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

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
Add to My manuals

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

Assistant Bot

Need help? Our chatbot has already read the manual and is ready to assist you. Feel free to ask any questions about the device, but providing details will make the conversation more productive.

MAXON BMR Installation Manual | Manualzz

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

Frequently Answers and Questions

What are the required body strength requirements for installing a BMR Liftgate?
Refer to the document for details on vehicle body strength requirements and force limitations. The BMR Liftgate puts forces on the walls of truck and trailer bodies.
What are the minimum bed height requirements for installing a BMR Liftgate?
The minimum bed height varies depending on the type and size of the platform. Refer to the document for specifications.
What are the different installation methods for a BMR Liftgate?
There are three methods for installing a BMR Liftgate: pre-installing the mounting plates and extension plate on the vehicle, pre-installing the mounting plates and extension plate on the Liftgate, or welding the Liftgate to the body. The document outlines each method in detail.
What is the maximum operating bed height for a BMR Liftgate?
The maximum operating bed height for the body is 56 inches (unloaded).
What type of hydraulic fluid should I use for my BMR Liftgate?
Refer to the document for the recommended type of hydraulic fluid. The document provides the part number for the compatible hydraulic fluid.

Related manuals

Download PDF

advertisement

Table of contents