Maxon RCM-1600C AB Installation manual

M-91-17
REV. E
AUGUST 2012
INSTALLATION
MANUAL
RCM-1250 C
RCM-1250 C AB
RCM-1600
RCM-1600 C AB
LIFT CORP.
© MAXON Lift Corp. 2012
11921 Slauson Avenue
Santa Fe Springs, CA 90607
(800) 227-4116
TABLE OF CONTENTS
WARNINGS ........................................................................................................................... 3
SAFETY INSTRUCTIONS .................................................................................................... 3
RCM-1250 C INSTALLATION PARTS BOX ......................................................................... 4
RCM-1600 C INSTALLATION PARTS BOX ......................................................................... 5
PREPARING VEHICLE BODY .............................................................................................. 6
POSITIONING LIFTGATE ..................................................................................................... 8
WELDING LIFTGATE TO VEHICLE...................................................................................... 9
INSTALLING PUMP & PUMP BOX ..................................................................................... 17
ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) ................ 19
RUNNING POWER CABLE ................................................................................................ 25
FRAMELESS - REFRIGERATION/SMOOTH UNDERSIDE TRAILER ............................... 26
FRAMELESS - DRY VAN TRAILER .................................................................................... 27
CONNECT POWER CABLE ............................................................................................... 28
CONNECT GROUND CABLE ............................................................................................. 29
CONNECT CONTROL WIRING .......................................................................................... 31
CONNECT RETURN HOSE................................................................................................ 32
CONNECT POWER CABLE TO BATTERY ........................................................................ 33
ADJUST DRIVE CHAINS (ABOVE BED MODELS)............................................................ 36
CHECKING HYDRAULIC FLUID ........................................................................................ 37
ATTACHING DECALS ......................................................................................................... 39
TOUCHUP PAINT ............................................................................................................... 40
HYDRAULIC SYSTEM DIAGRAM ...................................................................................... 41
ELECTRICAL SYSTEM DIAGRAM ..................................................................................... 42
OPTIONS ............................................................................................................................ 43
RECOMMENDED LIFTGATE POWER CONFIGURATION ................................................ 44
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.
!
WARNING
• Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your
feet are clear of the Liftgate.
• Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
• Make sure vehicle battery power is disconnected while installing Liftgate. Connect vehicle
battery power to the Liftgate only when installation is complete or as required in the installation
instructions.
• If it is necessary to stand on the platform while operating 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 extension plate.
• Never perform unauthorized modifications on the Liftgate. Modifications may result in early failure
of the Liftgate and may create hazards for Liftgate operators and maintainers.
• 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 can result from welds that are done incorrectly.
SAFETY SAFETY
INSTRUCTIONS
INSTRUCTIONS
• Read and understand the instructions in this Installation Manual before installing 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.
• 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
• Do not allow untrained persons to operate 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.
• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no flames 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 first aid. If acid gets on your
skin, immediately wash it off with soap and water.
• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the control 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 and lowered. Listen for
scraping, grating and binding noises and correct the problem before continuing to operate Liftgate.
3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WARNINGS
WARNINGS
RCM-1250 C INSTALLATION PARTS BOX
REF PARTS BOX, RCM-1250C
QTY
PART NUMBER
1
251813-01
1
FRAME CLIP, 1/2” X 1-3/8”
7
050079
2
TAPPING SCREW, #10 x 1/2” LG.
4
030458
3
FUSED POWER CABLE, 175 AMP, 38’ LG.
1
264422
4
JIFFY CLAMP, #130
1
125674
5
BUTT CONNECTOR, 14AWG
1
030491
6
FLAT WASHER, 3/8”
2
030556
7
BRASS ELBOW, 1/4” X 1” LG.
1
202406
8
LOOM CLAMP, #8 RUBBER
3
214663
9
ELBOW, 3/8” FEM-3/8” FEM
1
228950
PUMP BOX KIT (RCM)
1
251738-02
A. PUMP BOX ASSY
1
251741
B. PUMP BOX BRACKET
1
251817
C. ANGLE, 2-1/2” X 2-1/2”
1
251815
D. BOLT, 3/8”-16 X 1-1/4” LG.
2
030074
E. HEX NUT, 3/8”-16
2
030348
F. FLAT WASHER, 3/8”
2
030556
G. LOCK WASHER, 3/8”
2
030555
11
ANGLE, 2-1/2” X 2-1/2”
1
251815
12
BRACKET, PUMP MOUNT
1
251816
13
INSTALLATION MANUAL
1
M-91-17
14
OPERATION MANUAL
1
M-91-19
15
MAINTENANCE MANUAL
1
M-91-18
16
INSTRUCTIONS, FUSED POWER CABLE
1
M-00-14
17
DECAL, 1250 LB CAPACITY
1
226006
18
DECAL, UP & DOWN
1
250993
19
DECAL, OPER INSTRUCTION
1
252899
20
DECAL, WARNING
1
282479-01
21
DECAL, STOW WARNING
1
282847-01
22
HEATSHRINK TUBING, 3/4” X 1-1/2” LG.
1
253316-04
23
SEALANT (FOR THREADED HYDRAULIC FITTINGS)
1
260798-02
24
BUSHING, 3/8” X 1/4” LG.
1
800183
25
HEX CAP SCREW, 3/8”-16 X 1” LG, GRADE 8
2
900014-4
26
LOCK WASHER, 3/8”
2
902011-4
27
COPPER LUG, 2GA (5/16” I.D. RING)
1
906497-02
28
PIPE NIPPLE, 3/8” X 2” LG.
1
030304
10
4
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM NOMENCLATURE OR DESCRIPTION
RCM-1600 C INSTALLATION PARTS BOX
REF PARTS BOX, RCM-16C
QTY
PART NUMBER
1
251814-01
1
FRAME CLIP, 1/2” X 1-3/8”
7
050079
2
TAPPING SCREW, #10 x 1/2” LG.
4
030458
3
FUSED POWER CABLE, 175 AMP, 38’ LG.
1
264422
4
JIFFY CLAMP, #130
1
125674
5
BUTT CONNECTOR, 14AWG
1
030491
6
FLAT WASHER, 3/8”
2
030556
7
BRASS ELBOW, 1/4” X 1” LG.
1
202406
8
LOOM CLAMP, #8 RUBBER
3
214663
9
ELBOW, 3/8” FEM-3/8” FEM
1
228950
PUMP BOX KIT (RCM)
1
251738-02
A. PUMP BOX ASSY
1
251741
B. PUMP BOX BRACKET
1
251817
C. ANGLE, 2-1/2” X 2-1/2”
1
251815
D. BOLT, 3/8”-16 X 1-1/4” LG.
2
030074
E. HEX NUT, 3/8”-16
2
030348
F. FLAT WASHER, 3/8”
2
030556
G. LOCK WASHER, 3/8”
2
030555
11
ANGLE, 2-1/2” X 2-1/2”
1
251815
12
BRACKET, PUMP MOUNT
1
251816
13
INSTALLATION MANUAL
1
M-91-17
14
OPERATION MANUAL
1
M-91-19
15
MAINTENANCE MANUAL
1
M-91-18
16
INSTRUCTIONS, FUSED POWER CABLE
1
M-00-14
17
DECAL, 1600 LB CAPACITY
1
224751
18
DECAL, UP & DOWN
1
250993
19
DECAL, OPER INSTRUCTION
1
252899
20
DECAL, WARNING
1
282479-01
21
DECAL, STOW WARNING
1
282847-01
22
HEATSHRINK TUBING, 3/4” X 1-1/2” LG.
1
253316-04
23
SEALANT (FOR THREADED HYDRAULIC FITTINGS)
1
260798-02
24
BUSHING, 3/8” X 1/4” LG.
1
800183
25
HEX CAP SCREW, 3/8”-16 X 1” LG, GRADE 8
2
900014-4
26
LOCK WASHER, 3/8”
2
902011-4
27
COPPER LUG, 2GA (5/16” I.D. RING)
1
906497-02
28
COPPER LUG, 2GA (3/8” I.D. RING)
2
226778
29
PIPE NIPPLE, 3/8” X 2” LG.
1
030304
10
5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM NOMENCLATURE OR DESCRIPTION
!
WARNING
This unit cannot be used with swing type doors.
Do not remove banding from shipping pallet or attempt to move the platform, until:
1. The unit is welded to the vehicle.
2. The pump installation is complete and motor wiring cable installation thru vehicle battery is complete, and pump is filled with oil
and operating.
NOTE: BODIES WITH ALUMINUM CORNER POSTS.
The Aluminum corner posts must be re-inforced before installing unit.
NOTE: FOR AB UNITS.
See page 36 for platform travel (chain) adjustment.
This unit must be installed as described in this Installation Manual. If any deviation
is deemed necessary by the installer, written permission must first be obtained from
MAXON.
Any change in the installation method without written permission from MAXON, will
void any warranty issued with this unit.
Please read thru this Installation Manual before commencing the installation of this
unit.
The methods of hoisting or supporting the unit during installation are those found in most
shops. If any other method of hoisting or supporting is used, precautions must be taken
to ensure the support is adequate and does not endanger the personnel working on the
installation of this unit.
Rear lights. In many cases the rear lights will need to be relocated. Relocate your rear
lights to satisfy your local codes and Federal Vehicle Safety Standard 108.
6
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PREPARING VEHICLE BODY
PREPARING VEHICLE BODY - Continued
The ideal installation, when the rear of the column assemblies are touching the body
corner posts, and the rear of the main frame is touching the sill. On some body configurations this is not possible, therefore the following examples must be taken into consideration before hoisting the unit up to the body.
VEHICLES WITH ALUMINUM FRAMES. These bodies are covered on pages 13, 14
and 15. The steel mounting channels will need to be fabricated and installed to the corner posts before the unit is hoisted up to the body.
FLAT BED VEHICLES. This installation is covered on page 12.
The bracing channels for this installation cannot be cut until the unit is hoisted up to the
bed.
CORNER POST CONFIGURATIONS. In the
cases where the corner post is not square
or rectangular, a filler will need to be fabricated (FIG. 7-1A and 7-1B) to fill the space
between the corner post and the unit column
assemblies. A typical example is illustrated
below.
CORNER POST
(VEHICLE)
LIFTGATE
COLUMN
STEEL BAR STOCK 1/4” X 6”
LG. BY REQUIRED WIDTH
FILLER PLATE
RUNNER
TOP VIEW
FIG. 7-1A
THE FILLER PLATES WILL BE WELDED IN
AFTER THE UNIT IS HOISTED INTO POSITION AND TACK WELDED TO THE BODY
FIG. 7-1B
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PREPARATION OF BODY INSTALLATION OF UNIT
The center line of the unit must be in line with the center line of the body rear door opening (FIG. 8-1). The columns and main frame assembly must be touching the corner post
and sill. The temporary support angles will be resting on the floor and the top surface of the
main frame should be flush and level with the body floor.
CENTER LINE OF
THE UNIT.
CENTER LINE OF
BODY
TEMPORARY
SUPPORT ANGLES RESTING
ON THE FLOOR
CENTER LINE OF LIFTGATE MUST BE IN LINE WITH
THE CENTER OF BODY REAR DOOR OPENING
FIG. 8-1
8
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
POSITIONING LIFTGATE
WELDING LIFTGATE TO VEHICLE
If a fork lift was used to hoist the unit and the fork lift is required for other work, the column
assemblies must be tack welded to the vehicle corner posts (FIG. 9-1) before dis-engaging the fork lift. Tack weld on both columns as shown in FIG. 9-1. See page 10.
If an overhead chain hoist was used, it should remain hooked to the unit until the welding
procedure is completed. If the hoist needs to be removed before welding, tack weld as
shown in FIG. 9-1 before removing hoist.
!
WARNING
When welding operations are in progress NEVER allow flame,
heat or sparks to come in contact with lift chain.
NOTE: Repeat procedure for right hand column.
TACK WELD (TYPICAL)
1/2” LG.
1/4”
TACK WELD TO VEHICLE FRAME
(LEFT HAND COLUMN SHOWN)
FIG. 9-1
9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELDING PROCEDURE
WELDING LIFTGATE TO VEHICLE - Continued
Right hand and left hand column assemblies (FIG. 10-1) are welded to right and left hand
corner posts. Welds shall be 1/4” fillets welds spaced as shown in FIG. 10-1 (except
where noted).
!
WARNING
When welding operations are in progress NEVER allow flame,
heat or sparks to come in contact with lift chain.
BOTH SIDES OF
COLUMN, 2” LG.
(TYPICAL)
1/4”
2”
1/4”
ALL UNITS:
APPROX.
HALF WAY
DOWN THE
COLUMN.
1/8” WELD
2”
WELD COLUMN ASSEMBLIES TO VEHICLE CORNER POSTS
(LEFT HAND SHOWN)
FIG. 10-1
10
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELDING PROCEDURE - STANDARD STEEL FRAME
20”
20”
20”
20”
1” - 20”
1/8”
WELD REAR OF LIFTGATE MAIN FRAME
TO VEHICLE SILL
(UNDER BODY VIEW)
FIG. 11-1
11
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELDING LIFTGATE TO VEHICLE - Continued
WELDING LIFTGATE TO VEHICLE - Continued
The column assemblies are tied in to the flat bed side
rails with two lengths of channel as shown in FIG.
12-1A. Weld column assembly to its corresponding
side rail to a distance of 60” approximately, just above
a cross member (FIG. 12-1A). If side rail is less than
1/4”, weld a 1/4” plate to side rail, then weld channel
to 1/4” plate as shown in FIG. 12-1B.
NOTE: Mounting channel is not supplied by MAXON.
1/4”
3” LG. MINIMUM
1/4”
SIDE RAIL THICK
LESS THAN 1/4”
FIG. 12-1B
1/4”
60”
APPROX
CROSS MEMBER
WELDING LIFTGATE TO FLAT BED VEHICLE
FIG. 12-1A
12
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELDING PROCEDURE - FLAT BED VEHICLE
WELDING LIFTGATE TO VEHICLE - Continued
Four steel mounting channels will need to be fabricated before hoisting unit up to vehicle.
The mounting channels will be riveted to the aluminum frame before installing the unit.
The required mounting dimensions are shown in FIG. 13-1.
To fill gap between body and rear of main frame, fabricate 2 pieces of 10 GA 8” x 4”(FIG.
13-1). See pages 14 and 15 for details of installation.
NOTE: Mounting channel is not supplied by MAXON.
STEEL MOUNTING
CHANNEL
(4 PLACES)
INSERT PLATE
8”
WELD ACROSS
BODY, PLATE
MAIN FRAME,
REPEAT FOR
OTHER SIDE OF
UNIT.
8”
VEHICLE FLOOR
FILLER
(2 PLACES)
POSITIONING STEEL MOUNTING CHANNELS AND
FILLER TO ALUMINUM FRAME VEHICLE
FIG. 13-1
13
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELDING PROCEDURE - ALUMINUM FRAME VEHICLES
WELDING LIFTGATE TO VEHICLE - Continued
Steel mounting channels shall be
10 gauge material, 8” in length
(FIG. 14-1). All other dimensions
1-3/4”
shall suit dimensions of vehicle
corner posts. Drill 10 holes to
1-3/4”
larger side of mounting channel,
1-3/4”
and 5 to smaller face. Drillings
should be suitable to accept 1/4” 1-3/4”
drive rivets. FIG. 14-1 shows
1/2”
locations for drillings.
1/2”
1-3/4”
1-3/4”
1-3/4”
1-3/4”
1/2”
1/2”
1/2”
DRILLINGS LOCATIONS ON
STEEL MOUNTING CHANNELS
FIG. 14-1
Position and rivet each steel mountOUTSIDE FACE
ing channel using 1/4” drive rivets
IF CORNER
as shown in FIG. 14-2. The 10 drillPOST
ing face is located over outside face
(LH POST IS
of corner post (FIG. 14-2). Position
SHOWN)
for upper and lower mounting channels is shown in FIG. 13-1.
FRONT FACE OF
CORNER POST
STEEL
MOUNTING
CHANNEL
(4 PLACES)
POSITION AND RIVET STEEL MOUNTING
CHANNELS TO VEHICLE CORNER POST
FIG. 14-2
2” LONG
1/4”
After installing the 4 mounting
channels, hoist unit into position
and weld to mounting channels
as shown in FIG. 14-3.
OUTSIDE OF
COLUMN
INSIDE OF
COLUMN
WELDING COLUMN ASSEMBLY TO
STEEL MOUNTING CHANNEL
(LH COLUMN IS SHOWN)
FIG. 14-3
14
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1/2”
INSIDE OF COLUMN ASSEMBLY
Weld two 1/8” gussets to channels
and column assembly as shown in
FIG. 15-1. The channel located at
bottom of the column assembly is
gusseted in an identical manner.
Repeat for right head column assembly.
1/8”
WELDING GUSSETS TO COLUMN
ASSEMBLY AND CORNER POST
(LH COLUMN ASSY IS SHOWN,
INSIDE UPPER FACE)
FIG. 15-1
WELDING MAIN FRAME TO SILL
The rear of the main frame shall be
welded to sill as illustrated in FIG.
15-2. Main frame upper side must be
flush to sill upper side (FIG. 15-2).
See FIG. 15-2 for welding details.
VEHICLE
BODY
2” - 10”
1/8”
17”
1/8”
10”
10”
10”
8-1/2”
10”
10”
17”
MAIN FRAME
WELDING MAIN FRAME TO SILL
FIG. 15-2
15
28”
10”
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELDING LIFTGATE TO VEHICLE - Continued
WELDING LIFTGATE TO VEHICLE - Continued
The lower portion of the column can be cut off 18”
(maximum) above the ground 18” (FIG. 16-1) to improve
the entry and exit angle of the vehicle.
NOTE: Vehicles with air ride suspension must have
air bags fully inflated before columns are cut
18” from ground.
18”
ENTRY/EXIT
ANGLE
CUTTING OFF LOWER PORTION OF COLUMN
FIG. 16-1
16
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CUTTING OFF LOWER PORTION OF COLUMN
INSTALLING PUMP & PUMP BOX
PUMP
PUMP BOX
PUMP MOUNT
1/4”
VEHICLE FRAME
1/4”
2 PLACES
PUMP
MOUNT
13/16”
10-7/8”
3-3/4”
251817
MOUNT BRACKET
17
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELD ON PUMP MOUNT & BRACKET
INSTALLING PUMP & PUMP BOX - Continued
251681
COVER
251741
PUMP BOX
ASSY
PUMP ASSY
(REF)
251680
BOX
BOLT
3/8”-16 X
1-1/4” LG
PUMP MOUNT
(REF)
3/8” LOCK
WASHERS
(2 PLACES)
MOUNT BRACKET
(REF)
3/8” LOCK
WASHERS
(2 PLACES)
3/8” FLAT
WASHERS
(2 PLACES)
3/8”-16 HEX NUT
(2 PLACES)
18
BOLT
3/8”-16 X 1” LG
(2 PLACES)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BOLT ON PUMP BOX & PUMP ASSEMBLY
1. Select holes on top of battery box
frame to align mounting brackets
flush to cross members. Refer
to FIGS. 19-1A & 19-1B for trailers and FIG. 19-2 for trucks. Bolt
mounting brackets to battery box
frame as shown in FIG. 19-1C.
Torque each bolt and lock nut to
85-128 lb-ft.
LOCK
WASHER
LOCK NUT
WASHER
CROSS
MEMBER
MOUNTING
BRACKETS
WASHER
CAP SCREW
BOLTING BRACKETS
(8 PLACES)
FIG. 19-1C
TRAILER BODY
CROSS MEMBER
MOUNTING
BRACKETS
BATTERY BOX
FRAME
BATTERY BOX
FRAME
ALIGNING BATTERY
BOX FRAME
(TRAILER SHOWN)
FIG. 19-1A
FLUSH BRACKETS
FOR TRAILERS
(8 PLACES)
FIG. 19-1B
TRUCK BODY
CROSS MEMBER
BATTERY BOX
FRAME
MOUNTING
BRACKETS
FLUSH BRACKETS FOR TRUCKS
(8 PLACES)
FIG. 19-2
19
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH OPTIONAL BATTERY BOX & FRAME TO
VEHICLE (IF EQUIPPED)
ATTACH OPTIONAL BATTERY BOX & FRAME TO
VEHICLE (IF EQUIPPED) - Continued
2. Using mounting brackets as a template mark and drill holes through
cross members (FIG. 20-1). Bolt
mounting brackets to cross members as shown in FIGS. 20-2A and
20-2B. Torque bolts and lock nuts
to 85-128 lb-ft.
CROSS
MEMBER
MOUNTING
BRACKETS
1/2” HOLES
MARK AND DRILL
FIG. 20-1
WASHERS
(4 PLACES)
LOCK NUTS
(2 PLACES)
CAP SCREWS
(2 PLACES)
LOCK WASHERS
(2 PLACES)
MOUNTING
BRACKETS
CROSS
MEMBER
BOLTING BRACKETS
(8 PLACES)
FIG. 20-2B
CROSS
MEMBERS
BOLTING BATTERY BOX FRAME
FIG. 20-2A
20
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
NOTE: If welding mounting brackets to cross members, skip instruction 2.
WARNING
!
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 can result from welds
that are done incorrectly.
CAUTION
To prevent pump box components from being damaged by electric current
from welding, connect welder grounding cable to the part being welded.
CAUTION
Cover pump box and optional battery box with flame-resistant covering before
welding pump box frame to vehicle.
3. For galvanized frame, read
warning decal shown in FIGS.
21-1A and FIGS. 21-1B before
welding. Weld each bracket to
cross members as shown in
FIGS. 21-1A and 21-1C. Weld
top of bracket if accessible.
IF ACCESSIBLE
3/16”
CROSS
MEMBERS
3/16”
3/16”
BRACKET
WELDING BRACKETS
(8 PLACES)
FIG. 21-1C
CROSS
MEMBERS
WELDING GALVANIZED, WARNING DECAL
FIG. 21-1B
21
BOLTING PUMP & BATTERY
BOX FRAME
FIG. 21-1A
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH OPTIONAL BATTERY BOX & FRAME TO
VEHICLE (IF EQUIPPED) - Continued
!
WARNING
Remove all rings, watches and jewelry before doing any electrical work.
NOTE: Always connect fused end of power cable to battery positive (+) terminal.
NOTE: To connect charge lines, refer to instructions provided with each charge
line kit.
NOTE: MAXON recommends using dielectric grease on all electrical connections.
4. Connect battery cables, fused
cables, and ground cables as
shown in FIG. 22-1.
ELECTRICAL COMPONENTS - BATTERY BOX
(GROUND CABLE
TO PUMP BOX OR COMMON
CHASSIS GROUND)
74” LG.
12 VOLT BATTERY CONNECTIONS
(-) BATTERY CABLE
TO COMMON
GROUND
FUSED CABLE
(SEE NOTE)
(FUSED CABLE TO
PUMP BOX)
(IN PARTS BOX)
42” LG.
CIRCUIT
BREAKER
CABLE
18” LG.
CABLE
10” LG.
FIG. 22-1
22
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH OPTIONAL BATTERY BOX & FRAME TO
VEHICLE (IF EQUIPPED) - Continued
!
WARNING
Explosive hydrogen gas from charging batteries can accumulate in battery
box if not vented from the box. To prevent hydrogen gas from accumulating,
ensure the 3 ventilation holes in battery box are not plugged or covered.
VENTILATION HOLES
BATTERY BOX ASSEMBLY
(REAR VIEW SHOWN)
FIG. 23-1
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH OPTIONAL BATTERY BOX & FRAME TO
VEHICLE (IF EQUIPPED) - Continued
ATTACH OPTIONAL BATTERY BOX & FRAME TO
VEHICLE (IF EQUIPPED) - Continued
PAN HEAD SCREW
1/4”-20 X 1” LG.
FLAT WASHER
1/4”
REFER TO
BATTERY BOX
LOCK NUT
1/4”-20
HEX NUT
5/16”-18, GR8
(3 PLACES)
L-SHAPE ROD
LOCK WASHER
#10
(3 PLACES)
FLAT WASHER
5/16”
(3 PLACES)
CAP SCREW
1/2”-20 X 2 1/4” LG. GR8
(4 PLACES)
ROD
(2 PLACES)
HEX NUT
5/16”-18
(2 PLACES)
FLAT WASHER
M8
(2 PLACES)
BRACKET
MOUNTING
PLATE
LOCK NUT
5/16”-18
(2 PLACES)
LOCK WASHER
9/16”
(4 PLACES)
FIG. 24-1
24
FLAT WASHER
9/16”
(4 PLACES)
HEX NUT
1/2”-20
(4 PLACES)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BATTERY BOX ASSEMBLY
RUNNING POWER CABLE
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. Avoid making sharp bends in wiring. Attach securely. If drilling
is necessary, first check behind the drilling surface to prevent damage to any
fuel lines, vent lines, brake lines or wires.
NOTE: Make sure cable is long enough to reach positive terminal on Liftgate pump box
without putting tension on the cable.
Install vehicle charge line by running the line along the inside of vehicle frame (FIG.
25-1). Make sure 175 amp fuse (FIG. 25-1) end of cable is by the battery. Run the
charge line from vehicle battery to Liftgate pump box positive terminal. Use frame clips
(parts box item) and plastic ties (as required) from charge line kit to secure cable.
VEHICLE FRAME
CHARGE LINE TO
PUMP BOX OR
BATTERY BOX
175 AMP
FUSE
FRAME
CLIPS
FRONT OF VEHICLE
REAR OF VEHICLE
18” - 24”
SPACING
CHARGE LINE
TO VEHICLE
BATTERY
FIG. 25-1
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
!
RUNNING POWER CABLE - Continued
!
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. Avoid
making sharp bends in wiring. Attach securely. If drilling is
necessary, first check behind the drilling surface to prevent
damage to any fuel lines, vent lines, brake lines or wires.
NOTE: Make sure cable is long enough to reach positive terminal
on Liftgate pump box without putting tension on the cable.
Run power cable from trailer nose to tail of trailer underside (FIG.
26-1A). Route cable around pin (install loom to protect power
cable) as shown in FIG. 26-1B.
Install cable clamps every 3 ft. approximately as illustrated in FIG.
26-1C.
NOTE: Loom and cable clamps are supplied in installation kit.
INSTALL LOOM TO CABLE.
ROUTE CABLE AROUND PIN.
INSTALL CABLE CLAMPS AT
3 FT. APPROX.
FIG. 26-1B
FIG. 26-1C.
LIFTGATE
PUMP
BOX
POWER
CABLE
PIN
RUNNING POWER CABLE ON REFRIGERATION/
SMOOTH BASE TRAILER
(UNDERSIDE VIEW)
FIG. 26-1A
26
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FRAMELESS - REFRIGERATION/SMOOTH UNDERSIDE TRAILER
RUNNING POWER CABLE - Continued
!
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. Avoid
making sharp bends in wiring. Attach securely. If drilling is
necessary, first check behind the drilling surface to prevent
damage to any fuel lines, vent lines, brake lines or wires.
NOTE: Make sure cable is long enough to reach positive terminal
on Liftgate pump box without putting tension on the cable.
Run power cable from trailer nose to tail of trailer underside (FIG.
27-1A). Route cable around pin (install loom to protect power
cable) as shown in FIG. 27-1B.
To fix and protect power cable, install trim-lock to cross member holes
as illustrated in FIG. 27-1C.
NOTE: Loom and trim-lock is supplied in installation kit.
INSTALL LOOM TO CABLE.
ROUTE CABLE AROUND PIN.
INSTALL TRIM-LOCK TO CROSS MEMBER
HOLES. POSITION JOINT AT TOP
FIG. 27-1B
FIG. 27-1C.
LIFTGATE
POWER
CABLE
PIN
RUNNING POWER CABLE ON DRY VAN TRAILER
(UNDERSIDE VIEW)
FIG. 27-1A
27
PUMP BOX
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FRAMELESS - DRY VAN TRAILER
CONNECT POWER CABLE
2. On the bare wire end of fused power cable, keep enough length to attach copper terminal lug and reach motor solenoid without putting tension on cable (after connection)
(FIG. 28-1A). Measure (if needed), and then cut excess cable from bare wire end of
cable. Put heatshrink tubing (Parts Box item) (FIG. 28-1B) on the end of the cable and
leave room for terminal lug. Crimp copper terminal lug (5/16” ring, Parts Box item) on
the fused power cable and shrink the heatshrink tubing (FIG. 28-1C).
COPPER
TERMINAL
LUG
FUSED
POWER CABLE
HEATSHRINK
TUBING
FIG. 28-1B
FIG. 28-1C
TYPICAL FUSED POWER CABLE ROUTING
FIG. 28-1A
CAUTION
Do not over-tighten the terminal nuts on
starter switch. For the load terminals, torque
nuts to 40 lb.-in. max. Torque the nuts on #1032 control terminals 15-20 lb.-in.
NUT & LOCK
WASHER
STARTER
SWITCH
FUSED
POWER CABLE
NOTE: MAXON recommends using
dielectric grease on all electrical connections.
NOTE: Do not remove flat washer from
the battery power terminal.
3. Remove hex nut and lock washer
from battery power terminal on
the starter solenoid. Connect the
fused power cable to the starter
switch as shown in FIG. 28-2.
Reinstall and tighten lock washer
and hex nut.
CONNECTING POWER CABLE TO
PUMP STARTER SWITCH
FIG. 28-2
28
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Run power cable through hole in pump
box wall (FIG. 28-1A).
NOTE: To ensure power unit is correctly grounded, MAXON recommends
connecting 2 gauge ground cable from grounding bolt on pump manifold to
grounding point on vehicle frame. Use remaining length of 2 gauge cable
(Parts Box item) and 2 copper lugs (Parts Box item) to make ground cable.
1. Put heatshrink tubing (Parts Box
item) (FIG. 29-1) on each end of
ground cable and leave room for
terminal lug. Crimp copper terminal lug (3/8” ring, Parts Box item)
on each end of ground cable and
shrink the heatshrink tubing (FIG.
29-2).
COPPER TERMINAL
LUG (2 PLACES)
HEATSHRINK TUBING
(2 PLACES)
FIG. 29-1
HEATSHRINK TUBING
(2 PLACES)
FIG. 29-2
NOTE: MAXON recommends using dielectric
grease on all electrical connections.
2. Run ground cable through hole in
pump box wall (FIG. 29-3).
SOL. VALVE
GROUND WIRE
GROUND
CABLE
PUMP
MANIFOLD
GROUND
BOLT
GROUND
CABLE
PUMP MANIFOLD
REAR VIEW
3. Unbolt solenoid valve ground
wire from pump manifold (FIG.
29-3). Bolt ground cable lug and
ground wire lug to pump manifold (FIG. 29-3). Tighten bolt
securely.
CONNECTING GROUND CABLE
TO PUMP MANIFOLD
FIG. 29-3
29
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONNECT GROUND CABLE
NOTE: If there is a grounding point on the frame,
use it to connect ground cable. Then, skip
the step for drilling a hole.
NOTE: Clean the ground cable connection point
on the frame down to bare metal.
4. Extend the ground cable to reach
vehicle frame (FIG. 30-1) without
putting tension on cable (after
connection). Connect to existing
grounding point if available.
5. If necessary, drill a 11/32” (0.343”)
hole in vehicle frame for bolting
the ground cable terminal lug
(FIG. 30-1).
VEHICLE CHASSIS
(TRUCK FRAME SHOWN)
TERMINAL LUG
(GROUND CABLE)
BARE
METAL
3/8” FLAT
WASHER
3/8”-16
LOCK NUT
3/8"-16 X 1" LG
CAP SCREW
3/8” STAR
WASHER
FIG. 30-1
6. Bolt the ground cable terminal
lug to vehicle frame as shown in
FIG. 30-1.
30
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONNECT GROUND CABLE - Continued
1. Extend the control switch cable through hole in
pump box wall (FIG. 31-1). Connect 3 control
wires to solenoid valve and starter switch (FIG.
31-1). Ensure wiring has slack after connections
are made.
BLACK
(SOL. VALVE)
BUTT
CONNECTOR
GROUND
CABLE (REF)
GREEN
(BATTERY+)
WHITE
(START SWITCH
COIL+)
POWER
CABLE (REF)
CONNECTING CONTROL SWITCH CABLE
TO PUMP ASSEMBLY
FIG. 31-1
2. Connect 3 control wires to solenoid
valve and starter switch as follows
(FIG. 31-1). Crimp butt connector
on BLACK wire to open solenoid
valve wire (FIG. 31-1). Connect the
2 lugs on GREEN and WHITE wires
to correct posts on starter switch
(FIG. 31-1). Ensure wiring has slack
when connected.
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONNECT CONTROL WIRING
CONNECT RETURN HOSE
ELBOW
(1/4” X 1/4”)
PLASTIC HOSE
(1/4” O.D.)
RESERVOIR
BUSHING
(3/8” TO 1/4”)
RETURN
PORT
RETURN HOSE CONNECTED TO PUMP RESERVOIR
FIG. 32-1
NOTE: Apply thread sealant (Parts Box item)
to hydraulic line connections.
2. Connect bushing and 1/4” x 1/4” elbow
(Parts Box items) to return port on
reservoir (FIG. 32-1).
3. Connect return hose to elbow
(FIG. 32-1).
32
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Remove shipping plug from return port in
reservoir (FIG. 32-1).
CONNECT POWER CABLE TO BATTERY
! WARNING
To prevent accidental personal injury
and equipment damage, make sure
power is disconnected from Liftgate
while installing parts.
NEGATIVE (-)
BATTERY CABLE
NEGATIVE (-)
POST
1. Disconnect power from Liftgate by
disconnecting negative (-) cable
from negative (-) post on battery
(FIG. 33-1).
DISCONNECTING BATTERY
FIG. 33-1
2. Remove nut from positive (+) battery
terminal connector. Connect power
cable to the positive (+) battery terminal
connector (FIG. 33-2). Re-install and
tighten nut.
POSITIVE (+)
BATTERY TERMINAL
FUSED
POWER CABLE
BOLT
NUT
CONNECTING POWER CABLE
FIG. 33-2
NEGATIVE (-)
BATTERY CABLE
3. Reconnect power to Liftgate by
reconnecting negative (-) cable
to (-) negative post on battery
(FIG. 33-3).
NEGATIVE (-)
POST
RECONNECTING BATTERY
FIG. 33-3
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
NOTE: MAXON recommends using dielectric grease on all electrical connections.
NOTE: To set pressure relief valve, hydraulic pressure gauge must be connected
to lifting port on pump manifold. Do the pump pressure relief valve adjustment before connecting pressure hose from cylinder.
1. Remove shipping plug from pressure port on
pump manifold (FIG. 34-1). Then, connect
5000 psi pressure gauge to pressure port.
PRESSURE
GAUGE
PRESSURE
PORT
MANIFOLD
RELIEF VALVE
ADJUSTMENT
ADJUSTING PRESSURE RELIEF VALVE
FIG. 34-1
2. Remove relief valve cover from manifold
(FIG. 34-1).
3. Hold control switch in UP position and observe pressure gauge (FIG. 34-1). Turn relief
valve adjustment until gauge reads 2200 to
2300 psi (FIG. 34-1). Then release control
switch.
4. Reinstall relief valve cover. Then disconnect pressure gauge (FIG. 34-1).
34
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ADJUST PRESSURE RELIEF VALVE
CONNECT PRESSURE LINE
1. Connect pipe nipple and swivel elbow
(Parts Box items) to pressure port on
pump manifold (FIG. 35-1).
SWIVEL
PRESSURE
HOSE
ELBOW
2” LG PIPE
NIPPLE
MANIFOLD
PRESSURE
PORT
PRESSURE HOSE CONNECTED TO PUMP MANIFOLD
FIG. 35-1
2. Connect pressure hose to swivel end of pipe
nipple (FIG. 35-1).
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
NOTE: Apply thread sealant (Parts Box item) to hydraulic line connections.
NOTE: Vehicle body must be empty
(unloaded) before performing
the following adjustment.
ADJUSTING
RODS
1. Adjust drive chains as follows.
ADJUSTING
NUTS
CYLINDER
LOCK NUTS
2. Remove cover from cylinder housing. Loosen the lock nut on each chain
adjusting rod (FIG. 36-1). Then lower
platform to ground level.
ADJUSTING DRIVE CHAIN
FIG. 36-1
3. Turn each chain adjusting nut (FIG.
36-1) an equal amount of clockwise
turns (alternate from chain to chain) until
hydraulic cylinder is fully compressed.
Then tighten the lock nut (FIG. 36-1)
on each chain.
4. If either of the 2 chain rods are too
long, cut off the excess as shown in
FIG. 36-1.
36
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ADJUST DRIVE CHAINS (ABOVE BED MODELS)
CHECKING HYDRAULIC FLUID
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.
NOTE: Use correct grade of hydraulic fluid for your location.
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 38-1 and 38-2 for recommended brands.
1. Open and lower platform to ground level.
Unfasten latch and remove the pump cover
(FIG. 37-1) .
PUMP COVER
2. Remove threaded filler cap (FIG. 37-2).
Check the hydraulic fluid level in reservoir.
Hydraulic fluid level should be 1” below
the top of filler hole (FIG. 37-2). If needed,
add hydraulic fluid to fill the reservoir to the
level shown in FIG. 37-2.
LATCH
REMOVING / REINSTALLING
PUMP COVER
FIG. 37-1
3. Reinstall filler cap (FIG. 37-2).
FILLER CAP
CAUTION
RESERVOIR
Pump Cover must be correctly secured
to prevent it from becoming a hazard.
To secure Pump Cover, fasten the rubber latch on the Pump Box to the receiver on the Pump Box Cover.
4. Reinstall the pump cover and fasten
latch (FIG. 37-2).
1”
CHECKING FLUID LEVEL
FIG. 37-2
37
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
ISO 32 HYDRAULIC OIL
RECOMMENDED
BRANDS
PART NUMBER
AMSOIL
AWH-05
CHEVRON
HIPERSYN 32
KENDALL
GOLDEN MV
SHELL
TELLUS S2 V32
EXXON
UNIVIS N-32
MOBIL
DTE-13M, DTE-24,
HYDRAULIC OIL-13
TABLE 38-1
ISO 15 OR MIL-H-5606 HYDRAULIC OIL
RECOMMENDED
BRANDS
PART NUMBER
AMSOIL
AWF-05
CHEVRON
FLUID A, AW-MV-15
KENDALL
GLACIAL BLU
SHELL
TELLUS S2 V15
EXXON
UNIVIS HVI-13
MOBIL
DTE-11M
ROSEMEAD
THS FLUID 17111
TABLE 38-2
38
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CHECKING HYDRAULIC FLUID - Continued
NOTE: Ensure there is no residue, dirt, or corrosion
where decals are attached. If neccessary,
clean surface before attaching decals.
CONTROL SWITCH DECAL
P/N 250993
MAXPRO DECAL
P/N 265388-01
CAPACITY DECAL
(RCM-1600 ONLY)
P/N 224751
CAPACITY DECAL
(RCM-1250 ONLY)
P/N 226006
INSTRUCTION DECAL
P/N 252899
WARNING DECAL
P/N 282479-01
WARNING DECAL
P/N 282847-01
39
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACHING DECALS
TOUCHUP PAINT
Damaged cylinder seals and contaminated hydraulic fluid can result from painting the polished portion of the cylinder rod. To prevent damage, protect the
exposed polished portion of the cylinder rod while painting.
If bare metal or primer is exposed on the painted portions of the Liftgate, touch up the
paint. To maintain the protection provided by the original paint system, MAXON recommends aluminum primer touchup paint kit, P/N 908134-01.
40
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
HYDRAULIC
CYLINDER
2 GPM FLOW
CONTROL VALVE
AUX. TANK PORT
(PLUGGED)
VENT
PORT
PRESSURE
PORT
“A” VALVE
CHECK
VALVE
PRESSURE
RELIEF VALVE
(SET AT
2250 +/- 50 PSI)
PUMP
MOTOR
(REF)
FILTER
41
HAND
PUMP PORT
(PLUGGED)
HAND
PUMP PORT
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SYSTEM DIAGRAM
CONTROL
SWITCH
WHITE
GREEN
BLACK
CABLE ASSY
STARTER
SOLENOID
SOLENOID,
VALVE “A”
BLACK
MOTOR
CABLE WITH
175 AMP FUSE
BATTERY
42
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SYSTEM DIAGRAM
DESCRIPTION
PART NO
CAB CUT-OFF SWITCH
250477
CIRCUIT BREAKER (150 AMP)
251576
AUXILIARY HAND PUMP KIT
251849
LVS, RCM
282991-01
TRAFFIC CONE KIT
268893-01
EXTRA CONTROLS & CONTROL KITS
HAND HELD CONTROL
053513
HAND HELD CONTROL WITH COILED CORD
053513-200
TOUCH-UP PAINT KIT
TOUCH-UP PAINT (BCG) WITH ALUMINUM PRIMER, SMALL
43
908134-01
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
OPTIONS
NOTE: Make sure the Liftgate power unit, and all batteries on the vehicle for the
power unit, are connected correctly to a common chassis ground.
1. Liftgate and additional
battery box are typically
installed on trailers as
shown in FIG. 44-1 and
on trucks as shown in
FIG. 44-2. See the following page for battery
and cable connections.
TRACTOR BATTERIES,
TYPICAL LOCATION
175 AMP
FUSED CABLE
200 AMP FUSED
CABLE
LIFTGATE
LIFTGATE
POWER UNIT
BATTERY BOX,
TYPICAL LOCATION
CIRCUIT
BREAKER
RECOMMENDED BATTERY BOX
INSTALLATION ON TRAILER
FIG. 44-1
TRUCK BATTERIES,
TYPICAL LOCATION
175 AMP
FUSED CABLE
200 AMP
FUSED CABLE
LIFTGATE
LIFTGATE
POWER UNIT
BATTERY BOX,
TYPICAL LOCATION
CIRCUIT
BREAKER
RECOMMENDED BATTERY BOX
INSTALLATION ON TRUCK
FIG. 44-2
44
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RECOMMENDED LIFTGATE POWER CONFIGURATION
NOTE: Always connect fused end of power cable to battery positive (+) terminal.
2. Recommended battery box
setup for 12 volt batteries is
shown in FIG. 45-1.
GROUND CABLE TO
PUMP BOX OR GROUND
COMMON CHASSIS
(-) BATTERY
CABLE
(-) BATTERY CABLE TO
COMMON GROUND
POWER CABLE
TO PUMP BOX
150 AMP CIRCUIT
BREAKER
FUSED CABLE
(SEE NOTE)
(+)
BATTERY
CABLES
FUSED CABLE
(SEE NOTE)
12 VOLT BATTERY CONNECTIONS
FIG. 45-1
45
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued
NOTE: Always connect fused end of power cable to battery positive (+) terminal.
3. Recommended battery box
setup for getting +24 volt dc
power from 12 volt batteries
is shown in FIG. 46-1.
GROUND CABLE TO
PUMP BOX OR COMMON
CHASSIS GROUND
(-) BATTERY CABLE TO
COMMON GROUND
150 AMP CIRCUIT
BREAKER
FUSED CABLE
(SEE NOTE)
(+) BATTERY
CABLE
FUSED CABLE
(SEE NOTE)
12 VOLT BATTERY CONNECTIONS FOR +24 VDC POWER
FIG. 46-1
46
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued