MAXON BMR 35, BMR 44, BMR 55, BMR 66, BMR 35 PD, BMR 44 PD, BMR 55 PD, BMR 66 PD, BMR 35 GD, BMR 44 GD, BMR 55 GD, BMR 66 GD Liftgate Installation Manual
Below you will find brief product information for BMR 35, BMR 44, BMR 55, BMR 66, BMR 35 PD, BMR 44 PD, BMR 55 PD, BMR 66 PD, BMR 35 GD, BMR 44 GD, BMR 55 GD, BMR 66 GD. BMR Liftgates are body-mounted Liftgates that are designed to be installed on trucks and trailers. The Liftgate is capable of lifting and lowering heavy loads, making it ideal for a variety of applications. The BMR Liftgate is equipped with a variety of features, including a hydraulic system, a platform, and a control panel. The Liftgate is easy to operate and can be customized to meet the specific needs of your application.
advertisement
M-14-08
REV. B
MAY 2015
Installation Manual Contains:
• Warnings & Safety Instructions
• Requirements - Body Strength & Installed Liftgate
• Liftgate Installation Components
• Liftgate Component Installation Instructions
• Hydraulic Fluid Filling Instructions
• Decals
• Hydraulic & Electrical System Diagrams
• Pre-delivery Inspection Form
To fi nd maintenance & parts information for your BMRB Liftgate, go to www.maxonlift.com. Click the PRODUCTS, COLUMNLIFT
& BMRB buttons. Open the Maintenance Manual in the PROD-
UCT DOCUMENTATION window.
© MAXON Lift Corp. 2015
TABLE OF CONTENTS
SUMMARY OF CHANGES: M-14-08, REVISION B ............................................................. 5
WARNINGS ........................................................................................................................... 6
VEHICLE REQUIREMENTS ................................................................................................. 8
BODY STRENGTH ................................................................................................................ 8
INSTALLED LIFTGATE ....................................................................................................... 12
LIFTGATE INSTALLATION COMPONENTS ...................................................................... 13
COMPONENTS ................................................................................................................... 14
STEP 1 - PREPARE VEHICLE IF REQUIRED ................................................................... 17
STEP 2 - CHOOSE METHOD OF INSTALLATION ............................................................. 19
STEP 3 - POSITION LIFTGATE .......................................................................................... 20
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE ....................................................................................................... 20
METHOD 2 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON LIFTGATE ...................................................................................................... 26
METHOD 3 - WELD LIFTGATE TO BODY .......................................................... 31
STEP 4 - BOLT LIFTGATE TO VEHICLE ............................................................................ 33
STEP 5 - REMOVE LOWER SUPPORT FIXTURES .......................................................... 37
STEP 6 - POSITION PUMP BOX FRAME .......................................................................... 38
STEP 7 - ATTACH PUMP & BATTERY BOX FRAME TO VEHICLE ................................... 40
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES ............................................... 45
RUN GRAVITY DOWN HYDRAULIC LINES ....................................................... 46
RUN POWER DOWN HYDRAULIC LINES ......................................................... 48
RUN ELECTRIC CABLES ................................................................................... 50
WIRING HARNESS TWIST-LOCK CONNECTORS ........................................... 51
STEP 9 - CONNECT GROUND CABLE ............................................................................. 52
TABLE OF CONTENTS - Continued
GROUNDING TO TRUCK FRAME .................................................................... 52
GROUNDING TO BATTERY BOX (IF EQUIPPED) ........................................... 53
STEP 10 - RUN CHARGE LINES ....................................................................................... 54
STEP 11 - CONNECT BATTERIES TO LIFTGATE ............................................................ 58
STEP 12 - ADD HYDRAULIC FLUID TO RESERVOIR ...................................................... 59
STEP 13 - PRESSURIZE HYDRAULIC SYSTEM .............................................................. 60
STEP 14 - OPTIMIZE HYDRAULIC FLUID LEVEL ............................................................. 61
STEP 15 - CHECK MOUNTING BRACKET FIT .................................................................. 66
STEP 16 - REMOVE UPPER SUPPORT FIXTURES ........................................................ 68
STEP 17 - SECURING COLUMNS ..................................................................................... 69
METHOD 1 AND METHOD 2 ............................................................................ 69
STEP 18 - FINISH WELDING LIFTGATE TO VEHICLE ..................................................... 74
METHOD 3 - WELD LIFTGATE TO BODY ........................................................ 74
STEP 19 - PLATFORM CHAIN ADJUSTMENT .................................................................. 78
STEP 20 - PLACE “ALIGN ARROWS” DECAL ................................................................... 80
STEP 21 - ADJUST PLATFORM ASSEMBLY ..................................................................... 81
STEP 22 - ACTIVATE PLATFORM LIGHTS ........................................................................ 82
ATTACH DECALS .............................................................................................................. 83
TOUCH UP PAINTED OR GALVANIZED FINISH .............................................................. 85
OPTIONS ............................................................................................................................ 86
RECOMMENDED LIFTGATE POWER CONFIGURATION ................................................ 86
HYDRAULIC SYSTEM DIAGRAMS ................................................................................... 88
PUMP & MOTOR SOLENOID OPERATION - POWER DOWN .......................................... 88
PUMP & MOTOR SOLENOID OPERATION - GRAVITY DOWN ........................................ 89
GRAVITY DOWN HYDRAULIC SCHEMATIC ..................................................................... 90
POWER DOWN HYDRAULIC SCHEMATIC ....................................................................... 91
TABLE OF CONTENTS - Continued
ELECTRICAL SYSTEM DIAGRAMS ................................................................................. 92
INTERCONNECTING ELECTRICAL SCHEMATIC ............................................................. 92
GRAVITY DOWN SINGLE PUMP ELECTRICAL SCHEMATIC .......................................... 93
GRAVITY DOWN DUAL PUMP ELECTRICAL SCHEMATIC .............................................. 94
POWER DOWN SINGLE PUMP ELECTRICAL SCHEMATIC ............................................ 95
POWER DOWN DUAL PUMP ELECTRICAL SCHEMATIC ................................................ 96
PRE-DELIVERY INSPECTION FORM ................................................................................ 97
SUMMARY OF CHANGES: M-14-08, REVISION B
PAGE
COVER
10, 11
25
50,51
95, 96
DESCRIPTION OF CHANGE
Updated REV and date.
Added clearance dimensions.
Added removal of cover and bolts from hangers on mounting plate.
Added information about wiring harness twist-lock connectors.
Updated latching relay wiring connection on power down electrical schematic.
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.
WARNINGS
!
WARNING
• 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.
• 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.
• Remove all rings, watches and jewelry before doing any electrical work.
• 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 modifi cations on the Liftgate. Modifi cations 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.
• Welding on galvanized parts gives off especially hazardous fumes. Comply with WARNING decal on the galvanized part (
FIG. 6-1)
. To minimize hazard remove galvanizing from weld area, provide adequate ventilation, and wear suitable respirator.
FIG. 6-1
6
• 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 or children 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 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.
• 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.
7
VEHICLE REQUIREMENTS
NOTE: Installer is responsible for ensuring vehicle meets Federal, State, and Local standards and regulations.
BODY STRENGTH
!
WARNING
Consult vehicle body manufacturer for vehicle body strength data. Make sure the forces created by the Liftgate are within the limits prescribed by the vehicle body manufacturer.
NOTE: Maximum operating bed height for body is 56” (Unloaded). Minimum is 44”
(Loaded). Do not install this Liftgate on vehicle bodies equipped with swing open doors.
The BMR is a body-mounted Liftgate that puts forces on the side walls of truck and trailer bodies (FIG. 8-1). For correct installation, truck and trailer bodies must be strong enough to withstand the tension, compression and shear forces shown in FIG. 8-1. Use TABLES 9-1,
9-2, 9-3, and 9-4 on the following page to determine the forces that apply to the type of platform, size of platform, and load capacity of your Liftgate.
77”
X= Tension on each sidewall
Y= Compression on each sidewall
Z= Shear on each sidewall
Z
X
Y
BED HEIGHT
FIG. 8-1
8
VEHICLE REQUIREMENTS - Continued
BODY STRENGTH - Continued
MODEL CAPACITY
BMR-35
3500 LBS.
(STEEL PLATFORM)
BMR-44
4400 LBS.
(STEEL PLATFORM)
P/F
SIZE
84
42
84
72
60
48
42
72
60
48
TABLE 9-1
(X)(Y)
LBS.
2101
1780
1475
1180
1043
2504
2110
1772
1426
1262
(Z)
LBS.
4176
4071
3962
3840
3786
4851
4746
4637
4515
4461
MODEL CAPACITY
BMR-55
5500 LBS.
(STEEL PLATFORM)
BMR-66
6600 LBS.
(STEEL PLATFORM)
P/F
SIZE
84
72
60
48
42
84
72
60
48
42
TABLE 9-2
(X)(Y)
LBS.
2998
2559
2137
1726
1529
3491
2989
2500
2025
1738
(Z)
LBS.
5676
5571
5462
5340
5286
6501
6396
6287
6165
6111
MODEL CAPACITY
BMR-35
3500 LBS.
(ALUMINUM
PLATFORM)
BMR-44
4400 LBS.
(ALUMINUM
PLATFORM)
P/F
SIZE
84
72
60
48
42
84
72
60
48
42
TABLE 9-3
(X)(Y)
LBS.
1785
1580
1339
1081
964
2233
1931
1637
1326
1183
(Z)
LBS.
3683
3649
3619
3533
3510
4358
4324
4294
4208
4185
MODEL CAPACITY
BMR-55
5500 LBS.
(ALUMINUM
PLATFORM)
BMR-66
6600 LBS.
(ALUMINUM
PLATFORM)
P/F
SIZE
84
72
60
-
-
84
72
60
-
-
TABLE 9-4
(X)(Y)
LBS.
2725
2360
2001
-
-
3219
2788
2365
-
-
(Z)
LBS.
5183
5749
5119
-
-
6008
5974
5944
-
-
9
VEHICLE REQUIREMENTS - Continued
CLEARANCE DIMENSIONS
NOTE: Maximum bed height is 56” (unloaded).
Minimum bed height (loaded) varies with type and size of platform.
13-1/4” (INCLUDES 3/4” BUMPER)
56” (MAX. BED HT.)
(REFER TO TABLE 10-1 FOR MIN. BED HT.)
13-3/4” (INCLUDES 3/4” BUMPER)
56” (MAX. BED HT.)
(REFER TO TABLE 10-1 FOR MIN. BED HT.)
WELD-ON LIFTGATE
FIG. 10-1
BOLT-ON LIFTGATE
FIG. 10-2
PLATFORM
ALUMINUM
ALUMINUM
ALUMINUM
ALUMINUM
ALUMINUM
ALUMINUM
STEEL
STEEL
STEEL
STEEL
STEEL
STEEL
SIZE
80” X 30”
85” X 30”
80” X 36”
85” X 36”
80” X 42”
85” X 42”
80” X 30”
85” X 30”
80” X 36”
85” X 36”
80” X 42”
85” X 42”
MIN. BED HEIGHT
32”
32”
33”
33”
39”
39”
45”
38”
38”
44”
44”
45”
MINIMUM BED HEIGHT BY PLATFORM TYPE AND SIZE
TABLE 10-1
10
VEHICLE REQUIREMENTS - Continued
82” (96” WIDE VEHICLE)
87” (102” WIDE VEHICLE)
77-1/2” (96” WIDE VEHICLE)
82-1/2” (102” WIDE VEHICLE)
97” (96” WIDE VEHICLE)
102” (102” WIDE VEHICLE)
CLEARANCE DIMENSIONS
FIG. 11-1
18-1/8”
95-5/8”
11
VEHICLE REQUIREMENTS - Continued
INSTALLED LIFTGATE
NOTE: If Liftgate columns exceed a 91 degree angle from level ground when installed on body, or if columns cannot be mounted fl ush against rear of vehicle, a steel fi ller may be used to bridge gap between vehicle body and Liftgate columns. Make sure the added materials and welds meet the BODY STRENGTH requirements shown on the previous pages.
With the vehicle parked on level ground, the columns of the BMR must be perpendicular to the ground (vertical) for the Liftgate to operate correctly (FIGS. 12-1
and 12-2).
LEVEL
91° MAX.
LIFTGATE INSTALLED ON VAN BODY (COLUMNS
SHOWN PERPENDICULAR TO LEVEL GROUND)
FIG. 12-1
LEVEL
91° MAX.
LIFTGATE INSTALLED ON FLAT BED (COLUMNS & SUP-
PORTS SHOWN PERPENDICULAR TO LEVEL GROUND)
FIG. 12-2
12
LIFTGATE INSTALLATION COMPONENTS
Each BMR Liftgate includes items shown in FIG. 13-1.
1
8
4
6
7
5A
3C
2
3C
9
3B
3A
3A
5B
FIG. 13-1
DESCRIPTION
1
BMR Liftgate.
Hardware parts bag, mounting bracket parts bag, hydraulic lines & fi ttings, wiring
2
harness, power cable, molded switch control box.
3A
Mounting plate (bolt-on installation kit).
3B
Extension plate (bolt-on installation kit).
3C
Gusset (bolt-on installation kit).
4
Pump box assembly.
5A
Pump installation kit (3’, 10’, 15’, or 20’).
5B
Channel guard (for 10’, 15’, or 20’ installation kits only)
6
Frame for pump box with optional battery box is shown. A shorter frame is also available for mounting single pump box or an optional battery box.
7
Battery box (optional)
8
9
Optional equipment
Instruction manuals and decals
TABLE 13-1
13
COMPONENTS
NOTE:
Make sure you have components and parts before you start installing Liftgate.
Compare parts in the part box and each kit box with packing list enclosed in each box. If parts and components are missing or incorrect, call:
Maxon Customer Service
Call (800) 227-4116 or
Send e-mail to [email protected]
BMR
MODEL
BMR 35
BMR 44
BMR 55
BMR 66
BOLT-ON
INSTALLATION KIT,
STNL-STEEL
BOLT-ON
INSTALLATION KIT,
STEEL
EXTENSION PLATE,
STNL-STEEL
(WELD-ON UNITS)
EXTENSION PLATE,
GALVANIZED
(WELD-ON UNITS)
EXTENSION PLATE,
PAINTED
(WELD-ON UNITS)
MANUAL &
DECAL KIT
288875-11
(96” WIDE VEHICLE)
288875-01
(96” WIDE VEHICLE)
286215-101
(96” WIDE VEHICLE)
288790-01G
(96” WIDE VEHICLE)
288790-01
(96” WIDE VEHICLE)
288875-12
(102” WIDE VEHICLE)
288875-02
(102” WIDE VEHICLE)
286215-111
(102” WIDE VEHICLE)
288790-11G
(102” WIDE VEHICLE)
288790-11
(102” WIDE VEHICLE)
288876-35
288876-44
288876-55
288876-66
TABLE 14-1
BMR
MODEL
PART BOX
3 FT PUMP
BOX INSTALL
KIT
10 FT PUMP
BOX INSTALL
KIT
15 FT PUMP
BOX INSTALL
KIT
20 FT PUMP
BOX INSTALL
KIT
BMR 35 PD
BMR 44 PD
BMR 55 PD
BMR 66 PD
288877-02
(WELD-ON)
288877-12
(BOLT-ON)
288880-11 288880-12 288880-13 288880-14
BMR
MODEL
PART BOX
3 FT PUMP
BOX INSTALL
KIT
10 FT PUMP
BOX INSTALL
KIT
15 FT PUMP
BOX INSTALL
KIT
20 FT PUMP
BOX INSTALL
KIT
BMR 35 GD
BMR 44 GD
BMR 55 GD
BMR 66 GD
288877-01
(WELD-ON)
288877-11
(BOLT-ON)
288880-01 288880-02 288880-03 288880-04
TABLE 14-1
14
COMPONENTS - Continued
BMR
MODEL
BMR 35 PD
BMR 44 PD
BMR 55 PD
BMR 66 PD
SINGLE
PUMP
ASSY
SECOND
PUMP
KIT
FRAME,
PUMP OR
BATTERY
BOXES
287660-12 287675-01
288180-11G
SINGLE FRAME
(GALVANIZED)
287980-11G
DUAL FRAME
2 BATT BOX
(GALVANIZED)
288810-11G
DUAL FRAME
3 BATT BOX
(GALVANIZED)
LOW VOLTAGE
SWITCH
OPTIONS
CYCLE
COUNTER
HEADER
KIT
(ADJUSTABLE)
HEADER
KIT
(RECESSED
DOME LAMP)
289188-01
(PAINTED, 96”
WIDE VEHICLE)
DOME
LAMP
RECESSED
- MOUNT
289536-01 289537-01
289190-01
(PAINTED)
289188-11
(GALV, 96” WIDE
VEHICLE)
289190-02
(GALVANIZED)
289188-02
(PAINTED, 102”
WIDE VEHICLE)
906589-01
289190-02
(GALV, 102”
WIDE VEHICLE)
BMR
MODEL
BMR 35 GD
BMR 44 GD
BMR 55 GD
BMR 66 GD
SINGLE
PUMP ASSY
287670-12
SECOND
PUMP
KIT
FRAME,
PUMP OR
BATTERY
BOXES
287675-01
288180-11G
SINGLE FRAME
(GALVANIZED)
287980-11G
DUAL FRAME
2 BATT BOX
(GALVANIZED)
288810-11G
DUAL FRAME
3 BATT BOX
(GALVANIZED
LOW VOLTAGE
SWITCH
OPTIONS
CYCLE
COUNTER
HEADER
KIT
(ADJUSTABLE)
HEADER
KIT
(RECESSED
DOME LAMP)
289188-01
(PAINTED, 96”
WIDE VEHICLE)
289190-01
(PAINTED)
289188-11
(GALV, 96” WIDE
VEHICLE)
DOME
LAMP
RECESSED
- MOUNT
289536-01 289537-01 906589-01
289190-02
(GALVANIZED)
289188-02
(PAINTED, 102”
WIDE VEHICLE)
289190-02
(GALV, 102”
WIDE VEHICLE)
TABLE 15-1
15
COMPONENTS - Continued
BMR
MODEL
BATTERY
BOX
BATTERY
12V HD
OPTIONS
KIT,
TOUCHUP
PAINT
WITH
AL PRIMER
HYDRAULIC
OIL
UNIVIS
HV1-13
NON-SKID
COATING
BMR 35 PD
BMR 44 PD
BMR 55 PD
BMR 66 PD
269560-01 267318-01 908134-01 284098-01
281531-100
(NOT FOR
GALVANIZED
PLATFORMS)
AUXILIARY
CONTROL
HAND HELD
CONTROL
289850-12 289840-01
BMR
MODEL
BATTERY
BOX
BATTERY
12V HD
OPTIONS
KIT,
TOUCHUP
PAINT
WITH
AL PRIMER
HYDRAULIC
OIL
UNIVIS
HV1-13
NON-SKID
COATING
BMR 35 GD
BMR 44 GD
BMR 55 GD
BMR 66 GD
269560-01 267318-01 908134-01 284098-01
281531-100
(NOT FOR
GALVANIZED
PLATFORMS)
TABLE 16-1
AUXILIARY
CONTROL
HAND HELD
CONTROL
289850-11 289840-01
BMR
MODEL
SINGLE POLE
TRACTOR KIT
DUAL POLE
TRACTOR KIT
SINGLE POLE
TRAILER CHARGE
LINE
CHARGE LINE OPTIONS
DUAL POLE
TRAILER CHARGE
LINE
ADAPT DUAL & SINGLE
POLE TRACTOR
KIT
TRAILER
SINGLE/DUAL
POLE NOSE
BOX KIT
BATTERY STATE
OF CHARGE
INDICATOR
BMR 35
BMR 44
BMR 55
BMR 66
280275-03 280275-04 280275-01 280275-02 280275-05 280275-06 908171-01
TABLE 16-2
BMR
MODEL
BMR 35
BMR 44
BMR 55
BMR 66
TC-4 KIT
WITH
SEL-BOX
TC-5 KIT
WITH
EXTENDER
TC-6 KIT
WITH
LOCKOUT
CHARGE LINE OPTIONS
TC-7 KIT
DUAL-SINGLE
POLE
TC-8 KIT
3-IN-1 WITH
LOCKOUT
TC-9 KIT 2-IN-1
WITH
LOCKOUT
TC-10 KIT
WITH
MODULE
TC-23 KIT
DUAL/SINGLE
NOSE BOX
TC-24 KIT
DUAL NOSE
BOX
295210-01 286117-01 286115-01 286122-01 286125-01 286124-01 286123-01 286112-01 286111-01
TABLE 16-3
16
STEP 1 - PREPARE VEHICLE IF REQUIRED
NOTE: Perform the following step for fl atbed vehicle body only. If vehicle body is
not a fl atbed, skip this step.
NOTE: LH and RH supports must be perpendicular to level ground. See VEHICLE
REQUIREMENTS, INSTALLED LIFTGATE.
NOTE: Materials for support framework are not provided with Liftgate.
!
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.
1. Fabricate framework, as shown in FIGS. 17-1A, -1B & -1C, to support Liftgate on a fl atbed vehicle. Then, go to the next page for welding instructions.
LEFT HAND (LH)
SUPPORT
60”
RIGHT HAND (RH)
SUPPORT
RECTANGULAR TUBING, 1/8” WALL
ASTM-A36 GENERAL PURPOSE
STEEL, 2” x 4” x 85” LG.
(QTY. 2)
36”
Approx.
32”
RECTANGULAR TUBING, 1/8” WALL
ASTM-A36 GENERAL PURPOSE
STEEL, 2” x 4” x 70” LG.
(QTY. 2)
2” 12” (MAX. BELOW
BED HEIGHT)
FLOOR PLATE,
1/4” THICK, ASTM-A36
GENERAL PURPOSE STEEL
4” x 10” LG.
(QTY. 2)
LIFTGATE SUPPORT
FRAMEWORK FOR FLATBED
RECTANGULAR TUBING,
1/8” WALL, ASTM-A36
GENERAL PURPOSE STEEL
2” x 4” x 88” LG. (96”WIDE BODY)
2” x 4” x 94” LG. (102”WIDE BODY)
(QTY. 1)
FIG. 17-1A
VEHICLE BODY
SIDE RAIL
POSITIONING FLOOR PLATE
FIG. 17-1B
LOWER SUPPORT GUSSET,
1/4” THICK, ASTM-A36
GENERAL PURPOSE STEEL
8” x 8” LG. SIDES
(QTY. 2)
LOWER SUPPORT GUSSET,
1/4” THICK, ASTM-A36
GENERAL PURPOSE STEEL
8” x 16” LG. SIDES
(QTY. 2)
POSITIONING GUSSETS
FIG. 17-1C
17
STEP 1 - PREPARE VEHICLE IF REQUIRED - Continued
2. Weld Liftgate supports, as shown in
FIGS. 18-1A, -1B, -1C & -1D.
TYP. AT LH & RH
SUPPORTS
1/8”
VEHICLE BODY
SIDE RAIL
RIGHT HAND
(RH) SUPPORT
1/8”
WELDING THE SUPPORTS
FIG. 18-1D
TYP. LH &
RH TUBING
1/8”
TYP. LH & RH
FLOOR PLATES
60”
WELDING THE
FLOOR PLATES
FIG. 18-1A
LEFT HAND (LH)
SUPPORT
36”
Approx.
32”
12”
(MAX. BELOW
BED HEIGHT)
2”
1/8” 2-8
1/8”
TYP. AT LH &
RH SUPPORTS
WELDING LIFTGATE SUPPORTS
FIG. 18-1B
1/8”
TYP. AT LH & RH VERTICAL SUP-
PORTS. WELD HERE BEFORE
WELDING HORIZONTAL TUBE &
SUPPORT GUSSETS.
1/8”
TYP. AT LH & RH SUPPORT GUS-
SETS. MOUNT EACH GUSSET
FLUSH WITH OUTER EDGES OF
BODY FRAME.
1/8”
1/8”
WELDING THE GUSSETS
FIG. 18-1C
TYP. AT LH & RH
VERTICAL SUPPORTS.
WELD HERE BEFORE
WELDING HORIZONTAL
TUBE & SUPPORT
GUSSETS.
TYP. AT LH & RH
SUPPORT GUSSETS.
MOUNT EACH GUSSET
FLUSH WITH OUTER
EDGES OF BODY
FRAME.
18
STEP 2 - CHOOSE METHOD OF INSTALLATION
NOTE: MAXON recommends pre-installing the extension plate and mounting plates on the vehicle body before installing the Liftgate.
NOTE: In methods 1 and 2, the extension plate and mounting plates come separate as part of the bolt-on installation kit.
Three methods for mounting a BMR Liftgate on a vehicle body are covered in this manual.
Method 1 - Column mounting plates and extension plate can be welded to vehicle body before bolting on the Liftgate (FIG. 19-1). Refer to the PRE-INSTALL MOUNT-
ING PLATES AND EXTENSION
PLATE ON VEHICLE instructions in STEP 3.
FIG. 19-1
Method 2 - Column mounting plates and extension plate can be bolted to liftgate before welding the Liftgate to vehicle (FIG. 19-2). Refer to the PRE-INSTALL MOUNT-
ING PLATES AND EXTENSION
PLATE ON LIFTGATE instructions in STEP 3.
FIG. 19-2
Method 3 - Liftgate equipped with extension plate can be welded to vehicle body (FIG. 19-3). Refer to the
WELD LIFTGATE TO BODY
instructions in STEP 3.
FIG. 19-3
19
STEP 3 - POSITION LIFTGATE
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE
CAUTION
Some mild steel Liftgate mounting channels and extension plates are coated with a protective fi lm and shipped unpainted. The fi lm, if not removed for painting, can cause paint to separate from surface. Use hot soapy water and rinse water to remove the protective fi lm before painting.
NOTE: Before installing the mounting plates and extension plate, use hot soapy water and rinse water to remove the protective fi lm from these parts.
!
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.
1. Center the extension plate on rear of vehicle body and fl ush with top of the rear sill. Then, weld as shown in FIGS. 20-1, 20-2 and
20-3.
VEHICLE
BODY
FLUSH
CENTER
LINE
TOP OF
REAR SILL
EXTENSION
PLATE
START AT CENTER.
BOTH ENDS MUST BE
WELDED.
TOP OF
REAR SILL
1/4”
1/4”
2-5
2-5
EXTENSION
PLATE
CENTERING EXTENSION PLATE
ON 96” WIDE VEHICLE BODY
FIG. 20-1
VEHICLE
BODY
FLUSH
FLUSH EXTENSION PLATE
FIG. 20-3
START AT CENTER.
BOTH ENDS MUST BE
WELDED.
1/4”
1/4”
2-5
2-5
CENTER
LINE
TOP OF
REAR SILL
EXTENSION
PLATE
CENTERING EXTENSION PLATE
ON 102” WIDE VEHICLE BODY
FIG. 20-2
20
STEP 3 - POSITION LIFTGATE - Continued
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE - Continued
NOTE: Distance between extension plate and RH mounting bracket is measured from the inside edge of mounting plate as shown in illustration.
2. Position RH mounting plate as shown in FIGS. 21-1 and 21-1A.
TOP HANGER
RH MOUNTING
PLATE
70-1/2”
(REF)
77-3/8”
+/- 1/16”
INSIDE WALL
VEHICLE FLOOR
EXTENSION PLATE
REAR OF VEHICLE BODY
FIG. 21-1
INSIDE WALL
RH MOUNTING
PLATE
EXTENSION PLATE
3-3/16”
+1/16” / -0”
RH MOUNTING PLATE
FIG. 21-1A
21
STEP 3 - POSITION LIFTGATE - Continued
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE - Continued
NOTE: Installer can use either set of dimensions shown in FIG. 22-1 to install RH mounting plate. The fi rst set of dimensions is taken from the center of each hanger, and the second set of dimensions is taken from the inner edge of the mounting plates.
3. Position LH mounting plate on vehicle body as shown in
FIGS. 22-1, 22-1A, and 22-1B.
91-1/4” + 3/16” / - 1/16” (96” WIDE VEH)
96-1/4” + 3/16” / - 1/16” (102” WIDE VEH)
(DIMENSIONS TAKEN FROM
CENTER OF EACH TOP HANGER)
INNER EDGE INNER EDGE
TOP HANGER
LH MOUNTING
PLATE
FIG. 22-1A
TOP HANGER
TOP HANGER
87-1/4” + 3/16” / - 1/16” (96” WIDE VEH)
92-1/4” + 3/16” / - 1/16” (102” WIDE VEH)
(DIMENSIONS TAKEN FROM INNER EDGE
OF MOUNTING BRACKETS)
LH MOUNTING
BRACKET
RH MOUNTING
BRACKET
VEHICLE
BODY
EXTENSION PLATE
TOP HANGER
RH MOUNTING
PLATE
FIG. 22-1B
FIG. 22-1
22
STEP 3 - POSITION LIFTGATE - Continued
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE - Continued
NOTE: Before welding mounting plates to vehicle frame, check squareness to make sure mounting plates are perpendicular to extension plate.
4. Check to make sure mounting plates are square and perpendicular to the extension plate by measuring dimensions A and B as shown in FIG. 23-1. Squareness is acceptable when dimensions A and B are within 1/8” of each other.
5. Weld RH mounting plate onto vehicle body
(FIG. 23-1), then weld LH mounting plate onto vehicle body .
ALTERNATE
2” LG. X 10
PLACES
INBOARD &
2” LG. X 10
PLACES OUT-
BOARD OF LH
& RH
COLUMNS OR
MOUNTING
BRACKETS
1/4”
1/4”
2-10
2-10
VEHICLE
BODY
A B
1/4”
1/4”
2-10
2-10
ALTERNATE
2” LG. X 10
PLACES
INBOARD & 2”
LG. X 10 PLACES
OUTBOARD OF
LH & RH
COLUMNS OR
MOUNTING
BRACKETS
FLUSH WITH
EXTENSION
PLATE
LAST 2” WELD
TO GO TO END
OF CORNER
POST ON BOTH
SIDES
1/4”
1/4”
LH MOUNTING
BRACKET
RH MOUNTING
BRACKET
EXTENSION PLATE
1/4”
1/4”
FLUSH WITH
EXTENSION
PLATE
LAST 2” WELD
TO GO TO END
OF CORNER
POST ON
BOTH SIDES
REAR OF VEHICLE BODY
FIG. 23-1
23
STEP 3 - POSITION LIFTGATE - Continued
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE - Continued
NOTE: If mounting plates extend more than 4” below bottom of rear sill, support gussets must be installed.
NOTE: Use 4” x 5” gussets if mounting plates extend more than 4” below the rear sill of the vehicle.
NOTE: Offset gusset on mounting plate 3/8” so bolt holes stay clear (FIG.
24-1A)
LH MOUNTING
PLATE
RH MOUNTING
PLATE
6. Check distance the mounting plates extend below the rear sill of vehicle (FIGS. 24-1 and
24-1A). If the distance is 4” or greater, then weld the gussets 3/8” from the inside of the mounting plates as shown in
FIG. 24-1A.
REAR SILL
REAR OF VEHICLE BODY
FIG. 24-1
1/4”
1/4”
GUSSET
+4”
REAR SILL
MOUNTING PLATE
3/8”
WELDING GUSSET
(3-1/2” GUSSET SHOWN)
FIG. 24-1A
24
STEP 3 - POSITION LIFTGATE - Continued
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE - Continued
NOTE: If the rear of the vehicle & Liftgate mounting plates are galvanized,
• Bolts are removed from top hanger
• Bolt & cover are removed from
hanger lock
7. Check if the Liftgate mounting plates and rear of vehicle are galvanized (FIG. 25-1). If galvanized, remove 2 bolts from top hanger on the RH mounting plate (FIG. 25-1). Then, remove screw and cover from hanger lock (FIG. 25-1). Repeat for LH mounting plate.
CAP SCREW
COVER BOLTS
HANGER LOCK
LH MOUNTING
PLATE
RH MOUNTING
PLATE
25
LIFTGATE MOUNTING
PLATES
FIG. 25-1
STEP 3 - POSITION LIFTGATE - Continued
METHOD 2 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON LIFTGATE
NOTE: Save column cover hardware to reattach column cover later.
1. Remove screws, lock washers, fl at washers and column cover from LH column (FIGS. 26-1 and
26-1A). Repeat for RH top column cover.
2. Attach mounting plates to liftgate columns by inserting hangers and mounting pin through matching slots in the columns (FIGS. 26-1
and 26-1B).
LH COLUMN COVER
FLAT WASHER
(2 PLACES)
LOCK WASHER
(2 PLACES)
SCREW
(2 PLACES)
LH COLUMN
TOP HANGER
OPENING LH
COLUMN COVER
FIG. 26-1A
COLUMN
SLOTS
FIG. 26-1B
MOUNTING
PIN
26
FIG. 26-1
MOUNTING
PLATES
STEP 3 - POSITION LIFTGATE - Continued
METHOD 2 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON LIFTGATE - Continued
3. Get (2) hanger bolts from parts bag. Then look down into the top of LH column (FIGS. 27-1
and 27-1A) and locate top hanger. Repeat for RH column.
MOUNTING
PLATE
4. Insert (1) hanger bolt through top hanger in LH column (FIGS.
27-1 and 27-1B) and tighten against bolt guide until mounting plate is fl ush with column.
Repeat for RH column.
TOP HANGER
LOCATING LH TOP HANGER
FIG. 27-1A
LH COLUMN
FIG. 27-1
FLUSH HANGER BOLT,
5/8”-11 X 4-1/2” LG.
MOUNTING
PLATE
LH COLUMN
BOLT GUIDE
TOP HANGER
INSERTING CAP SCREW
INTO LH TOP HANGER
FIG. 27-1B
27
STEP 3 - POSITION LIFTGATE - Continued
METHOD 2 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON LIFTGATE - Continued
5. Get (4) cap screws, (4) fl at washers, (4) locknuts and (4) spacers from parts bag. Then, install (2) cap screws, (2) fl at washers, (2) locknuts and
(2) spacers in the LH column and extension plate (FIGS.
28-1 and 28-1A). Repeat for the RH column and extension plate.
EXTENSION PLATE
1/32” SPACER
1/16” SPACER
LH COLUMN
FIG. 28-1
CAP SCREWS,
3/8”-16 X 1-1/4” LG.
LOCK NUTS,
3/8”
FLAT WASHERS,
3/8”
FIG. 28-1A
28
STEP 3 - POSITION LIFTGATE - Continued
METHOD 2 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON LIFTGATE - Continued
!
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.
NOTE: Before welding extension plate to vehicle body, make sure:
• Inboard edge of extension plate is fl ush with the top of sill on vehicle body.
• Top surface of extension plate is level with the ground.
CAUTION
Comply with welding CAUTION decals on the LH & RH runners.
CAUTION
To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.
(APPROX.)
9”
6. Weld 2 pieces of 10” X
2” angle stock to the top surface of the extension plate near the LH column as shown in FIGS. 29-1
and 29-1A. Repeat for RH column. The angle stock helps keep extension plate fl ush with top of vehicle bed while installing Liftgate.
COLUMN
ANGLE STOCK
(NOT PROVIDED
WITH LIFTGATE)
FIG. 29-1A
29
FIG. 29-1
1” WELD
EXTENSION
PLATE
STEP 3 - POSITION LIFTGATE - Continued
METHOD 2 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON LIFTGATE - Continued
TYPICAL
CLAMPS
7. Use overhead hoist or
forklift to center Lift-
gate against the vehicle
(FIG. 30-1). Let angle
stock, welded to extension
plate, rest on the top
surface of the vehicle bed.
8. Clamp top of each column to vehicle body to prevent gap (FIG. 30-1).
CAUTION
To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.
1/4”
1/4”
ALTERNATE
2” LG. X 3
PLACES
INBOARD & 2”
LG. X 3 PLACES
OUTBOARD OF
LH & RH
COLUMNS OR
MOUNTING
BRACKETS
9. Weld the RH and LH columns to vehicle body as shown in FIG.
30-1.
NOTE: Use 4” x 5” gussets if mounting plates extend
4” or more below the rear sill of the vehicle.
WELDING LIFTGATE TO
VEHICLE
FIG. 30-1
1/4”
1/4”
NOTE: Offset gusset on mounting plate 3/8” so bolt holes stay clear (FIG.
30-1A)
10. Check the distance the mounting plates extend below the rear sill of vehicle (FIGS. 30-1 and
30-1A). If the distance is 4” or greater, weld 4” x 5” gussets to the mounting plates and vehicle body as shown in FIG. 30-1A.
11. Remove clamp from each of the columns. Then, move forklift away from work area.
+4”
REAR SILL
GUSSET
3/8”
MOUNTING
PLATE
WELDING GUSSET
(3-1/2” GUSSET SHOWN)
FIG. 30-1A
30
STEP 3 - POSITION LIFTGATE
METHOD 3 - WELD LIFTGATE TO BODY
!
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.
NOTE: Before welding extension plate to vehicle body, make sure:
• Inboard edge of extension plate is fl ush with the top of sill on vehicle body.
• Top surface of extension plate is level with the ground.
CAUTION
Comply with welding CAUTION decals on the LH & RH runners.
CAUTION
To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.
1. Weld 2 pieces of 10”
X 2” angle stock to the top surface of the extension plate near the
LH column as shown in
FIGS. 31-1 and 31-1A.
Repeat for RH column.
The angle stock helps keep extension plate fl ush with top of vehicle bed while installing
Liftgate.
COLUMN
(APPROX.)
9”
ANGLE STOCK
(NOT PROVIDED
WITH LIFTGATE)
FIG. 31-1A
31
FIG. 31-1
1” WELD
EXTENSION
PLATE
STEP 3 - POSITION LIFTGATE - Continued
METHOD 3 - WELD LIFTGATE TO BODY - Continued
TYPICAL
CLAMPS
2. Use overhead hoist or
forklift to center Lift-
gate against the vehicle
(FIG. 32-1). Let angle
stock, welded to extension
plate, rest on the top
surface of the vehicle bed.
3. Clamp top of each column to vehicle body to prevent gap (FIG. 32-1).
1/4”
1/4”
ALTERNATE
2” LG. X 3
PLACES
INBOARD & 2”
LG. X 3 PLACES
OUTBOARD OF
LH & RH
COLUMNS OR
MOUNTING
BRACKETS
CAUTION
To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.
4. Weld the RH and LH columns to vehicle body as shown in FIG.
32-1.
5. Remove clamp from each of the columns. Then, move forklift away from work area.
WELDING LIFTGATE TO
VEHICLE
FIG. 32-1
32
STEP 4 - BOLT LIFTGATE TO VEHICLE
METHOD 1 - PRE-INSTALLED MOUNTING PLATES & EXTENSION PLATE
ON VEHICLE
NOTE: Save all hardware to reattach column cover and extension plate.
1. Remove screws, lock washers, fl at washers and top column cover from LH column (FIGS. 33-1 and
33-1A). Repeat for RH top column cover.
2. Remove (2) cap screws, fl at washers, locknuts and spacers from LH column and extension plate (FIGS. 33-1 and 33-1B)
Repeat for RH column and extension plate.
LH COLUMN COVER
LH COLUMN
FLAT WASHER
(2 PLACES)
LOCK WASHER
(4 PLACES)
SCREW
(4 PLACES)
REMOVING LH TOP
COVER HARDWARE
FIG. 33-1A
LH COLUMN
RH COLUMN
LOCK NUT
1/32” SPACER
REAR VIEW OF LIFTGATE
FIG. 33-1
33
CAP SCREW
FLAT WASHER
1/16” SPACER
REMOVING LH EXTENSION
PLATE HARDWARE
FIG. 33-1B
STEP 4 - BOLT LIFTGATE TO VEHICLE
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE - Continued
HANGER
(4 PLACES)
HANGER
(4 PLACES)
!
WARNING
Do not remove forklift until after top hanger bolts are tightened as shown in FIGS. 36-1 and 36-
1A. Removing forklift before cap screws are tightened may cause liftgate to lift off the hangers when pressurizing and fall down, which can result damage to liftgate, vehicle and/or personal injury.
MOUNTING
PLATE
3. Hang liftgate on the mounting plates by inserting hangers into hanger slots
(FIGS. 34-1 and 34-2).
HANGING LIFTGATE
FIG. 34-1
HANGER SLOT
(4 PLACES)
HANGER SLOT
(4 PLACES)
34
REAR VIEW OF LIFTGATE
FIG. 34-2
STEP 4 - BOLT LIFTGATE TO VEHICLE
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE - Continued
!
WARNING
Do not remove forklift until after top hanger bolts are tightened as shown in FIGS. 36-1 and 36-
1A. Removing forklift before cap screws are tightened may cause liftgate to lift off the hangers when pressurizing and fall down, which can result damage to liftgate, vehicle and/or personal injury.
COLUMN
SLOTS
4. Slightly loosen support channel cap screws on the LH column (FIGS.
35-1 and 35-1A) to allow column slots to sit on top hangers and mounting pins (FIG. 35-1B). Repeat for RH column.
LH COLUMN
TOP HANGER
MOUNTING
PIN
FIG. 35-1B
CAP SCREW CAP SCREW
LH COLUMN
SUPPORT CHANNEL
LOOSENING LH
SUPPORT CHANNELS
FIG. 35-1A
35
FIG. 35-1
STEP 4 - BOLT LIFTGATE TO VEHICLE
METHOD 1 - PRE-INSTALL MOUNTING PLATES AND EXTENSION PLATE
ON VEHICLE - Continued
!
WARNING
Do not remove forklift until after top hanger bolts are tightened as shown in FIGS. 36-1 and 36-
1A. Removing forklift before cap screws are tightened may cause liftgate to lift off the hangers when pressurizing and fall down, which can result damage to liftgate, vehicle and/or personal injury.
MOUNTING
PLATE
TOP HANGER
LH COLUMN
5. Get (2) hanger bolts from parts bag.
Then look down into the top of LH column (FIGS. 36-1 and 36-1A) and locate top hanger.
6. Insert (1) hanger bolt through top hanger in LH column (FIGS. 36-1 and 36-1B) and tighten against bolt guide until mounting plate is fl ush with column.
Repeat for RH column.
7. Remove forklift.
LOCATING LH TOP HANGER
FIG. 36-1A
CAP SCREW
CAP SCREW
LH COLUMN
RH COLUMN
HANGER BOLT,
5/8”-11 X 4-1/2” LG.
MOUNTING
PLATE
FLUSH
LH COLUMN
BOLT GUIDE
TOP HANGER
INSERTING CAP SCREW
INTO LH TOP HANGER
FIG. 36-1B
36
FIG. 36-1
STEP 5 - REMOVE LOWER SUPPORT FIXTURES
NOTE: Use short wrenches for unbolting lower support fi xtures.
Unbolt and remove lower support fi xture from LH column (FIG. 37-1).
Repeat for lower support fi xture on
RH column (FIG. 37-1).
RH LOWER SUPPORT
FIXTURE
CAP SCREW, 1/2”-13 X 1-1/2” LG.
LOCK WASHER, 1/2”
LH LOWER SUPPORT FIXTURE
HEX SCREW,
5/8”-11 X 1-3/4” LG.
FLAT WASHER, 1/2”
LOCK NUT, 1/2”-13
HEX SCREW,
5/8”-11 X 1-3/4” LG.
LOCK WASHER, 1/2”
REMOVING LOWER SUPPORT FIXTURES
FIG. 37-1
37
STEP 6 - POSITION PUMP BOX FRAME
NOTE: Make sure pump box is closer to Liftgate than battery box (if installed) and pump
box cover opens toward curb-side of vehicle. Also, make sure hydraulic hoses are
installed without straining hoses. Distance from pump box to Liftgate is limited by
lengths of hydraulic hoses and wiring harness supplied with Liftgate.
Position pump box frame (or optional battery box) on the ground where it will be welded to vehicle body in the next step. Make sure pump box (and battery box if supplied) are securely bolted to the frame. Typical installations are shown in FIGS. 38-1, 38-2, 39-1, and
39-2.
12” - 36”
12”
PUMP BOX
10’
(Viewed from under truck.)
TYPICAL 3 FT. INSTALLATION
FIG. 38-1
12”
(Viewed from under truck.)
PUMP BOX
TYPICAL 10 FT. INSTALLATION
FIG. 38-2
38
STEP 6 - POSITION PUMP BOX FRAME - Continued
20’
12”
(Viewed from under truck.)
PUMP BOX
TYPICAL 20 FT. INSTALLATION
FIG. 39-1
20’
12”
(Viewed from under trailer.)
PUMP BOX
TYPICAL 20 FT. INSTALLATION
FIG. 39-2
39
STEP 7 - ATTACH PUMP & BATTERY BOX FRAME
TO VEHICLE
1. Use fl oor jack or equivalent lifting device to place pump and battery box frame in position on vehicle body cross members as shown in FIG. 40-1.
VEHICLE
BODY CROSS
MEMBERS
PUMP & BATTERY
BOX FRAME
TRAILER WITH PUMP & BATTERY BOX FRAME
FIG. 40-1
40
STEP 7 - ATTACH PUMP & BATTERY BOX FRAME TO
VEHICLE - Continued
2. Select holes on top of battery box frame to align mounting brackets fl ush to cross members. Refer to
FIGS. 41-1 & 41-1A for trailers and
FIG. 41-2 for trucks. Bolt mounting brackets to battery box frame as shown in FIG. 41-1B. Torque each bolt and lock nut to 85-128 lb-ft.
LOCK NUT
WASHER
MOUNTING
BRACKETS
TRAILER BODY
CROSS MEMBER
CROSS
MEMBER
WASHER
BOLTING BRACKETS
(8 PLACES)
FIG. 41-1B
CAP SCREW
PUMP & BATTERY
BOX FRAME
MOUNTING
BRACKETS
BATTERY
BOX FRAME
FLUSH BRACKETS
FOR TRAILERS
(8 PLACES)
FIG. 41-1A
ALIGNING PUMP & BATTERY
BOX FRAME
FIG. 41-1
BATTERY BOX
FRAME
TRUCK BODY
CROSS MEMBER
MOUNTING
BRACKETS
FLUSH BRACKETS FOR TRUCKS
(8 PLACES)
FIG. 41-2
41
STEP 7 - ATTACH PUMP & BATTERY BOX FRAME TO
VEHICLE - Continued
NOTE: If welding mounting brackets to cross members, skip instruction 3.
3. Using mounting brackets as a template mark and drill holes through cross members (FIG. 42-1). Bolt mounting brackets to cross members as shown in FIGS. 42-2 and
42-2A. Torque bolts and lock nuts to 85-128 lb-ft.
MOUNTING
BRACKETS
CROSS
MEMBER
1/2” HOLES
MARK AND DRILL
FIG. 42-1
WASHERS
(4 PLACES)
LOCK NUTS
(2 PLACES)
CROSS
MEMBER
CAP SCREWS
(2 PLACES)
BOLTING BRACKETS
(8 PLACES)
FIG. 42-2A
CROSS
MEMBERS
MOUNTING
BRACKETS
42
BOLTING PUMP & BATTERY
BOX FRAME
FIG. 42-2
STEP 7 - ATTACH PUMP & BATTERY BOX FRAME TO
VEHICLE - Continued
!
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 fl ame-resistant covering before welding pump box frame to vehicle.
4. Weld each bracket to cross members as shown in FIGS.
43-1 and 43-1A. Weld top of bracket if accessible.
IF ACCESSIBLE
3/16”
3/16”
BRACKET
3/16”
WELDING BRACKETS
(8 PLACES)
FIG. 43-1A
CROSS
MEMBERS
CROSS
MEMBERS
43
BOLTING PUMP & BATTERY
BOX FRAME
FIG. 43-1
STEP 7 - ATTACH PUMP & BATTERY BOX FRAME TO
VEHICLE - 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. 44-1
44
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES
!
CAUTION
Always route hydraulic hoses and electrical wiring clear of moving parts, brake lines, sharp edges and exhaust systems. Avoid making sharp bends in hoses and wiring. Make sure that bends in the electrical wiring are 1” or more away from electrical connector. Attach securely. If drilling is necessary, fi rst check behind the drilling surface so you do not damage any fuel lines, vent lines, brake lines or wires.
NOTE: The hydraulic cylinders in the Liftgate are fi lled with hydraulic fl uid and bled at the factory. To keep air out of the hydraulic system, follow instructions carefully for installing hydraulic system components.
NOTE: The fold and unfold hydraulic hoses are the same. To avoid confusion when running hoses through the channel, MAXON recommends taping both ends of one of the hoses for easy identifi cation.
1. Get hydraulic hoses, hydraulic tee, channel guard (if required) and plastic ties from parts
box and pump box installation kit. Run hydraulic hoses from LH and RH columns to
pump box. Connect hydraulic hoses as shown in FIG. 46-1 and TABLE 47-1 for Gravity
Down Liftgate or FIG. 48-1 and TABLE 49-1 for Power Down Liftgate.
2. Get molded extension cable from pump box installation kit. Run the molded extension cable from RH column to pump box as shown in FIG. 50-1.
3. If channel guard is required, bolt up one side of the channel (FIGS. 46-1, 48-1 and 50-
1) to vehicle body. Leave bolts loose until all hydraulic hoses (FIGS. 46-1 and 48-1) and wiring harness (FIG. 50-1) are run through channel. After hoses and wiring harness are run, bolt up second side of channel and tighten all bolts and nuts. Use plastic ties to secure runs of hydraulic hoses and wiring harness that are outside of channel guard.
45
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES
- Continued
RUN GRAVITY DOWN HYDRAULIC LINES
NOTE: See TABLE 47-1 for information on the numbered hoses in this illustration.
CAUTION
Before connecting hoses, ensure face seal o-rings are in place.
RH
LH
CHANNEL
GUARD
VEHICLE
(BOTTOM VIEW)
LIFTING
LINE
6
RETURN LINE
(TO PUMP RESERVOIR)
RETURN
LINE
LH COLUMN
5
3
3
2
TEE
1
RETURN
LINE
LIFTING
LINE
4
RH COLUMN
NOTE: Lifting & folding hoses run up from column connectors, as shown, to bottom of vehicle fl oor.
LIFTING
LINE
FIG. 46-1
46
1
2
5
6
3
4
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES
- Continued
RUN GRAVITY DOWN HYDRAULIC LINES
GRAVITY DOWN PUMP BOX INSTALLATION: REQUIRED HOSES & PLASTIC TUBING
3 FT.
10 FT.
15 FT.
20 FT.
HP 3/8” X 64” LG.
HP 3/8” X 64” LG.
HP 1/4” X 56” LG.
HP 3/8” X 196” LG.
PLASTIC 3/8” OD X
192” LG.
HP 1/4” X 188” LG.
HP 3/8” X 256” LG.
PLASTIC 3/8” OD X
192” LG.
HP 1/4” X 248” LG.
PLASTIC 3/8” OD X 24” LG.
HP 3/8” X 316” LG.
PLASTIC 3/8” OD X
324” LG.
HP 1/4” X 308” LG..
HP 3/8” X 142” LG.
PLASTIC 3/8” OD X 108” LG.
HP 3/8” X 274” LG.
HP 3/8” X 334” LG.
HP 3/8” X 394” LG.
TABLE 47-1
47
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES
- Continued
RUN POWER DOWN HYDRAULIC LINES
NOTE: See TABLE 49-1 for information on the numbered hoses in this illustration.
CAUTION
Before connecting hoses, ensure face seal o-rings are in place.
RH
LIFTING
LINE
LH
6
5
CHANNEL
GUARD
VEHICLE
(BOTTOM VIEW)
POWER DOWN
LINE
LH COLUMN
HYDRAULIC
TEE
3
1
1
4 2
POWER
DOWN LINE
RH COLUMN
LIFTING
LINE
NOTE: Lifting & folding hoses run up from column connectors, as shown, to bottom of vehicle fl oor.
LIFTING LINE
POWER DOWN
LINE
FIG. 48-1
48
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES
- Continued
RUN HYDRAULIC LINES
3
4
1
2
5
6
3 FT.
POWER DOWN PUMP BOX INSTALLATION: REQUIRED HOSES
10 FT.
15 FT.
HP 1/4” X 56” LG.
HP 1/4” X 188” LG.
HP 1/4” X 248” LG.
20 FT.
HP 1/4” X 308” LG.
HP 1/4” X 34” LG.
HP 3/8” X 64” LG.
HP 1/4” X 24” LG.
HP 1/4” X 166” LG.
HP 1/4” X 226” LG.
HP 3/8” X 196” LG.
HP 3/8” X 256” LG.
HP 1/4” X 100” LG.
HP 1/4” X 286” LG.
HP 3/8” X 316” LG.
HP 3/8” X 142” LG.
HP 3/8” X 274” LG.
HP 3/8” X 334” LG.
HP 3/8” X 394” LG.
TABLE 49-1
49
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES
- Continued
RUN ELECTRIC CABLES
RH
CHANNEL
GUARD
LH
VEHICLE
(BOTTOM VIEW)
LH TAILLIGHT CONNECTORS
(TO VEHICLE WIRING HARNESS)
MOLDED
EXTENSION
CABLE
(6’, 15’, 23’, OR
31’ LG.)
PUMP
BOX
ELECTRICAL
CONNECTOR
LH COLUMN
MOLDED
D-VALVE
CABLE
RH TAILLIGHT CONNECTORS
(TO VEHICLE WIRING HARNESS)
D-VALVE CABLE
CONNECTOR
CONTROL
SWITCH CABLE
CONNECTOR
RH COLUMN
FIG. 50-1
50
NOTE: Go to next page for more information about connecting
& disconnecting twist-lock connectors.
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES
- Continued
WIRING HARNESS TWIST-LOCK CONNECTORS
CAUTION
Before connecting, ensure connectors are clean inside. Ensure there is a thin coating of dielectric grease on face of receptacle, and there is no dielectric grease on connector contacts.
Refer to illustrations below for disconnecting, checking for dielectric grease, and reconnecting twist-lock style connectors.
TWIST COUPLING
RING TO UNLOCK
FIG. 51-1
PULL COUPLING RING
TO DISENGAGE
FIG. 51-2
PULL CONNECTORS
TO DISCONNECT
FIG. 51-3
ENSURE THERE IS A THIN COAT-
ING OF DIELECTRIC GREASE
ON THIS SHADED AREA
ALIGN
MARKS
DIELECTRIC GREASE
ON RECEPTACLE
FIG. 51-4
ALIGN & CONNECT
FIG. 51-5
51
TWIST TO LOCK
FIG. 51-6
STEP 9 - CONNECT GROUND CABLE
GROUNDING TO TRUCK FRAME
NOTE: Make sure the Liftgate power unit, all batteries on the vehicle for power unit,
and taillights on Liftgate are connected correctly to a common ground.
1. Bolt ground cable to the ground stud on pump box (FIG. 52-1).
NOTE: If there is an existing grounding point on truck frame, use it to connect
ground cable and skip the step for drilling a hole.
2. Extend the ground cable to reach vehicle frame (FIG. 52-1B) without putting tension on cable (after connection). Connect to an existing grounding point if available.
3. If necessary, drill a 11/32” (0.343”) hole in vehicle frame for bolting the ground cable terminal lug (FIG. 52-1B).
NOTE: Clean the ground cable connection point on the frame down to bare metal.
NOTE: MAXON recommends using dielectric grease on all electrical connections.
4. Bolt the ground cable terminal lug to vehicle frame as shown in FIG. 52-1B.
PUMP
BOX
GROUND
STUD
NUT
FLAT
WASHER
GROUND
CABLE
FIG. 52-1
VEHICLE CHASSIS
(TRUCK FRAME SHOWN)
TERMINAL LUG
(GROUND CABLE)
5/16” FLAT
WASHER
LOCK
NUT
FIG. 52-1A
BARE
METAL
52
5/16"-18 X 1" LG.
CAP SCREW
FIG. 52-1B
STEP 9 - CONNECT GROUND CABLE - Continued
GROUNDING TO BATTERY BOX (IF EQUIPPED)
NOTE: Make sure the Liftgate power unit, battery box and batteries, taillights on
Liftgate, and vehicle charging system are connected correctly to a common
ground. For trailers, if possible, use 2-pole charge line to connect charging
system on tractor to the Liftgate batteries.
1. Attach ground cable to ground stud outside the pump box (FIG. 53-1). Tighten nut.
GROUND
CABLE
FLAT
WASHER
GROUND
STUD
LOCK
NUT
GROUND
CABLE
BATTERY
GROUND
STUD
GROMMET
NUT
PUMP
BOX
FIG. 53-1
2. Route ground cable behind pump box to the grommet on the side wall of battery box (FIG. 53-1).
Then, pull ground cable through grommet to the battery ground stud (FIG. 53-1).
BATTERY
BOX
NOTE: Ensure battery box is connected by cable to common ground on vehicle.
3. Attach ground cable to battery ground stud (FIG.
53-1). Tighten lock nut.
53
STEP 10 - RUN CHARGE LINES
!
CAUTION
Never route an energized wire. Make sure 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, fi rst check behind the drilling surface so you do not damage any fuel lines, vent lines, brake lines or wires.
VEHICLE
FRAME
NOTE: Make sure cable is long enough to reach master disconnect switch on Liftgate pump box (or circuit breaker in optional battery box, if installed) without putting tension on the cable.
CHARGE LINE TO
PUMP BOX OR
BATTERY BOX
FRONT OF VEHICLE
REAR OF VEHICLE
FRAME
CLIPS
18” - 24”
SPACING
200 AMP
FUSE
FIG. 54-1
CHARGE LINE
TO VEHICLE
BATTERY
1. Install vehicle charge line by running the line along the inside of vehicle frame (FIG. 54-1).
Make sure 200 amp fuse (FIG. 54-1) end of cable is by the vehicle battery. Run the charge line from vehicle battery to Liftgate pump box master disconnect switch (FIG. 54-2) or 150 amp circuit breaker in optional battery box
(FIG. 54-3), if installed. Use frame clips (parts box item) and plastic ties (as required) from charge line kit to secure cable.
FIG. 54-2
MASTER
DISCONNECT
SWITCH
2. If Liftgate comes with:
150 AMP
CIRCUIT
BREAKER
• Single Pole Tractor Charge Line Kit
• Single Pole Trailer Charge Line Kit
• Dual Pole Tractor Charge Line Kit
• Dual Pole Trailer Charge Line Kit
Install charge line according to
Instruction Sheet contained in each kit.
FIG. 54-3
54
STEP 10 - RUN CHARGE LINES - Continued
3. Bolt 200 amp circuit breaker (Parts Box item) to pump box (FIG. 55-1).
LOCK NUTS
(2 PLACES)
1/4” FLAT WASHERS
(4 PLACES)
1/4”-20 SCREWS
(2 PLACES)
200 AMP CIRCUIT
BREAKER
BATTERY BOX
FIG. 55-1
55
STEP 10 - RUN CHARGE LINES - Continued
4. Get cable (parts box) and connect to 200 amp circuit breaker as shown in FIGS. 56-1 and
56-1A.
FIG. 56-1
200 AMP
CIRCUIT
BREAKER
2 GA RED CABLE
FIG. 56-1A
56
STEP 10 - RUN CHARGE LINES - Continued
5. Route red cable as shown in FIGS.
57-1 and 57-1B.
6. Connect red cable to master disconnect switch FIG. 57-1A.
MASTER
DISCONNECT
SWITCH
RED CABLE
FIG. 57-1A
RED CABLE
REAR VIEW
57-1B
RED CABLE
FIG. 57-1
57
STEP 11 - CONNECT BATTERIES TO LIFTGATE
!
WARNING
To prevent injury and equipment damage, make sure (-) battery cable is disconnected and master disconnect switch is in the OFF position before connecting vehicle charge lines or power cables.
NOTE: For recommended 6 volt and 12 volt battery connections, refer to the
RECOMMENDED LIFTGATE POWER CONFIGURATION section in this manual.
1. Disconnect (-) battery cable
(FIG. 58-1) from battery.
(-) BATTERY
CABLE
GROUND CABLE
TO PUMP BOX (REF)
150 AMP
CIRCUIT
BREAKER
CHARGE LINE
FROM
VEHICLE BATTERY
(+) POWER CABLE
TO PUMP BOX
2. If optional battery box is installed, connect vehicle charge line to unconnected terminal on master disconnect switch
(FIGS. 58-2 and 58-2A).
200 AMP CIRCUIT
BREAKER
10” RED CABLE
BATTERY BOX
FIG. 58-1
MASTER
DISCONNECT
SWITCH
NOTE: After battery cables are connected, ensure pump box cover and battery box cover
(if equipped) are closed.
3. If optional battery box (FIG. 58-1) is installed, connect 10” red cable (Parts
Box item) between 200 amp circuit breaker and battery (+) terminal (FIG.
58-1). Next, connect (+) power cable between 200 amp circuit breaker in battery box and master switch in the pump box (FIG. 58-2). Then, connect vehicle charge line to 150 amp circuit breaker in battery box (FIG. 58-1).
PUMP BOX
FIG. 58-2
FIG. 58-2A
MASTER
DISCONNECT
SWITCH
58
STEP 12 - ADD HYDRAULIC FLUID TO RESERVOIR
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
1. Open pump box cover (FIG. 59-1).
FILLER CAP
FIG. 59-1A
2. Remove the fi ller cap (FIGS. 59-1
AND 59-1A). Add 7 quarts of
Exxon Univis HVI-13 hydraulic fl uid to pump reservoir until fl uid level reaches the full line.
3. Reinstall the fi ller cap (FIG. 59-1).
PUMP BOX SHOWN WITH SINGLE PUMP
FIG. 59-1
59
STEP 13 - PRESSURIZE HYDRAULIC SYSTEM
!
WARNING
To prevent injury and equipment damage, pressurize hydraulic system before removing lower support fi xtures and operating Liftgate.
NOTE: Before operating liftgate, read and understand the operating instructions in the Operation Manual.
1. To pressurize lifting cylinders, set control box toggle switch to UP for 10-15 seconds as shown in FIG. 60-1.
UP
PRESSURIZING LIFTING CYLINDERS
FIG. 60-1
2. To pressurize closing cylinder, set control box toggle switches to FOLD for 10-15 seconds as shown in FIG. 60-2.
FOLD
PRESSURIZING CLOSING CYLINDER
FIG. 60-2
NOTE: Liftgate is shipped with Exxon Univis HVI-13 hydraulic fl uid in the hydraulic cylinders. This fl uid is suitable for operation in temperature range of -40° F
to +120° F. If necessary, a different brand or higher viscosity hydraulic fl uid may be used. Refer to the CHANGING HYDRAULIC FLUID procedure in the
BMR Maintenance Manual.
60
STEP 14 - OPTIMIZE HYDRAULIC FLUID LEVEL
NOTE: If equipped, select power down on demand for optimizing hydraulic fl uid level (FIG. 61-1).
1. Lower (DOWN) the platform about 6” using toggle switch settings shown in FIG. 61-1.
POWER DOWN
ON DEMAND
2. Open (UNFOLD) the platform by setting toggle switches as shown in FIG. 61-2.
LOWERING PLATFORM
FIG. 61-1
DOWN
UNFOLDING PLATFORM
FIG. 61-2
61
UNFOLD
STEP 14 - OPTIMIZE HYDRAULIC FLUID LEVEL -
Continued
3. Close (FOLD) the platform by setting toggle switches as shown in FIG.
62-1. Then, open (UNFOLD) the platform by setting toggle switches as shown in FIG. 62-2.
FOLDING PLATFORM
FIG. 62-1
FOLD
62
UNFOLDING PLATFORM
FIG. 62-2
UNFOLD
STEP 14 - OPTIMIZE HYDRAULIC FLUID LEVEL -
Continued
4. Lower (DOWN) the platform to 10” above ground level using the toggle switch settings shown in FIG. 63-1.
DOWN
10”
5. Raise (UP) the platform to about
6” below bed height using toggle switch setting shown in FIG.
63-2.
GROUND
LOWERING PLATFORM
FIG. 63-1
63
RAISING PLATFORM
FIG. 63-2
UP
STEP 14 - OPTIMIZE HYDRAULIC FLUID LEVEL -
Continued
6. Close (FOLD) the platform by setting toggle switches as shown in FIG.
64-1.
7. Raise (UP) the runners to stow platform by setting toggle switches as shown in FIG. 64-2.
FOLDING PLATFORM
FIG. 64-1
FOLD
64
RAISING PLATFORM
FIG. 64-2
UP
STEP 14 - OPTIMIZE HYDRAULIC FLUID LEVEL -
Continued
NOTE: Information for checking hydraulic fl uid level is shown on a decal on the pump reservoir.
8. Check if hydraulic fl uid level is at the full line (FIG. 65-1). If necessary, remove fi ller cap (FIG. 65-1) and add hydraulic fl uid until level rises to the full line (FIG. 65-1). Then, reinstall fi ller cap (FIG. 65-1).
FILLER
CAP
CHECKING HYDRAULIC FLUID LEVEL
FIG. 65-1
65
STEP 15 - CHECK MOUNTING BRACKET FIT
1. To check for interference between mounting bracket and stop block
(FIG. 66-1A), lower columns to approximately 10” above the ground, then begin to unfold platform (FIG. 66-1).
2. As platform is unfolding, check for interference from the mounting bracket as it slides into the stop block (FIG. 66-1A).
MOUNTING
BRACKET
STOP
BLOCK
APPROX. 10”
FIG. 66-1
INTERFERENCE
66
REAR VIEW OF LH RUNNER
FIG. 66-1A
STEP 15 - CHECK MOUNTING BRACKET FIT - Continued
NOTE: Perform this step only if folding operation is not smooth or there is interference (FIG. 67-1B).
3. If LH mounting bracket fi ts too tight against either side of stop block, operation is not smooth, or if there is interference (FIG. 67-1A) adjust with spacers as shown in FIG.
67-1A.
4. To adjust stop block, make sure platform is lowered to the ground
(FIG. 67-1). Then, loosen (4) bolts
(FIGS. 67-1A and 62-1B) and check gap (FIG. 67-1A). Add or remove shims (parts box) to fi ll or lessen the gap, then retighten bolts
(FIGS. 67-1A and 62-1B).
BOLTS
FIG. 67-1
STOP
BLOCK
GAP
1/16” SPACER
1/32” SPACER
FRONT VIEW OF LH RUNNER
FIG. 67-1B
67
BOLTS
STOP
BLOCK
MOUNTING BRACKET
REAR VIEW OF LH RUNNER
FIG. 67-1A
STEP 16 - REMOVE UPPER SUPPORT FIXTURES
!
CAUTION
Upper support fi xtures are heavy. To prevent injury to installer and damage to
Liftgate, use forklift or hoist to hold support fi xtures during removal.
1. Stow the platform as shown in
FIG. 68-1.
2. Position forklift or hoist to hold upper support fi xtures as shown in FIG. 68-1.
3. Unbolt the 2 upper support fi xtures from the LH column (FIGS.
68-1 and 68-1A). Repeat for RH column. Use forklift to remove upper support fi xtures from work area.
UPPER SUPPORT
FIXTURES
FIG. 68-1
LH COLUMN
FIG. 68-1A
68
STEP 17 - SECURING COLUMNS
METHOD 1 AND METHOD 2
NOTE: Skip this step if using the Method 3 weld on version of installation with no mounting plates.
1. Slightly lower and open platform for access to mounting pin.
2. Get (2) lock plates and (2) 1”-8 lock nuts from parts bag. Then, install
(1) lock plate and (1) lock nut to top rear guide on the mounting plate on the LH column (FIGS. 69-1 and
69-1A). Torque lock nut to 200 lb.-
ft. Repeat for RH column.
MOUNTING PLATE
LOCK PLATE
LOCK
NUT
LH COLUMN
MOUNTING PIN
INSTALLING LOCK PLATE
FIG. 69-1A
FIG. 69-1
69
STEP 17 - SECURING COLUMNS - Continued
METHOD 1 AND METHOD 2
NOTE: Skip this step if using the Method 3 weld on version of installation with no mounting plates.
3. Tighten cap screw against bolt guide in the LH column as shown in (FIGS. 70-1 and 70-1A) and torque to 170 lb.-ft. Repeat for RH column.
CAP SCREW
MOUNTING
PLATE
TOP HANGER
LH COLUMN
BOLT GUIDE
TIGHTENING CAP SCREW
FIG. 70-1A
FIG. 70-1
70
STEP 17 - SECURING COLUMNS - Continued
METHOD 1 AND METHOD 2
NOTE: Skip this step if using the Method 3 weld on version of installation with no mounting plates.
NOTE: MAXON recommends using the upper bolt hole
(FIG. 71-1A) to attach mounting plate. However, if the upper hole will be covered by vehicle corner post, then use the lower bolt hole (FIG.
71-1B).
4. Get (2) fl ange hex bolts, (2) fl ange lock nuts (if needed), and (2) fl at washers (if needed) from parts bag. Then, install (1) bolt, (1) nut (if needed), and (1) fl at washer
(if needed) through mounting plate and RH column (FIGS.
71-1, 71-1A and 24-1B) Repeat for LH column.
MOUNTING
PLATE
FIG. 71-1
5. Torque to 170 lb.-ft. Repeat for LH column.
RH COLUMN
FLANGE HEX
BOLT, 5/8”-11 X
1-3/4” LG.
UPPER BOLT HOLE
FIG. 71-1A
OR
FLANGE HEX
BOLT, 5/8”-11 X
1-3/4” LG.
RH COLUMN
FLANGE LOCK
NUT, 5/8-11”
LOWER BOLT HOLE
FIG. 71-1B
FLAT
WASHER, 5/8”
71
STEP 17 - SECURING COLUMNS - Continued
METHOD 1 AND METHOD 2
NOTE: Skip this step if using the Method 1 weld on version of installation with no mounting plates, or Method 3 version where the extension plate was already installed.
NOTE: Only use spacers if necessary.
6. Lower platform to access extension plate
(FIG. 72-1).
7. Get the (4) cap screws, fl at washers, locknuts and spacers that were removed in STEP 4. Then, reinstall (2) cap screws, fl at washers, locknuts and spacers in the LH column and extension plate
(FIGS. 72-1 and 72-1A). Repeat for the
RH column and extension plate.
FLAT WASHER
LOWERING LIFTGATE
FIG. 72-1
EXTENSION PLATE
CAP SCREW
1/16” SPACER
LH COLUMN
1/32” SPACER
REINSTALLING HARDWARE
FIG. 72-1A
72
STEP 17 - SECURING COLUMNS - Continued
METHOD 1 AND METHOD 2
NOTE: Skip this step if using the Method 3 weld on version of installation with no mounting plates.
8. Reinstall RH top column cover, screws, lock washers and fl at washers (FIGS. 73-1 and 73-1A).
Tighten screws, then repeat for LH top column cover.
LH COLUMN COVER
RH COLUMN
LH COLUMN
FIG. 73-1
RH COLUMN COVER
SCREW
(4 PLACES)
LOCK WASHER
(4 PLACES)
RH COLUMN
FLAT WASHER
(4 PLACES)
REINSTALLING RH COLUMN COVER
FIG. 73-1A
73
STEP 18 - FINISH WELDING LIFTGATE TO VEHICLE
METHOD 3 - WELD LIFTGATE TO BODY
NOTE: Skip this step if using Method 1 or Method 2 versions of installation where mounting plates and extension plate are preinstalled on the liftgate or vehicle.
1. Disconnect power from pump by removing nut from negative (-) battery terminal and disconnect negative
(-) battery cable (FIG. 74-1). Reinstall nut on negative (-) battery terminal.
NUT
NEGATIVE (-)
BATTERY TERMINAL
NEGATIVE (-)
BATTERY CABLE
DISCONNECTING POWER
FIG. 74-1
74
STEP 18 - FINISH WELDING LIFTGATE TO VEHICLE
METHOD 3 - WELD LIFTGATE TO BODY - Continued
!
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.
NOTE: Refer to INSTALLED LIFTGATE in the VEHICLE REQUIREMENTS section of this manual.
NOTE: If Liftgate columns cannot be mounted fl ush against rear of vehicle, a fi ller such as tubing, channel, or plate stock may be used to bridge gap between vehicle body and Liftgate columns. Make sure the added materials and welds meet the BODY STRENGTH REQUIREMENTS indicated in this manual.
CAUTION
To prevent damage to Liftgate, connect welder ground to vehicle body.
2. Cover platform as shown in FIG. 75-1.
3. Weld the Liftgate RH
and LH columns to
vehicle body as shown
in FIG. 75-1.
NOTE: Use 4” x 5” gussets if columns extend 4” or more below the rear sill of the vehicle.
NOTE: Offset gusset on mounting plate 3/8” so bolt holes stay clear (FIG. 75-1A)
4. Check the distance the columns extend below the rear sill of vehicle (FIGS. 75-1 and 75-1A). If the distance is 4” or greater, weld
4” x 5” gussets to the columns and vehicle body as shown in FIG.
75-1A.
FIG. 75-1
1/4”
1/4”
COLUMN
+4”
1/4”
ALTERNATE
2” LG. X 7
PLACES
INBOARD
& 2” LG. X
7 PLACES
OUTBOARD
OF LH & RH
COLUMNS
REAR SILL
GUSSET
3/8”
WELDING GUSSET
(3-1/2” GUSSET SHOWN)
FIG. 75-1A
75
STEP 18 - FINISH WELDING LIFTGATE TO VEHICLE
METHOD 3 - WELD LIFTGATE TO BODY - Continued
CAUTION
To prevent damage to Liftgate components, welder ground must be connected to Liftgate extension plate.
5. Make sure platform is at ground level to provide access to the extension plate.
NOTE: After welding top of extension plate, if you see a gap between bottom of extension plate & vehicle body sill, fi ll the gap. To fi ll the gap, use A-36
General Purpose steel and the same welds shown in FIG.
76-2.
6. Weld the top and bottom surfaces of extension plate (FIGS. 76-1 &
76-2) to vehicle body sill with 2” long welds centered every 8”.
7. Weld entire length (FIG. 76-2) on the bottom of LH and RH end blocks.
FULL LENGTH OF
END BLOCK
1/8”
1/8”
2” LG, CENTERED
EVERY 8”
TYPICAL -
9 WELDS FOR 96”
WIDE &
10 WELDS FOR 102”
WIDE LIFTGATE
WELDING TOP OF EXTENSION PLATE
FIG. 76-1
RH END
BLOCK
LH END
BLOCK
2” LG, CENTERED EVERY 8”
TYPICAL-
9 WELDS FOR 96” WIDE &
10 WELDS FOR 102” WIDE
LIFTGATE
1/8”
WELDING BOTTOM OF EXTENSION PLATE
FIG. 76-2
76
STEP 18 - FINISH WELDING LIFTGATE TO VEHICLE
METHOD 3 - WELD LIFTGATE TO BODY - Continued
8. Reconnect negative (-) battery cable to negative (-) battery terminal (FIG. 77-3). Then, reinstall nut on negative (-) battery terminal (FIG. 77-3).
NUT
NEGATIVE (-)
BATTERY TERMINAL
NEGATIVE (-)
BATTERY CABLE
RECONNECTED BATTERY CABLES
FIG. 77-3
77
STEP 19 - PLATFORM CHAIN ADJUSTMENT
1. Lower the platform to ground level.
Check if tip of the fl ipover and bottom of the runners touch the ground at the same time (FIG. 78-1).
2. If the bottom of the runners are off the ground, measure the distance “H1”
(FIG. 78-2) from the ground to the bottom of the runners.
• Adjustment is not required if
distance “H1” is 1” or less.
TIP OF
PLATFORM
GROUND
BOTTOM OF
RUNNER
TIP AND RUNNER TOUCHING GROUND
FIG. 78-1
to the steps that follow to adjust the
platform chains.
3. Refer to measured distance “H1” at the runners and TABLE 78-1. Note the method(s) that will be required to raise the tip of platform
(or retention ramp) the expected distance.
”H1”
”H2”
BOTTOM OF
RUNNER
GROUND
RUNNERS NOT TOUCHING
FIG. 78-2
EXPECTED RISE
“H2” (AT TIP)
MEASURED “H1”
(AT RUNNER)
1” - 2-1/4”
ADJUSTMENT METHODS
(
•
REQUIRED FOR EXPECTED RISE AT TIP)
REMOVE 1 LINK REMOVE 2 LINKS
OF BOTH CHAINS
(RAISES TIP 1-1/2”)
OF BOTH CHAINS
(RAISES TIP 3”)
-
2-1/2” - 3-3/4”
4”
•
•
•
-
TABLE 78-1
78
0” - 1-1/4”
1-1/2” - 2-3/4”
3” - 4”
STEP 19 - PLATFORM CHAIN ADJUSTMENT -
Continued
4. Raise platform enough to remove supports. Then, lower platform to the ground (FIG. 79-1). Tip of fl ipover and runners should touch the ground at the same time as shown in FIG.
79-1. If necessary, repeat instructions 3 and 4 until tip of platform and runners touch ground at the same time.
TIP OF
FLIPOVER
GROUND
BOTTOM OF
RUNNER
TIP AND RUNNER TOUCHING GROUND
FIG. 79-1
79
STEP 20 - PLACE “ALIGN ARROWS” DECAL
NOTE: Make sure RUNNERS are raised all the way up (closest to top of COLUMN) before doing the following steps.
1. Peel backing from alignment tape and place it
on LH column as shown in FIG. 80-1. Repeat for
RH column.
RUNNER
ALIGNMENT
ARROW
LH COLUMN
6”
3”
ALIGNMENT
TAPE
FIG. 80-1
80
STEP 21 - ADJUST PLATFORM ASSEMBLY
1. Ensure aluminum platform is completely unfolded (FIG. 81-1). Use long straight edge to determine if top surface of platform is fl ush with top surface of fl ipover as shown in FIG. 81-1.
NOTE: Recommend turning bolt in
60° increments so fl ats of the adjuster bolt are parallel to vertical surface of side plates.
2. If fl ipover requires adjustment, fold platform enough to gain access to adjustment bolt on each side of platform (FIG. 81-2). Next, loosen locking nut for each adjuster bolt
(FIG. 81-2). Then, alternately turn each bolt clockwise to raise tip of fl ipover or counter-clockwise to lower tip of fl ipover. Repeat 1 to check. When platform and fl ipover are fl ush, torque both locking nuts to 192 lb-ft.
ARROWS INDICATE WHERE TO CHECK
IF PLATFORM & FLIPOVER ARE FLUSH
FIG. 81-1
NORD-LOCK
WASHERS
LOCKING
NUT
ADJUSTER
BOLT FLAT
(SEE NOTE)
SIDE
PLATE
81
PLATFORM ADJUSTMENT BOLT
FIG. 81-2
STEP 22 - ACTIVATE PLATFORM LIGHTS
1. Activate the fl ashing platform lights by cutting the wire from the center of the link wire on both RH and LH fl ashing lights
(FIG. 82-1).
LINK WIRE
CUT HERE
2. Fold platform. Lights should stop fl ashing.
ACTIVATING PLATFORM LIGHTS
FIG. 82-1
82
ATTACH DECALS
NOTE: Ensure there is no residue, dirt, or corrosion where decals are attached. If necessary, clean surface before attaching decals.
NOTE: Preferred decal layout is shown. De-
cals on the Liftgate are attached at the
factory. If vehicle does not permit this
layout, decals in the manual and de-
cal kit must be applied so that they are
easily visible when approaching vehi-
cle to operate Liftgate. Use good com-
mon sense when locating these decals
on vehicle.
STOW WARNING DECAL
P/N 282847-01
YELLOW
ALIGNMENT TAPE
P/N 090175-15
DECAL “C”
DECAL “D”
DECAL “B”
DECAL “A”
SERIAL PLATE
FAMILY OWNED DECAL
P/N 283445-01
PAINT DECAL
P/N 267338-01
DECAL “E”
CAUTION DECAL
(2 PLACES)
P/N 260552
FAMILY OWNED DECAL
(2 PLACES)
P/N 283445-01
WARNING DECAL
P/N 288966-01
83
FIG. 83-1
PAINT DECAL
(2 PLACES)
P/N 267338-01
DECALS - Continued
(REFER TO TABLE 84-1)
DECAL SHEET
FIG. 84-1
MODEL ORDER P/N
BMRB-35 289163-01
BMRB-44 289163-02
BMRB-55 289163-03
BMRB-66 289163-04
DECAL “C”
3500 LBS. [1600 KG]
4400 LBS. [2000 KG]
5500 LBS. [2500 KG]
6600 LBS. [3000 KG]
DECAL SHEET PART NUMBERS
TABLE 84-1
84
TOUCH UP PAINTED OR GALVANIZED FINISH
CAUTION
Damaged cylinder seals and contaminated hydraulic fl uid 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 touch up paint kit, P/N 908134-01.
• If bare metal is exposed on galvanized portions of the Liftgate, touch up the galvanized fi nish. To maintain the protection provided by the original galvanized fi nish, MAXON recommends cold galvanize spray, P/N 908000-01.
85
OPTIONS
RECOMMENDED LIFTGATE POWER CONFIGURATION
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 battery box are typically installed on trailers as shown in FIG. 86-1.
TRACTOR BATTERIES,
TYPICAL LOCATION
200 AMP
FUSED CABLE
MASTER
DISCONNECT
SWITCH
POWER
CABLE
LIFTGATE
LIFTGATE
PUMP BOX
200 AMP
150 AMP
CIRCUIT
CIRCUIT
BREAKER
BREAKER
BATTERY BOX,
TYPICAL LOCATION
RECOMMENDED LIFTGATE & BATTERY BOX
INSTALLATION ON TRAILER
FIG. 86-1
86
OPTIONS
RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued
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.
2. Liftgate, pump box, and optional battery box are typically installed on trucks as shown in FIG.
87-1 and FIG. 87-2 . See the following page for battery and cable connections.
MASTER
DISCONNECT
SWITCH
POWER
CABLE
200 AMP
FUSED CABLE
TRUCK BATTERIES,
TYPICAL LOCATION
LIFTGATE
LIFTGATE
PUMP BOX
200 AMP
CIRCUIT
BREAKER
150 AMP
CIRCUIT
BREAKER
OPTIONAL
BATTERY BOX,
TYPICAL LOCATION
RECOMMENDED LIFTGATE & BATTERY BOX
INSTALLATION ON TRUCK
FIG. 87-1
MASTER
DISCONNECT
SWITCH
POWER
CABLE
200 AMP
CIRCUIT
BREAKER
TRUCK BATTERIES,
TYPICAL LOCATION
LIFTGATE
LIFTGATE
PUMP BOX
RECOMMENDED LIFTGATE
INSTALLATION ON TRUCK
FIG. 87-2
87
HYDRAULIC SYSTEM DIAGRAMS
PUMP & MOTOR SOLENOID OPERATION - POWER DOWN
“H” VALVE
“E” VALVE
“M” SOLENOID
“C” VALVE
FIG. 88-1
“D” VALVE
“B” VALVE
“D” VALVES
(TOP OF EACH COLUMN)
FIG. 88-2
POWER UNIT MOTOR & SOLENOID OPERATION - POWER DOWN
SOLENOID OPERATION ( MEANS ENERGIZED)
LIFTGATE
FUNCTION
PORT
SWITCH RELAY MOTOR
VALVE
“B”
VALVE
“C”
VALVE
“D”
VALVE
“E”
VALVE
“H”
LIFT B -
LOWER
OPEN
CLOSE
C
J
“PD”
-
-
-
A -
REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC
TABLE 88-1
88
HYDRAULIC SYSTEM DIAGRAMS
PUMP & MOTOR SOLENOID OPERATION - GRAVITY DOWN
“H” VALVE
“E” VALVE
“M” SOLENOID
FIG. 89-1
“D” VALVE
“B” VALVE
“D” VALVES
(TOP OF EACH COLUMN)
FIG. 89-2
POWER UNIT MOTOR & SOLENOID OPERATION - GRAVITY DOWN
SOLENOID OPERATION ( MEANS ENERGIZED)
LIFTGATE
FUNCTION
PORT
SWITCH RELAY MOTOR
VALVE
“B”
VALVE
“C”
VALVE
“D”
VALVE
“E”
VALVE
“H”
LIFT B -
LOWER C -
“GD”
OPEN J -
CLOSE A -
REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC
TABLE 89-1
-
89
DUAL PUMP
HYDRAULIC SYSTEM DIAGRAMS
GRAVITY DOWN HYDRAULIC SCHEMATIC
FIG. 90-1
90
DUAL PUMP
HYDRAULIC SYSTEM DIAGRAMS
POWER DOWN HYDRAULIC SCHEMATIC
FIG. 91-1
91
ELECTRICAL SYSTEM DIAGRAMS
INTERCONNECTING ELECTRICAL SCHEMATIC
FIG. 92-1
92
ELECTRICAL SYSTEM DIAGRAMS
GRAVITY DOWN SINGLE PUMP ELECTRICAL SCHEMATIC
FIG. 93-1
93
ELECTRICAL SYSTEM DIAGRAMS
GRAVITY DOWN DUAL PUMP ELECTRICAL SCHEMATIC
FIG. 94-1
94
ELECTRICAL SYSTEM DIAGRAMS
POWER DOWN SINGLE PUMP ELECTRICAL SCHEMATIC
FIG. 95-1
95
ELECTRICAL SYSTEM DIAGRAMS
POWER DOWN DUAL PUMP ELECTRICAL SCHEMATIC
FIG. 96-1
96
PRE-DELIVERY INSPECTION FORM
Serial Number: _______________ Technician: _______________
Pre-Installation Inspection:
Correct model
Correct capacity
Correct platform size
Correct options
Manuals & decals
Structural Inspection:
Inspect alignment of fi nal assembly
Inspect pump box secure mounting
Inspect all installation welds
Check roll pins, bolts and fasteners
Check for no twists in chain
Inspect tightness of hardware used for securing columns to mounting plates
Ensure platform ramp touches ground
Hydraulic Inspection:
Proper fl uid level (See OPTIMIZE
HYDRAULIC FLUID LEVEL step in this manual)
Check fi ttings for leaks in pump box
Check fi ttings for leaks in columns
Electrical Inspection:
Check power/charge plug and terminal
Check for loose wires and terminals
Circuit breaker
Battery hookup,12 volt
Check for fully charged batteries
Inspect all solenoid connections
Check all wiring harness connections
Outside control box location
Check electrical cable connections (at the bottom of the curb-side runner) tight and secure
Operation Inspection:
NOTE:
The following times are for 56” bed height, aluminum platform and fl ipover 85” W x 42” + 42” L, Exxon
Univis HVI-13 oil, & temperature at
70°F. Times are for reference only and may vary for larger platforms, smaller platforms, steel platforms, or temperature changes.
Check operation of main control
Check operation of runner control
All BMR: platform unfolds in 5 to 7 sec.
All BMR: platform folds in 5 to 7 sec.
BMR-35 or -44 only
Unloaded platform lowers in 8 to 20 sec.
Platform loaded with 1000 lb (plus)
Unloaded platform raises in 9 to 21 sec.
BMR-55 or -66 only
Unloaded platform lowers in 12 to 23 sec.
Platform loaded with 1000 lb (plus)
Unloaded platform raises in 13 to 26 sec.
All BMR: platform raises and lowers evenly. Maximum 1” difference from side to side.
All BMR: platform stores and locks securely behind both column wedges
Check lift operation under load
Decals in correct location and legible
97
advertisement
Key Features
- Body-mounted
- Hydraulic operation
- Platform lifting and lowering
- Control panel for operation
- Customizable
- Heavy load capacity
- Durable construction