ipover must be in the stowed position to accurately mea- sure clearance between main housing and bottom of fl ipover. The platform and fl...
  • Page 34 MEASURE & ADJUST CLEARANCE FOR PLATFORM WITH FLIPOVER - Continued 3. Unfold platform to gain 5/16”-18 access to the plastic platform LOCK NUT stops on the LH and RH runners (FIG. 34-1). PLASTIC STOP 5/16”-18 SOCKET HEAD SCREW PLASTIC STOP ON LH RUNNER FIG.
  • Page 35 NOTE: MAXON does not supply the fender washers to shim the stops. 6. Reinstall plastic stop bumper with 1 or more 1/16” thick fender washers, for 5/16” screws, to shim the plastic stops (FIGS. 35-1A and 35-1B). This will adjust the clearance between main housing and bottom of fl...

  • Page 36: Decals

    DECALS NOTE: Decals are preinstalled at factory. Decal location shown for reference. NOTE: Ensure there is no residue, dirt or corrosion where decals are attached. If necessary, clean surface before replacing decals. CAPACITY DECAL (SEE TABLE 36-1) WARNING DECAL P/N 298373-01 DECAL “B”...
  • Page 37 WARNING DECAL P/N 298373-01 WARNING DECAL DECAL SHEET P/N 299274-01 P/N 298155-03...

  • Page 38: Decals & Plates

    NOTE: Preferred decal layout is shown. Decals on the Liftgate are attached at the factory, except for the 24/7 SUPPORT decal. The 24/7 SUPPORT decal is placed at customer’s or installer’s preference. MAXON 24/7 SUPPORT DECAL P/N 298634-01 MAXON NAME PLATE P/N 050175 SERIAL PLATE (REF) PARTS QR CODE DECAL P/N 299143-01 FIG.

  • Page 39: System Diagrams

    SYSTEM DIAGRAMS PUMP MOTOR & VALVE OPERATION (MANUAL CLOSE) LOWERING VALVE STARTER SWITCH MOTOR POWER UNIT FIG. 39-1 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 39-1...

  • Page 40: Pump Motor & Valve Operation (Equipped With Hydraulic Closer)

    SYSTEM DIAGRAMS - Continued PUMP MOTOR & VALVE OPERATION (EQUIPPED WITH HYDRAULIC CLOSER) FOLD/UNFOLD VALVE LOWERING STARTER ASSEMBLY VALVE SWITCH MOTOR POWER UNIT FIG. 40-1 POWER UNIT MOTOR & VALVE OPERATION REMOTE VALVE OPERATION MEANS ENERGIZED) LIFTGATE FUNCTION LOWERING FOLD/UNFOLD MOTOR VALVE VALVE...

  • Page 41: Hydraulic Schematic (Manual Close)

    HYDRAULIC SCHEMATIC (MANUAL CLOSE) FIG. 41-1...

  • Page 42: Hydraulic Schematic (Equipped With Hydraulic Closer)

    SYSTEM DIAGRAMS - Continued HYDRAULIC SCHEMATIC (EQUIPPED WITH HYDRAULIC CLOSER) FIG. 42-1...

  • Page 43: Electrical Schematic (Manual Close)

    ELECTRICAL SCHEMATIC (MANUAL CLOSE) FIG. 43-1...

  • Page 44: Electrical Schematic (Equipped With Hydraulic Closer)

    SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC (EQUIPPED WITH HYDRAULIC CLOSER) FIG. 44-1...

  • Page 45: Electrical Schematic - Jumper Harness Assembly

    ELECTRICAL SCHEMATIC - JUMPER HARNESS ASSEMBLY CONNECT TERMINALS TO VEHICLE HARNESS GREEN ORANGE 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 46: Electrical Schematic - Housing Cover Assembly (Without Lights)

    SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY (WITHOUT LIGHTS) CONNECT TO WIRING HARNESS LICENSE PLATE LIGHT LH LICENSE PLATE RH LICENSE PLATE LIGHT LIGHT FIG. 46-1...

  • Page 47: Electrical Schematic - Housing Cover Assembly (With Four Lights)

    ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY (WITH FOUR LIGHTS)

  • Page 48: Electrical Schematic - Housing Cover Assembly, Foreign Vehicle

    SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY, FOREIGN VEHICLE (WITH 6 LIGHTS )
  • Page 49 DMD ELECTRICAL VALUES & TORQUE SPECIFICATIONS 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. LOWERING VALVE Coil resistance: 6.6Ω @ 70ºF. ±15% 26.7Ω @ 70ºF. ±15% Ampere: 1.8A 0.9A...
  • Page 50 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-18Dmd-22Dmd-33

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