Maxon DMD series Page 1 Maintenance Manual Download

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M-16-40
REV. C
SEPTEMBER 2022

© MAXON Lift Corp. 2022

Summary of Contents for DMD series

Page 1: ...M 16 40 REV C SEPTEMBER 2022 MAXON Lift Corp 2022...

Page 2: ......

Page 3: ...sing All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON s Warranty Department within 30 days of repair date All comp...

Page 4: ...LS 36 DECALS PLATES 38 SYSTEM DIAGRAMS 39 PUMP MOTOR VALVE OPERATION MANUAL CLOSE 39 PUMP MOTOR VALVE OPERATION EQUIPPED WITH HYDRAULIC CLOSER 40 HYDRAULIC SCHEMATIC MANUAL CLOSE 41 HYDRAULIC SCHEMATI...

Page 5: ...DMD ELECTRICAL VALUES TORQUE SPECIFICATIONS 49 BOLT TORQUES 50...

Page 6: ...16 Added a Note and Table to explain torsion bar functionality conditions for adjust ment and corrective actions 16 32 Changed torsion bar adjustment replacement instructions into separate proce dures...

Page 7: ...lding on steel parts are contained in the current AWS American Welding Society D1 1 Structural Welding Code Steel Damage to Liftgate and or vehicle and personal injury could result from welds that are...

Page 8: ...decals are available from Maxon Customer Service Consider the safety and location of bystanders and location of nearby objects when operating the Liftgate Stand to one side of the platform while oper...

Page 9: ...771 7713 9 LIFTGATE TERMINOLOGY RUNNER PLATFORM LH COLUMN HOUSING COVER UP DOWN CONTROL SWITCH OUTBOARD UP DOWN CONTROL SWITCH INBOARD TRANSIT HOOK MAIN FRAME HOUSING FOLD UNFOLD SWITCH IF EQUIPPED W...

Page 10: ...uid appears contaminated refer to the CHANGING HYDRAULIC FLUID procedure on following page Check for rust and oily surfaces on Liftgate If there is rust or oil on the Liftgate clean it o If cleaning...

Page 11: ...air required Corrected 12 Checking Oil Level gravity down with the platform unfolded and on the ground Oil level should be as shown in Installation Manual CHECKING HYDRAULIC FLUID Check for contaminat...

Page 12: ...Before opening the hydraulic uid reservoir ller cap drain plug and hydraulic lines clean up contaminants that can get in the openings Also protect the openings from accidental contamination Never mix...

Page 13: ...CA 90670 800 227 4116 FAX 888 771 7713 13 ISO 15 OR MIL H 5606 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER CHEVRON FLUID A AW MV 15 KENDALL GLACIAL BLU SHELL TELLUS S2 VX 15 EXXONMOBIL UNIVIS HVI 13...

Page 14: ...can get in the openings Also protect the openings from accidental contamination Never mix synthetic uids with conventional hydraulic uids Hydraulic system must be purged if the uids are mixed NOTE Li...

Page 15: ...15 2 POWER UNIT REF RESERVOIR 5 Raise platform to bed height FIG 15 1 Continue to hold UP DOWN control switch for 30 60 seconds to circulate hydraulic uid through slave cylinder and reservoir FIG 15 2...

Page 16: ...SION OF LH TORSION BAR PLATFORM IS DIFFICULT TO CLOSE OR WILL NOT CLOSE INCREASE TENSION OF LH TORSION BAR INCREASE TENSION OF LH TORSION BAR TABLE 16 1 NOTE This procedure applies to platforms equipp...

Page 17: ...ion 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 Any...

Page 18: ...ted FIG 18 1A Next remove cap screw lock washer and at washers from torsion bar pin FIG 18 1 Keep fasteners to reinstall Rotate the torsion bar pin counter clockwise to apply tension to torsion bar FI...

Page 19: ...tion 1 Pull platform to unfold Observe if platform starts to fold stays partially unfolded or starts to fall open with no restraint Platform should unfold slowly when released FIG 19 1 position 2 To i...

Page 20: ...inboard toward LH side of vehicle FIG 20 3 The range of adjustment is 0 to 10 to the left of stop block FIG 20 3 INCREASING TENSION ON LH TORSION BAR FIG 20 3 STOP BLOCK 0 10 5 To adjust tension on th...

Page 21: ...Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 21 7 Tighten locking screw securely to hold LH torsion bar housing in position FIG 21 1 LOCKING SCREW FIG 21 1 LH HOUSING LH TORSIO...

Page 22: ...nlatch platform WARNING 1 To adjust tension on the RH torsion bar loosen locking screw on housing for RH torsion bar FIGS 22 1 and 22 1A FIG 22 1 2 Increase tension by sliding RH housing inboard towar...

Page 23: ...or detailed operating instructions Ensure platform unfolds and folds correctly If needed repeat adjustment procedures for LH and RH torsion bars UNFOLDING PLATFORM FIG 23 2 PLATFORM FOLDING PLATFORM F...

Page 24: ...88 771 7713 24 TORSION BAR ADJUSTMENT Continued PERIODIC MAINTENANCE 6 Platform can be stowed or returned to operation after adjustment REATTACH TORSION BAR COVER PLATE FIG 24 2 PLATFORM TAPPING SCREW...

Page 25: ...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 Any per...

Page 26: ...m rotating while pin is being unbolted FIG 26 2A Remove cap screw and washers from torsion bar pin FIG 26 2 Initial torsion bar tension is removed when torsion bar pin is in position shown in FIG 26 2...

Page 27: ...88 771 7713 27 5 Remove LH torsion bar pin FIGS 27 1 and 27 1A FIG 27 1 TORSION BAR PIN 6 Loosen locking screw on LH torsion bar housing FIGS 27 2 and 27 2A FIG 27 2 FIG 27 2A LOCKING SCREW LH HOUSING...

Page 28: ...and engage with LH torsion bar housing FIGS 28 2 and 28 2A Tighten locking screw on LH torsion bar housing 9 Do the LH TORSION BAR ADJUSTMENT procedure in this manual LH TORSION BAR LH RUNNER PLATFORM...

Page 29: ...econd person to help unlatch platform WARNING REPLACE RH TORSION BAR 1 Lower platform to align arrows Refer to Operation Manual for detailed operating instructions Support platform and ipover evenly b...

Page 30: ...A Unbolt the pin from RH runner FIG 30 1B Next remove platform pin and thrust bearing FIG 30 1B FIG 30 1 CAP SCREW FIG 30 1A FIG 30 1B RH PIN WRENCH RH RUNNER LOCK WASHER RH RUNNER THRUST BEARING PLAT...

Page 31: ...t torsion bar through RH runner thrust bearing and RH torsion bar housing FIGS 31 2 and 31 2A 5 Remove RH torsion bar FIGS 31 1 and 31 1A FIG 31 1A RH TORSION BAR RH RUNNER REMOVING RH TORSION BAR FIG...

Page 32: ...ge 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 Next bolt RH pin to RH runner using cap screws and washers removed...

Page 33: ...asure clearance FIG 33 1 Refer to DMD Operation Manual for instructions to lower platform until arrow decals are aligned Ensure platform is kept folded stowed 11 16 1 4 PLATFORM FLIPOVER STOWED LOWERE...

Page 34: ...34 1A 5 Calculate the minimum thickness of shim washers needed to increase clearance to 11 16 1 4 between main housing and bottom of ipover For example if minimum clearance should be 7 16 and the meas...

Page 35: ...MING PLASTIC STOP ON LH RUNNER FIG 35 1A PLATFORM UNFOLDED TO ACCESS STOP BUMPERS FIG 35 1 SHIMMING PLASTIC STOP ON RH RUNNER FIG 35 1B 8 Repeat steps 2 through 7 until clearance is 11 16 1 4 between...

Page 36: ...e decals are attached If necessary clean surface before replacing decals WARNING DECAL P N 299274 01 RUNNER ARROW DECAL D P N 298155 03 MODEL ORDER P N CAPACITY DECAL DMD 18 220387 04 1800 LB 817 KG D...

Page 37: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 37 WARNING DECAL P N 298373 01 DECAL SHEET P N 298155 03 WARNING DECAL P N 299274 01...

Page 38: ...referred 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 PARTS QR CO...

Page 39: ...OR SOLENOID OPERATION LIFTGATE FUNCTION SOLENOID OPERATION MEANS ENERGIZED MOTOR STARTER SWITCH LOWERING VALVE RAISE LOWER REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC PUMP MOTOR VALVE OPERATION MANUA...

Page 40: ...C CLOSER TABLE 40 1 POWER UNIT FIG 40 1 STARTER SWITCH MOTOR LOWERING VALVE FOLD UNFOLD VALVE ASSEMBLY SYSTEM DIAGRAMS Continued POWER UNIT MOTOR VALVE OPERATION LIFTGATE FUNCTION REMOTE VALVE OPERATI...

Page 41: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 41 HYDRAULIC SCHEMATIC MANUAL CLOSE FIG 41 1...

Page 42: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 42 HYDRAULIC SCHEMATIC EQUIPPED WITH HYDRAULIC CLOSER FIG 42 1 ORIFICE SYSTEM DIAGRAMS Continued...

Page 43: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 43 ELECTRICAL SCHEMATIC MANUAL CLOSE FIG 43 1...

Page 44: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 44 ELECTRICAL SCHEMATIC EQUIPPED WITH HYDRAULIC CLOSER FIG 44 1 SYSTEM DIAGRAMS Continued...

Page 45: ...TERMINAL F LH STOP TURN TERMINAL E RH STOP TURN TERMINAL E RH STOP TURN TERMINAL D STOP TERMINAL D STOP TERMINAL C REVERSE TERMINAL C REVERSE TERMINAL B TAIL TERMINAL B TAIL TERMINAL A GROUND TERMINA...

Page 46: ...ngs CA 90670 800 227 4116 FAX 888 771 7713 46 ELECTRICAL SCHEMATIC HOUSING COVER ASSEMBLY WITHOUT LIGHTS CONNECT TO WIRING HARNESS LICENSE PLATE LIGHT LH LICENSE PLATE LIGHT RH LICENSE PLATE LIGHT FIG...

Page 47: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 47 ELECTRICAL SCHEMATIC HOUSING COVER ASSEMBLY WITH FOUR LIGHTS CONNECT TO VEHICLE HARNESS CONNECT TO JUMPER HARNESS...

Page 48: ...ve Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 48 ELECTRICAL SCHEMATIC HOUSING COVER ASSEMBLY FOREIGN VEHICLE WITH 6 LIGHTS CONNECT TO JUMPER HARNESS CONNECT TO VEHICLE HARNESS SYSTEM DIAG...

Page 49: ...b in max LOWERING VALVE Coil resistance 6 6 70 F 15 26 7 70 F 15 Ampere 1 8A 0 9A Coil terminal torque 15 45 lb in max Valve cartridge torque 25 30 lb ft max Coil nut torque 15 45 lb in FOLD UNFOLD VA...

Page 50: ...e for torquing electrical or hydraulic hose connections on the pump assembly CAUTION GRADE 8 BOLT TIGHTENING TORQUE DIAMETER THREAD PITCH TORQUE 1 4 20 10 14 lb ft 1 4 28 11 16 lb ft 5 16 18 20 29 lb...

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