Maxon DMD series Manuel utilisateur
M-16-40
REV. C
SEPTEMBER 2022
© MAXON Lift Corp. 2022
LIFT CORP.
11921 Slauson Ave.
Santa Fe Springs, CA. 90670
CUSTOMER SERVICE:
TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116
FAX: (888) 771-7713
WARRANTY/ RMA POLICY & PROCEDURE
NOTE: For latest version of all Manuals (and replacements), download the
Manuals from Maxon’s website at www.maxonlift.com.
LIFTGATE WARRANTY
Type of Warranty: Full Parts and Labor
Term of Warranty: Standard Liftgates - 2 years from ship date or 6,000 cycles
Premium Liftgates - 2 years from ship date or 10,000 cycles
This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s specifi cations as set forth in
MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments, damage or
malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this warranty does not
cover equipment that has had unauthorized modifi cations or alterations made to the product.
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. (Copy of the Flat Rate is available at www.maxonlift.com.)
All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and labor,
MAXON’s Technical Service Department must be notifi ed and an “Authorization Number” obtained.
All claims for warranty must be received within 30 Days of the repair date, and include the following information:
1. Liftgate Model Number and Serial Number
2. The End User must be referenced on the claim
3. Detailed Description of Problem
4. Corrective Action Taken, and Date of Repair
5. Parts used for Repair, Including MAXON Part Number(s)
6. MAXON R.M.A. # and/or Authorization # if applicable (see below)
7. Person contacted at MAXON if applicable
8. Claim must show detailed information i.e. Labor rate and hours of work performed
Warranty claims can also be placed online at www.maxonlift.com. Online claims will be given priority processing.
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 components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior written
approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with original
invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized returns will be
refused and will become the responsibility of the returnee.
Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in plain
view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned parts
are subject to no credit and returned back to the customer. Defective parts requested for return must be returned within 30 days of the claim date for
consideration to:
MAXON Lift Corp.
10321 Greenleaf Ave., Santa Fe Springs, CA 90670
Attn: RMA#__
MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income due to
downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.
MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.
All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not returned
in new condition will be subject to an additional reworking charge, which will be based upon the labor and material cost required to return the Liftgate or
component to new condition.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase.
Type of Warranty: Part replacement only. MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts
and original invoice.
All warranty replacements parts will be sent out via ground freight. If a rush shipment is requested, all freight charges will be billed to the requesting
party.
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 ........................................................................................ 14
TORSION BAR ADJUSTMENT ........................................................................................... 16
TORSION BAR REPLACEMENT ....................................................................................... 25
MEASURE & ADJUST CLEARANCE FOR PLATFORM WITH FLIPOVER ........................ 33
DECALS .............................................................................................................................. 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 SCHEMATIC (EQUIPPED WITH HYDRAULIC CLOSER) ............................ 42
ELECTRICAL SCHEMATIC (MANUAL CLOSE)
................................................................ 43
ELECTRICAL SCHEMATIC (EQUIPPED WITH HYDRAULIC CLOSER) ........................... 44
ELECTRICAL SCHEMATIC - JUMPER HARNESS ASSEMBLY ........................................ 45
ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY (WITHOUT LIGHTS) ......... 46
ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY (WITH FOUR LIGHTS) .... 47
ELECTRICAL SCHEMATIC - HOUSING COVER ASSEMBLY, FOREIGN VEHICLE
(WITH 6 LIGHTS ) ............................................................................................................... 48
DMD ELECTRICAL VALUES & TORQUE SPECIFICATIONS .......................................... 49
BOLT TORQUES ................................................................................................................ 50
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.
10, 11 Added Quarterly/1250 Cycles PM CHECK to measure and adjust clearance be-
tween main housing and bottom of stowed platform and fl ipover.
13 Removed table of recommended ISO 32 oils.
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 with hoist and stands to support platform, and a wrench to position torsion
bar pins.
33-35 Added procedure MEASURE & ADJUST CLEARANCE FOR PLATFORM WITH
FLIPOVER.
37 Decal sheet changed to P/N 298155-03 because of changes on the operation
instructions for decal "A".
43, 44 Updated numbered wiring connections for inner and outer switches on electrical
schematic.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
7
• Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your
feet are clear of the Liftgate.
• Keep fi ngers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.
• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.
• If it is necessary to stand on the platform while maintaining the Liftgate, keep your feet and any
objects clear of the inboard edge of the platform. Your feet or objects on the platform can become
trapped between the platform and the Liftgate housing cover.
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
• Recommended practices for welding 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 done incorrectly.
• Recommended practices for welding on aluminum parts are contained in the current AWS
(American Welding Society) D1.2 Structural Welding Code - Aluminum. Damage to Liftgate
and/or vehicle, and personal injury could result from welds that are done incorrectly.
WARNINGS
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.
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). For more information go to www.P65Warnings.ca.gov.
WARNING
!
WARNING
!
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
8
• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the con-
trol switch to stop the Liftgate.
• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the power unit while the platform is raised. 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. Customer Service
11921 Slauson Ave., Santa Fe Springs, CA 90670
Online: www.maxonlift.com
Express Parts Ordering: Phone (800) 227-4116 ext. 4345
Email: Ask your Customer Service representative
SAFETY INSTRUCTIONS
• Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement
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 operating the Liftgate.
• Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while
performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.
• Do not allow untrained persons to operate the Liftgate.
• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no fl ames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek fi rst aid. If acid gets on your
skin, immediately wash it off with soap and water.
• Read and understand the instructions in this Maintenance Manual before performing mainte-
nance on the Liftgate.
• Before operating the Liftgate, read and understand the operating instructions in Operation
Manual.
• Comply with all WARNING and instruction decals attached to the Liftgate.
SAFETY INSTRUCTIONS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 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 WITH
HYDRAULIC CLOSER)
LOCK
RH COLUMN
STOP
POWER
UNIT
(BEHIND
COVER)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
10
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.
Quarterly or 1250 Cycles (whichever occurs fi rst)
PERIODIC MAINTENANCE CHECKS
Never operate the Liftgate with parts loose or missing.
WARNING
!
Check the hydraulic fl uid level in the pump reservoir. Refer to the CHECKING HYDRAULIC
FLUID procedure in the PERIODIC MAINTENANCE section.
Check for loose or missing nuts, bolts, covers, roll pins, screws and pins.
Check that all WARNING and instruction decals are in place and legible.
Check electrical wiring for chaffi ng and make sure wiring connections are tight and free
of corrosion, and coated with electrical sealant (EP-03, REV. H).
Check lines and fi ttings for chaffi ng and fl uid leaks. Replace if necessary.
Keep track of the grade of hydraulic fl uid in the pump reservoir. Never mix two diff erent
grades of fl uid.
If hydraulic fl 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
off . If cleaning platform, ensure inside columns, runners and slide pads are free of corro-
sion, residue, dirt and debris.
Damaged cylinder seals and contaminated hydraulic fl uid can result from paint-
ing the polished portion of the cylinder rod. To prevent damage, protect the
exposed polished portion of the cylinder rod while painting.
CAUTION
PERIODIC MAINTENANCE
Check that platform latch and transit hook mechanisms work correctly and no parts are
missing.
NOTE: When replacing parts, refer to the Parts Portal on the Maxon website for
genuine MAXON replacement parts.
Visually check the entire Liftgate for excessively worn parts and broken welds, especially
check the platform hinge pins for excessive wear and broken welds.
Annually or 5000 Cycles (whichever occurs fi rst)
Perform all Quarterly Maintenance checks.
Check the clearance between main housing and bottom of fl ipover if the platform has a
fl ipover. Refer to MEASURE & ADJUST CLEARANCE FOR PLATFORM WITH
FLIPOVER in the PERIODIC MAINTENANCE section.
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