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Maxon DMD-22 Instruction Manual

Tool truck
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To fi nd maintenance & parts information for your Tool Truck DMD Liftgate, go to www.maxonlift.
com. Click the PRODUCTS, RAILIFT & DMD buttons. Open the Maintenance Manual in the
PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, RAILIFT &
DMD buttons.
M-21-01
SEPTEMBER 2022
© MAXON Lift Corp. 2022

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Summary of Contents for Maxon DMD-22

  • Page 1 To fi nd maintenance & parts information for your Tool Truck DMD Liftgate, go to www.maxonlift. com. Click the PRODUCTS, RAILIFT & DMD buttons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, RAILIFT & DMD buttons. © MAXON Lift Corp. 2022...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS WARNINGS ........................... 3 NOTICE ..........................4 VEHICLE REQUIREMENTS ....................5 BODY STRENGTH ........................ 5 INSTALLED LIFTGATE ......................7 LIFTGATE INSTALLATION COMPONENTS ................ 9 INSTALLATION & MANUALS KITS ................... 10 STEP 1 - POSITION LIFTGATE ..................11 BOLTING LIFTGATE TO BODY ...................11 STEP 2 - RUN POWER &...

  • Page 3: Warnings

    Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing 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 4: Notice

    Liftgate. NOTICE NOTICE • Maxon Lift is responsible for the instructions to correctly install MAXON Liftgates on trucks only. • Liftgate installers, not Maxon Lift, are responsible for reviewing and complying with all...

  • Page 5: Vehicle Requirements

    FIG. 5-1. Use TABLE 5-1 to determine the forces that apply to your Liftgate. 64-13/16” BED HEIGHT FIG. 5-1 DMD-22 FORCES 99” WIDE 102” WIDE MODEL CAPACITY P/F SIZE (X) (Y) LB (Z) LB...
  • Page 6 VEHICLE REQUIREMENTS - Continued NOTE: Dimensions are provided as reference for fi tting Liftgate to body. NOTE: Make sure vehicle is parked on level ground while preparing ve- hicle and installing Liftgate. 1. Check for correct clearances (FIGS. 6-1 and 6-2) on vehicle to prevent interference be- tween vehicle and Liftgate.

  • Page 7: Installed Liftgate

    VEHICLE REQUIREMENTS - Continued INSTALLED LIFTGATE NOTE: If Liftgate columns exceed a 91 degree angle from level ground when installed on body, or if columns cannot be mounted fl ush against rear of vehicle, a steel fi ller may be used to bridge gap between vehicle body and Liftgate columns.
  • Page 8 VEHICLE REQUIREMENTS - Continued 2. With Liftgate centered on vehicle body, each column should fi t on the corner posts of vehicle body with little or no off set (FIG. 8-1). Some off set from corner posts is allowed on the inboard side of the columns. Liftgate in stow position extends behind vehicle body as shown in FIG.

  • Page 9: Liftgate Installation Components

    Make sure you have 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 (800) 227-4116 or Send e-mail to cservice@maxonlift.com...

  • Page 10: Installation & Manuals Kits

    SPRING CLIP 050079 CIRCUIT BREAKER, 150 AMP 907207-02 2-BUTTON CONTROL PENDANT, GRAVITY DOWN 212516-01 TABLE 10-1 ITEM NOMENCLATURE OR DESCRIPTION QTY PART NUMBER DMD MANUALS KIT 298884-11 INSTALLATION MANUAL M-21-01 OPERATION MANUAL M-21-02 DECAL, MAXON 24/7 SUPPORT 298634-01 TABLE 10-2...

  • Page 11: Step 1 - Position Liftgate

    STEP 1 - POSITION LIFTGATE BOLTING LIFTGATE TO BODY 1. Use correct jig to drill holes in vehicle body. 2. Hoist liftgate by the installation support in position on the back of vehicle body (FIG.11-1). Next, align holes in the mount- ing fl...

  • Page 12: Step 2 - Run Power & Ground Cables

    STEP 2 - RUN POWER & GROUND CABLES 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. Keep power and ground wires separated. Avoid making sharp bends in wiring.

  • Page 13: Step 3 - Connect Power Cable

    STEP 3 - CONNECT POWER CABLE Unbolt cover, disconnect taillight wiring harness, and remove cover from main housing (FIG. 13-1). BOLT, FLAT WASHER & LOCK WASHER (4 PLACES) COVER REMOVED FROM MAIN HOUSING FIG. 13-1 2. Run power (+) cable through grommet on bottom of main hous- ing (FIG.
  • Page 14 STEP 3 - CONNECT POWER CABLE - Continued CAUTION Do not over-tighten the terminal nuts on starter solenoid. For the load ter- minals, torque nuts to 30-35 lb-in max. Torque the nuts on #10-32 control terminals 10-15 lb-in. NOTE: Do not remove fl at washer from battery power terminal on starter switch. 3.

  • Page 15: Step 4 - Connect Ground Cable

    STEP 4 - CONNECT GROUND CABLE NOTE: To ensure power unit is grounded correctly, connect black ground (-) cable (Kit item) to grounding point on pump manifold and common ground point on vehicle. 1. Run ground (-) cable through grommet on bottom of main housing (FIGS.
  • Page 16 STEP 4 - CONNECT GROUND CABLE - Continued 2. Remove hex bolt from grounding point on pump manifold (FIG. 16-1). Then, bolt lug on the ground cable to ground- ing point on manifold (FIG. 16-1). Torque bolt to 18-22 lb-ft. PUMP MANIFOLD GROMMET...
  • Page 17 STEP 5 - CONNECT POWER & GROUND CABLES TO VEHICLE BATTERIES CAUTION Make sure vehicle battery cables are disconnected before connectiong lift- gate power (+) and ground (-) cables to vehicle battery. 1. Connect power (+) cable with 150 AMP 150 amp circuit breaker for CIRCUIT BREAKER Liftgate to (+) terminal on OEM...

  • Page 18: Step 5 - Pressurize Hydraulic System

    STEP 5 - PRESSURIZE HYDRAULIC SYSTEM WARNING To prevent injury and equipment damage, pressurize hydraulic system before removing lower support fi xtures and operating Liftgate. 1. Get handheld control from parts kit. Next, open the elec- HANDHELD CONTROL & trical connector cover on the HOLDER RH column of liftgate (FIGS.

  • Page 19: Step 6 - Checking Hydraulic Fluid

    STEP 6 - 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 20 STEP 6 - CHECKING HYDRAULIC FLUID - Continued 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 20-1...

  • Page 21: Step 7 - Connecting Tailights

    STEP 7 - CONNECTING TAILIGHTS 1. Remove buttonhead screw, fl at washer, lock nut and small cover plate from inside of the main housing at the bottom (FIG. 21-1 and FIG. 21-1A). Save the cover and fasteners to reinstall. BUTTONHEAD RESERVOIR SCREW TAILIGHT...

  • Page 22: Step 8 - Remove Upper Support Fixture

    STEP 8 - REMOVE UPPER SUPPORT FIXTURE CAUTION Upper support fi xture is heavy. To prevent injury to installer and damage to Liftgate, use hoist to hold support fi xture during removal. 1. Stow the platform (FIG. 22-1). Refer to Operation Manual for detailed operating instructions.

  • Page 23: 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 P/N 220388-03 DECAL “B” P/N 211630-01 DECAL “A”...
  • Page 24 DECALS - Continued DECAL SHEET P/N 211630-01...

  • Page 25: 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 SERIAL PLATE...

  • Page 26: System Diagrams

    SYSTEM DIAGRAMS PUMP MOTOR & VALVE OPERATION LOWERING VALVE STARTER SWITCH HYDRAULIC CLOSER MOTOR SWITCH RELAY (REF) POWER UNIT FIG. 26-1 POWER UNIT MOTOR & VALVE OPERATION REMOTE VALVE OPERATION MEANS ENERGIZED) LIFTGATE FUNCTION LOWERING HYDRAULIC MOTOR CLOSER SWITCH VALVE RAISE LOWER UNFOLD...

  • Page 27: Hydraulic Schematic

    SYSTEM DIAGRAMS HYDRAULIC SCHEMATIC FIG. 27-1...

  • Page 28: Electrical Schematic

    SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC FIG. 28-1...

  • Page 29: Electrical Schematic (Above Bed Model)

    SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC (ABOVE BED MODEL) FIG. 29-1...

  • Page 30: Electrical Schematic - Jumper Harness Assembly

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

  • Page 31: Dmd Electrical Values & Torque Values

    SYSTEM DIAGRAMS 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...

  • Page 32: Pre-Delivery Inspection Form

    Important! This pre-delivery checklist is to aid the installer in confi rming the proper installation of this Maxon product. It is not a comprehensive list and does not replace the use of the installation manual. The installer is responsible for following all instructions in the installation manual.

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