Installation Manual RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC

Installation Manual RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC
M-90-1
REV. F
SEPTEMBER 2010
INSTALLATION
MANUAL
RC-2B
RC-3B
RC-4B
RC-5B
RC-6B
RC-6K
11921 Slauson Avenue.
Santa Fe Springs, CA. 90670
(800) 227-4116
© MAXON Lift Corp. 2010
TABLE OF CONTENTS
WARNINGS............................................................................................................................ 3
SAFETY INSTRUCTIONS..................................................................................................... 3
NOTICE.................................................................................................................................. 4
INTRODUCTION.................................................................................................................... 5
UNIT AS SHIPPED................................................................................................................. 6
INSTALLATION OF UNIT....................................................................................................... 7
WELDING TO FLATBED...................................................................................................... 12
HYDRAULIC PIPE INSTALLATION..................................................................................... 13
POWER PACK INSTALLATION........................................................................................... 14
FUSED POWER CABLE...................................................................................................... 17
PUMP WIRING CAM CLOSER............................................................................................ 18
PUMP WIRING HYDRAULIC CLOSER............................................................................... 19
ADD HYDRAULIC FLUID..................................................................................................... 20
FINAL ADJUSTMENTS........................................................................................................ 22
ATTACH DECALS................................................................................................................ 24
OPTIONS............................................................................................................................. 26
RCT LIGHT INSTALLATION................................................................................................. 26
HAND PUMP OPTION FOR CAM CLOSER........................................................................ 28
BATTERY PAK INSTALLATION (For Trailers)...................................................................... 29
RECOMMENDED LIFTGATE POWER CONFIGURATION................................................. 30
BATTERY CABLE MOUNTING, 6 VOLT SYSTEM.............................................................. 32
BATTERY CABLE MOUNTING, 12 VOLT SYSTEM............................................................ 33
FIXED RAMP INSTALLATION, 6”........................................................................................ 34
FIXED RAMP INSTALLATION, 12”...................................................................................... 35
CART STOP & DUAL CART STOP RAMP INSTALLATION................................................. 36
HINGED RAMP INSTALLATION (STEEL)........................................................................... 37
HINGED RAMP INSTALLATION (ALUMINUM).................................................................... 38
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
NOTICE
NOTICE
• Liftgate installers, not Maxon Lift, are responsible for reviewing and complying with all
applicable Federal, State, and Local regulations pertaining to the trailer or truck.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• Maxon Lift is responsible for the instructions to correctly install MAXON Liftgates on
trucks or trailers only.
This publication contains the information required to install the following
models and their options; RC, RCW, RCT, RC-CL, and RCHL from 2000
to 6000 pound capacities. If there is any doubt in your mind regarding the
suitability of these lifts being installed on its intended vehicle, or any portion
of these instructions that you do not understand, please contact the Maxon
Customer Service Department for consultation.
Unauthorized modification to this equipment may cause premature
failure or create hazards in its use that are not foreseen at the time of the
installation. These kinds of changes should be discussed with our Engineering
Department before being undertaken.
Bed height requirements to ground are 38” laden to 56” unladen.
These lifts cannot be installed on bodies with swing type doors.
These lifts have been designed to fit bodies that are 96” wide, (102”
wide, in the case of the RCW Models). If this body has dimensions that are
much different than these, special brackets will have to be fabricated for
attachment. The corner posts of the body must also be made of steel so that
the lift columns can be welded to it. If they are aluminum, then steel plates
will have to be fabricated to bolt to these corner posts for welding to the lift
assembly. Both of the above conditions are rare and therefore have not been
provided for in this manual. Contact the Customer Service Department if either
of the above conditions exist.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
INTRODUCTION
UNIT AS SHIPPED
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Do not remove stands at bottom of column until instructed to do so.
Steel box containing pump assembly, also contains a packing
list, instruction manuals, decals, and all necessary hardware
to complete installation.
COLUMN SUPPORT ANGLES 48”
Two of these 18” angle iron pieces are
to be used first to assist in mounting
the lift to the truck, and then to support
the pump box on trailer installations.
The other two are welded to the column
support angles.
POWER UNIT BOX
REINFORCEMENT ANGLE 8”
STAND
PUMP BOX
BATTERY
PAK OPTION
6
STAND
There are two pieces of angle iron supports (2-1/2 x 2-1/2 x
18”) that have been provided to assist in lining the unit up to the
body. Tack weld them to the top of the lifts main section, just
strong enough to support it on the truck floor till the lift is secured
and ready to weld. Put a chalk mark on the center of the unit (on
the thread plate surface) for aligning with the center of the truck
body.
Remove support angles after lift is mounted and use them for
pump box mount reinforcement.
SUPPORT ANGLE
SUPPORT ANGLE
7
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INSTALLATION OF UNIT
Corner posts and sill under rear of floor must be clean and free of any
obstructions so that the columns of the rail lift can fit flat against the rear of the
body.
Chalk mark a center line at the edge of the rear of the truck floor to line up
with the mark on the liftgate.
Using the lifting straps, the unit can now be raised either with a chain hoist or
fork lift to a height which will allow the temporary support angles to rest on the
body floor. The unit can be moved to the vehicle or the vehicle to the unit till
they meet.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
INSTALLATION OF UNIT - Continued
Clamp columns to the truck body and weld
as shown. Remove forklift or chain hoist.
RC-2000/3000/RC-CR3
1/4” Fillet Weld. 2” Long
RC-4000
1/4” Fillet Weld. 3” Long
RC-5000/6000
1/4” Fillet Weld. 4” Long
NOTE: See views A & B on next page.
ALL UNITS: 1/8” fillet weld
approx. halfway
down the column.
ALL UNITS: See view C on
the next page.
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INSTALLATION OF UNIT - Continued
A
DO NOT WELD COVER
B
COVER
Typ.
1/4”
(Length as
specified
on previous
page.)
INSIDE OF COLUMN ASSEMBLY
OUTSIDE OF COLUMN ASSEMBLY
C
TYP.
1/4”
2
WELD TO CORNER
POST AND SILL
BOTTOM CORNER OF TRUCK BODY
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
INSTALLATION OF UNIT - Continued
Cut columns off 20” from ground. Place the 2-1/2” x 18”
angle iron provided under at least 2 cross members, to
prepare for the following step and weld.
Cut one end of each of the 4 foot long angle iron braces
so that it lines up with the lift column and the other end
lays flat against the angle iron referred to in the previous
paragraph.
18”
ANGLE
WELD
WELD
CUT
STAND
OFF
20”
11
LIFT COLUMN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
INSTALLATION OF UNIT - Continued
The column assemblies are
tied in to the flat bed side rails
with two lengths of channel. The
required sizes are listed below.
RC-2000/3000/4000
3”of 1/4” fillet weld
RC-5000/6000
4”of 1/4” fillet weld
NOTE: Mounting Channel is not supplied by Maxon
RC-2000/3000/4000
3”-4.1 #/ft. Channel
RC-5000/6000
4”-5.4 #/ft. Channel
If side rail is less than 1/4” thick,
weld a 1/4” plate to side rail, then
weld channel to 1/4” plate.
RC-2000/3000/4000
3”of 1/4” fillet weld
RC-5000/6000
4”of 1/4” fillet weld
Weld to side rail
above a cross
member.
Cross Member
12
60”
Approx.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELDING TO FLATBED
Remove the seven foot long pipe that is strapped to this column of the
lift gate (two pipes if lift has hydraulic platform closer), and weld to under
side of floor cross members. End of pipe to be about two feet from the end of
the truck body. Connect the four foot hoses to the end of the pipe(s) closest
to the power unit and the other end through the pump box to the pump
assembly. See the last page of “Power Pak Installation” for details.
NOTE: Blow air through pipes and hoses before connections are made.
App
rox.
13
24”
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC PIPE INSTALLATION
POWER PACK INSTALLATION
Jack up the steel box containing the pump assembly until it touches at least
two cross members under the floor, three if possible, and the back of the
touches the truck chassis frame. Weld where instructed and remove jack.
Leave room for tail lights.
WELD
WELD
MAX.
TRAILER BODIES
FLOOR CROSS
MEMBERS
20 feet
WELD ALL
SIDES OF
ANGLE
8” (3 REQ’D,
2 SHOWN)
18” ANGLE
BRACE
POWE
R UNIT
BOX
Jack up the steel box containing the pump assembly until it touches
at least two cross members under the floor, three if possible and tack weld.
Add braces provided to the back of the box and the side of the floor cross
members. Weld both ends of braces and top of box. Use short pieces of angle
iron provided to weld from the side of the floor cross members to the front of
the box.
Make sure the box is not in a position to interfere with the wheels of the
trailer with sliding axle.
Box can also be placed behind the wheels if room permits.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
TRUCK BODIES
Run 32 ft. power cable from the pump box, along the chassis frame to the
positive terminal of the battery (assuming the negative is ground). Use frame
clips to secure the cable. (Do not attach to the battery terminal until the other
end is fastened on the pump). If the cable is too long, cut to proper length.
POWER
CABLE
3/8” CABLE END
TERMINAL
SHRINK TUBE
1/2”
Strip about 1/2” of the insulation from the end and slide one of the
pieces of shrink tube far enough down that it’s out of your way. Solder the
terminal end firmly onto the cable.
Always wear protective eye covering while you are doing soldering
operations.
When it’s cool, slide the shrink tube over the terminal end and heat with
a heat gun til it shrinks tightly over the cable and terminal.
NOTE:
Proper cable connections are extremely important to insure a long and
efficient life to all electrical components, therefore, solder type terminals,
solder and shrink tubing are provided to insure proper connections. Please
do not use the hammer smashing method since the constant bouncing and
vibration of the vehicle can eventually cause these types of joints to loosen
and deteriorate.
This could also be true of crimping if not done properly or the wrong size
tool is used.
POWER
CABLE
FRAME
CLIP
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POWER PACK INSTALLATION - Continued
TRUCKS ONLY
Route the two hoses (3 if hydraulic closer) and the three conductor cord
(two cords if hydraulic closer), that come out of the bottom of the lift gate main
frame through the power pak box and connect as shown.
TRAILERS ONLY
Connect hydraulic hose coming out of bottom of lift gate to
welded pipes under body. Tie the cord(s) and the low pressure line
to the pipe and route through power unit box.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
POWER PACK INSTALLATION - Continued
!
WARNING
Do not attach cable to battery until Liftgate is
completely installed.
SHORT END TO
VEHICLE BATTERY
175 AMP REPLACEMENT FUSE
KIT P/N 264687
BATTERY CABLE ASSEMBLY (38’ STD)
(INCLUDES REPLACEMENT FUSE KIT)
P/N 264422
LONG END TO
MOTOR SOLENOID
OPTIONAL POWER CABLE KITS
DESCRIPTION
PART NUMBER
40’ CABLE ASSEMBLY
(WITH 200 AMP FUSE)
264848
10’ EXTENSION CABLE
ASSEMBLY
264849
FIGURE
(CABLE ASSEMBLY)
(EXTENSION CABLE ASSEMBLY)
17
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FUSED POWER CABLE
TOGGLE
IDE
S
SWITCH EY )
K EF
(R
1
2
BLK
3
GRN
W
HT
+)
LE (
AB
YC
R
E
T
AT
B
TO
GND
POWER TO
UP
WHT.
DOWN
BLK.
18
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP WIRING CAM CLOSER
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP WIRING HYDRAULIC CLOSER
19
ADD 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 21-1 & 21-2 for recommended brands.
1. Open pump box cover (FIG. 20-1).
PUMP BOX
2. Remove the filler cap
(FIG. 20-1). Add 4
quarts of hydraulic fluid
to reservoir. (Refer to the
NOTE above.)
COVER
PUMP BOX WITH OPEN COVER
FIG. 20-1
3. Reinstall filler cap (FIG. 20-2).
NOTE: To check oil level in the pump
reservoir, platform must be at
ground level.
FILLER
CAP
4. When Liftgate is ready to operate,
unfold and lower the platform to
ground level. (See Operation
Manual.)
5. Remove the filler cap (FIG. 20-2).
Check if hydraulic fluid is at the top
of the GRAVITY DOWN bar on the
decal (FIG. 20-1). If necessary,
add fluid to the top of the bar.
6. Reinstall filler cap (FIG. 20-2).
DECAL
(FLUID FILL)
CHECKING FLUID LEVEL
(GRAVITY DOWN PUMP SHOWN - USED ON
RC WITH CAM PLATFORM CLOSER)
FIG. 20-2
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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 21-1
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 21-2
21
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ADD HYDRAULIC FLUID - Continued
Fill the system with fluid by activating the raise control switch until the runners
hit the stops.
Unlatch Chain before
activating liftgate.
Slide Block
must be in
its retracted
position.
Remove platform holding chain and activate
switch to let unit down until platform rests on
ground.
Weld 2” long fillets along threshold/floor
about every 8 to 10 inches. No welding
is necessary on the bottom.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FINAL ADJUSTMENTS
Adjust Flow Control valve on power pak so that platform opens from a
vertical position just slow enough so as not to create a banging condition.
To ensure that the platform brakes are working properly, perform the
following simple test:
1. Open Platform and let unit down so that the bottom of the Runner on one
side rests on a floor jack.
2. Raise the jack about 3” or so and let the jack down.
3. The Runner should stay in the position that it was jacked up to. If it falls
down to its origional position resting on the jack, then the brake is not
working and must be checked.
4. To release engaged brake, raise unit.
Perform test on opposite side as well.
If platform raises uneven from side to side, adjust per instructions in
maintenance manual. Install lights and add decals.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FINAL ADJUSTMENTS - Continued
PAINT DECAL
(2 PLACES)
P/N 267338-01
SERIAL PLATE
(REF)
DECAL “F” OR
DECAL “G”
DECAL “C”
DECAL “D”
DECAL “B”
DECAL “E”
DECAL “A”
DECAL “H”
DECAL “I”
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH DECALS
DECAL SHEET
MODEL
ORDER P/N
MODEL
ORDER P/N
RC-2 CAM CLOSER
268385-01
RC-2 HYD CLOSER
268386-01
RC-3 CAM CLOSER
268385-02
RC-3 HYD CLOSER
268386-02
RC-4 CAM CLOSER
268385-03
RC-4 HYD CLOSER
268386-03
RC-5 CAM CLOSER
268385-04
RC-5 HYD CLOSER
268386-04
RC-6 CAM CLOSER
268385-05
RC-6 HYD CLOSER
268386-05
DECAL SHEET PART NUMBERS
25
DECAL SHEET PART NUMBERS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
(FOR HYDRAULIC
CLOSER, ONLY)
ALL RCT UNITS INCLUDE BACK LIGHTS
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
OPTIONS
RCT LIGHT INSTALLATION
WHT
RED
GRN
BLK
27
RED
GRN
WHT
RIGHT HAND
-01
WHT
RED
BLK
RED
WHT
WHT
BLK
GRN
GRN
BLK
CONNECTOR
P/N 030488
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
TAIL LIGHT
BLK
STOP/TURN LIGHT
WHT
RED
LICENSE PLATE
WHT
BLK
WHT
BACK-UP LIGHT
RED
TAIL LIGHT
LEFT HAND
BASIC
RED
RED
STOP/TURN LIGHT
BLK
LICENSE PLATE
WHT
BACK-UP LIGHT
RCT LIGHT INSTALLATION - Continued
OPTIONS
The procedure for lifting the platform using the hand pump is as follows:
1. Check if the relief valve is closed by using the handle to turn it clockwise
until complete stop.
2. Close the flow control valve by turning the knob clockwise until it is fully
closed.
3. Locate the handle in the hand pump and operate with an up and down
motion.
To lower the platform, open the hand pump relief valve slowly to be able to
control the down speed with this valve.
NOTE:
When going back to normal operation,
a. Be sure to have the hand pump closed.
b. Open and adjust the flow control valve.
HANDLE
FLOW
CONTROL
KNOB
RELIEF VALVE
HAND PUMP
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HAND PUMP OPTION FOR CAM CLOSER
Mount the battery pak on either side of the trailer body, as close to the
power source as possible. Using a floor jack or other lifting device, raise the
box so that it’s top touches the underside of the cross members and tack weld
to the crossmembers (unless the cross members are aluminum).
Place the four plates (included with this kit) against the cross members
and slide down against
MOUNTING
the battery pak. Weld
PLATES
to both structures.
(NOTE: Holes are
provided in the mounting
plates to allow bolting
CROSS MEMBERS
to aluminum cross
members).
Make sure
the box is not in a
position to interfere
with the wheels
BATTERY PAK
of the trailer with
sliding axle.
NOTE:
These boxes
can also be
installed behind
the wheels if
room permits.
For easier service, mount boxes so that the front of each box is recessed
one foot from the side wall of the vehicle body.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BATTERY PAK INSTALLATION (For Trailers)
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, pump box, and
additional battery box
are typically installed on
trailers as shown in FIG.
30-1 and on trucks as
shown in FIG. 30-2.
See the following page
for battery and cable
connections.
TRACTOR BATTERIES,
TYPICAL LOCATION
MASTER
DISCONNECT
SWITCH
LIFTGATE
LIFTGATE
PUMP BOX
TRACTOR BATTERY
CIRCUIT BREAKER,
REQUIRED LOCATION
CHARGE LINE
POWER
CABLE
CIRCUIT
BREAKER
OPTIONAL
BATTERY BOX,
TYPICAL LOCATION
TRAILER-MOUNTED
CIRCUIT BREAKER,
ADDITIONAL RECOMMENDED LOCATION
RECOMMENDED LIFTGATE & BATTERY BOX
INSTALLATION ON TRAILER
FIG. 30-1
TRUCK BATTERY
CIRCUIT BREAKER,
REQUIRED LOCATION
MASTER
DISCONNECT
SWITCH
LIFTGATE
LIFTGATE
PUMP BOX
POWER
CABLE
CIRCUIT
BREAKER
TRUCK BATTERIES,
TYPICAL LOCATION
OPTIONAL
BATTERY BOX, CHARGE LINE
TYPICAL LOCATION
RECOMMENDED LIFTGATE & BATTERY BOX
INSTALLATION ON TRUCK
FIG. 30-2
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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 6 volt batteries is
shown in FIG. 31-1.
(+)
BATTERY
CABLES
150 AMP CIRCUIT
BREAKER
150 AMP CIRCUIT BREAKER
(NEAR TRUCK OR
TRACTOR BATTERY AND/OR
NOSE OF TRAILER)
175 AMP FUSED POWER CABLE
(SEE NOTE)
CHARGE LINE TO
TRUCK OR TRACTOR
BATTERY
POWER CABLE
TO PUMP BOX
(-) BATTERY
CABLE
GROUND CABLE
TO PUMP BOX
6 VOLT BATTERY CONNECTIONS
FIG. 31-1
NOTE: Always connect fused end of power cable to battery positive (+) terminal.
3. Recommended battery box
setup for 12 volt batteries is
shown in FIG. 31-2.
175 AMP FUSED POWER CABLE
(SEE NOTE)
150 AMP CIRCUIT
(+)
BREAKER
BATTERY
CABLES
150 AMP CIRCUIT BREAKER
(NEAR TRUCK OR
TRACTOR BATTERY AND/OR
NOSE OF TRAILER)
CHARGE LINE TO
TRUCK OR TRACTOR
BATTERY
POWER CABLE
TO PUMP BOX
GROUND CABLE
TO PUMP BOX
(-) BATTERY
CABLES
12 VOLT BATTERY CONNECTIONS
FIG. 31-2
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued
OPTIONS
CIRCUIT BREAKER
FROM CONNECTOR
PLUG
GROUND CABLE
+
+
T
OL
6 V ERY
TT
BA
T
OL Y
V
6 ER
TT
BA
MOTOR SOLENOID
CABLE
MOTOR SOLENOID
32
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BATTERY CABLE MOUNTING, 6 VOLT SYSTEM
CIRCUIT BREAKER
FROM CONNECTOR
PLUG
GROUND CABLE
+
+
LT
VO
12 TERY
T
BA
LT
VO
12 TERY
T
BA
MOTOR SOLENOID
CABLE
MOTOR SOLENOID
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
BATTERY CABLE MOUNTING, 12 VOLT SYSTEM
OPTIONS
Lower the platform to level ground. Line up top edge of ramp with the
front edge of the platform.
Weld 1/8” beads two inches long about every 6 or 8 inches along the
entire length of the platform. Repeat procedure for the underside of the
platform.
WELD
WELD
34
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FIXED RAMP INSTALLATION, 6”
Lower the platform to level ground. Line up top edge of ramp with the
front edge of the platform.
A
Cut rear edges of ramp as shown:
Single piece platform “A” = 3/8”
Folding platforms “A” = 1/2”
WELD
WELD
Weld 1/8” beads two inches long about every 6 or 8 inches along the
entire length of the platform. Repeat procedure for the underside of the
platform. Weld gussets full length.
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
FIXED RAMP INSTALLATION, 12”
1. With the platform on the ground, center the Cart Stop Ramp against the
butt end of the platform. Rest the Ramp Blocks on top of the platform and let
the Ramp Tip touch the ground. Weld both sides into place.
Cart Stop Ramp
Ramp Blocks
Platform
1/4” Weld
Cart Stop Ramp Tip to be flush
with bottom surface of Platform.
2. Pop open the Cart Stop Section of the ramp for ease of welding. Weld the
top & bottom of the Ramp to the Platform with 2” long welds on approximately
12” centers. Grind all welds smooth and touch up with paint.
Cart Stop Ramp
NOTE: REPEAT THE
STITCH WELD ON THE
BOTTOM OF RAMP
1/4” 2”-12”
Platform
36
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CART STOP & DUAL CART STOP RAMP INSTALLATION
HINGED RAMP INSTALLATION (STEEL)
3
5
1/8”
Typ.
1/8”
1/8”
Typ. 1/8”
6,7
8
Typ.
1/16”(Typ.)
4
C
L
1-7/8”
7” (12” & 20” ramps)
3” (6” ramp only)
1/2”(Typ.)
6”
1
12”
2
46”
43-1/4”
(Typ. 90” Ramp)
(Typ. 90” Ramp)
38-1/4”
(Typ.
80” Ramp)
7/8”
41”
(Typ.
80” Ramp)
2
1/2”
8
1/8”
4
1
1/8”
Item Qty.
1
12” & 20” RAMPS
8
1
Part No.
Description
225989-1
12"x 90" RAMP & HINGE ASSY.
225989-2
6"x 90" RAMP & HINGE ASSY.
225989-3
12"x 80" RAMP & HINGE ASSY.
225989-4
6"x 80" RAMP & HINGE ASSY.
225989-5
20"x 90" RAMP & HINGE ASSY.
225989-6
20"x 80" RAMP & HINGE ASSY.
2
4
092143-01 TUBE 1.5 OD x1.015 ID x1.75LG.
3
1
4
2
225998
BAR RD. 3/4" DIA. x 8" LG.
5
2
201020
FLAT, 3/8 x 1 x 1-1/2" LG
6
2
202698-41 CHAIN 18" LG. (12" & 20" RAMP ONLY)
7
2
202698-43 CHAIN 11" LG. (6" RAMP ONLY)
8
2
221739-1
LATCH PLT. WMT. 1PC PTFM.
221739-2
LATCH PLT. WMT. 2PC PTFM.
224342
LUBE FITTING
37
1
4
6” RAMPS
 
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Locate Swivel this way on
36”, 42”, 48” pltfm. only.

5/8”
3
Locate Swivel this
way
on 60”, 72”, 76”,
84”
pltfm. only.
1/8”

 
Typ.
6
5
1/8”
Typ.
1/8”
5/8”
Typ.
1/8
4
1-1/2”(Typ.)
11-1/2” (36”,42”,48”Pfm)
9-1/2” (60”,72”,76”,80”Pfm)
1/16”(Typ.)
10”
1
5/8”
1/2”
2
6-7/8”
(Typ. 80” Pltfm.)
3-13/32”
(Typ. 70” Pltfm.)
Item Qty.
1/8” 1-10
221543
221543-1
4
Part No.
1
1
229569-01
1
229569
Description
16"x 80" RAMP ASSY.
16"x 80" REINFORCED ALUM. RAMP ASSY.
20"x 80" ALUM. RAMP ASSY.
20"x 80" REINFORCED ALUM. RAMP ASSY.
221543-100 16"x 70" RAMP ASSY.
2
1
092143-01
TUBE 1.5 OD x1.015 ID x1.75LG.
3
1
221739-1
LATCH PLT. WMT. 1PC PTFM.
221739-2
LATCH PLT. WMT. 2PC PTFM.
4
1
225985
PIPE 3/4" SCH. 80 x 60" LG.
5
2
201020
FLAT, 3/8 x 1 x 1-1/2" LG
6
2
202698-41 CHAIN 18" LG.
38
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HINGED RAMP INSTALLATION (ALUMINUM)
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