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- RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (August 2010)
- Installation manual
Maxon RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (August 2010) Installation manual
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M-90-1 REV. E AUGUST 2010 INSTALLATION MANUAL RC-2B RC-3B RC-4B RC-5B RC-6B RC-6K 11921 Slauson Avenue. Santa Fe Springs, CA. 90670 (800) 227-4116 © MAXON Lift Corp. 2010 TABLE OF CONTENTS SAFETY INSTRUCTIONS..................................................................................................... 3 INTRODUCTION.................................................................................................................... 4 UNIT AS SHIPPED................................................................................................................. 5 INSTALLATION OF UNIT....................................................................................................... 6 WELDING TO FLATBED.......................................................................................................11 HYDRAULIC PIPE INSTALLATION..................................................................................... 12 POWER PACK INSTALLATION........................................................................................... 13 FUSED POWER CABLE...................................................................................................... 16 PUMP WIRING CAM CLOSER............................................................................................ 17 PUMP WIRING HYDRAULIC CLOSER............................................................................... 18 ADD HYDRAULIC FLUID..................................................................................................... 19 FINAL ADJUSTMENTS........................................................................................................ 21 ATTACH DECALS................................................................................................................ 23 OPTIONS............................................................................................................................. 25 RCT LIGHT INSTALLATION................................................................................................. 25 RCT LIGHT INSTALLATION - Continued............................................................................. 26 HAND PUMP OPTION FOR CAM CLOSER........................................................................ 27 BATTERY PAK INSTALLATION (For Trailers)...................................................................... 28 RECOMMENDED LIFTGATE POWER CONFIGURATION................................................. 29 BATTERY CABLE MOUNTING, 6 VOLT SYSTEM.............................................................. 31 BATTERY CABLE MOUNTING, 12 VOLT SYSTEM............................................................ 32 FIXED RAMP INSTALLATION, 6”........................................................................................ 33 FIXED RAMP INSTALLATION, 12”...................................................................................... 34 CART STOP & DUAL CART STOP RAMP INSTALLATION................................................. 35 HINGED RAMP INSTALLATION (STEEL)........................................................................... 36 HINGED RAMP INSTALLATION (ALUMINUM).................................................................... 37 2 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 WARNINGS............................................................................................................................ 3 Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates. See Operation Manual for operating safety requirements. ! WARNING • Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your feet are clear of the Liftgate. • Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform edges) when operating the Liftgate. • Correctly stow platform when not in use. Extended platforms could create a hazard for people and vehicles passing by. • Make sure vehicle battery power is disconnected while installing Liftgate. Connect vehicle battery power to the Liftgate only when installation is complete or as required in the installation instructions. • If it is necessary to stand on the platform while operating the Liftgate, keep your feet and any objects clear of the inboard edge of the platform. Your feet or objects on the platform can become trapped between the platform and the Liftgate extension plate. • Never perform unauthorized modifications on the Liftgate. Modifications may result in early failure of the Liftgate and may create hazards for Liftgate operators and maintainers. • Recommended practices for welding on steel parts are contained in the current AWS (American Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and personal injury can result from welds that are done incorrectly. SAFETY SAFETY INSTRUCTIONS INSTRUCTIONS • Read and understand the instructions in this Installation Manual before installing Liftgate. • Before operating the Liftgate, read and understand the operating instructions in Operation Manual. • Comply with all WARNING and instruction decals attached to the Liftgate. • Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement decals are available from Maxon Customer Service. • Consider the safety and location of bystanders and location of nearby objects when operating the Liftgate. Stand to one side of the platform while operating the Liftgate • Do not allow untrained persons to operate the Liftgate. • Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact with battery acid may injure unprotected eyes and skin. • Be careful working by an automotive type battery. Make sure the work area is well ventilated and there are no flames or sparks near the battery. Never lay objects on the battery that can short the terminals together. If battery acid gets in your eyes, immediately seek first aid. If acid gets on your skin, immediately wash it off with soap and water. • If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the control switch to stop the Liftgate. • A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise during operation comes from the power unit while the platform is raised and lowered. Listen for scraping, grating and binding noises and correct the problem before continuing to operate Liftgate. 3 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 WARNINGS WARNINGS This publication contains the information required to install the following models and their options; RC, RCW, RCT, RC-CL, and RCHL from 2000 to 6000 pound capacities. If there is any doubt in your mind regarding the suitability of these lifts being installed on its intended vehicle, or any portion of these instructions that you do not understand, please contact the Maxon Customer Service Department for consultation. Unauthorized modification to this equipment may cause premature failure or create hazards in its use that are not foreseen at the time of the installation. These kinds of changes should be discussed with our Engineering Department before being undertaken. Bed height requirements to ground are 38” laden to 56” unladen. These lifts cannot be installed on bodies with swing type doors. These lifts have been designed to fit bodies that are 96” wide, (102” wide, in the case of the RCW Models). If this body has dimensions that are much different than these, special brackets will have to be fabricated for attachment. The corner posts of the body must also be made of steel so that the lift columns can be welded to it. If they are aluminum, then steel plates will have to be fabricated to bolt to these corner posts for welding to the lift assembly. Both of the above conditions are rare and therefore have not been provided for in this manual. Contact the Customer Service Department if either of the above conditions exist. 4 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 INTRODUCTION UNIT AS SHIPPED 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 Do not remove stands at bottom of column until instructed to do so. Steel box containing pump assembly, also contains a packing list, instruction manuals, decals, and all necessary hardware to complete installation. COLUMN SUPPORT ANGLES 48” Two of these 18” angle iron pieces are to be used first to assist in mounting the lift to the truck, and then to support the pump box on trailer installations. The other two are welded to the column support angles. POWER UNIT BOX REINFORCEMENT ANGLE 8” STAND PUMP BOX BATTERY PAK OPTION 5 STAND There are two pieces of angle iron supports (2-1/2 x 2-1/2 x 18”) that have been provided to assist in lining the unit up to the body. Tack weld them to the top of the lifts main section, just strong enough to support it on the truck floor till the lift is secured and ready to weld. Put a chalk mark on the center of the unit (on the thread plate surface) for aligning with the center of the truck body. Remove support angles after lift is mounted and use them for pump box mount reinforcement. SUPPORT ANGLE SUPPORT ANGLE 6 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 INSTALLATION OF UNIT Corner posts and sill under rear of floor must be clean and free of any obstructions so that the columns of the rail lift can fit flat against the rear of the body. Chalk mark a center line at the edge of the rear of the truck floor to line up with the mark on the liftgate. Using the lifting straps, the unit can now be raised either with a chain hoist or fork lift to a height which will allow the temporary support angles to rest on the body floor. The unit can be moved to the vehicle or the vehicle to the unit till they meet. 7 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 INSTALLATION OF UNIT - Continued Clamp columns to the truck body and weld as shown. Remove forklift or chain hoist. RC-2000/3000/RC-CR3 1/4” Fillet Weld. 2” Long RC-4000 1/4” Fillet Weld. 3” Long RC-5000/6000 1/4” Fillet Weld. 4” Long NOTE: See views A & B on next page. ALL UNITS: 1/8” fillet weld approx. halfway down the column. ALL UNITS: See view C on the next page. 8 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 INSTALLATION OF UNIT - Continued A DO NOT WELD COVER B COVER Typ. 1/4” (Length as specified on previous page.) INSIDE OF COLUMN ASSEMBLY OUTSIDE OF COLUMN ASSEMBLY C TYP. 1/4” 2 WELD TO CORNER POST AND SILL BOTTOM CORNER OF TRUCK BODY 9 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 INSTALLATION OF UNIT - Continued Cut columns off 20” from ground. Place the 2-1/2” x 18” angle iron provided under at least 2 cross members, to prepare for the following step and weld. Cut one end of each of the 4 foot long angle iron braces so that it lines up with the lift column and the other end lays flat against the angle iron referred to in the previous paragraph. 18” ANGLE WELD WELD CUT STAND OFF 20” 10 LIFT COLUMN 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 INSTALLATION OF UNIT - Continued The column assemblies are tied in to the flat bed side rails with two lengths of channel. The required sizes are listed below. RC-2000/3000/4000 3”of 1/4” fillet weld RC-5000/6000 4”of 1/4” fillet weld NOTE: Mounting Channel is not supplied by Maxon RC-2000/3000/4000 3”-4.1 #/ft. Channel RC-5000/6000 4”-5.4 #/ft. Channel If side rail is less than 1/4” thick, weld a 1/4” plate to side rail, then weld channel to 1/4” plate. RC-2000/3000/4000 3”of 1/4” fillet weld RC-5000/6000 4”of 1/4” fillet weld Weld to side rail above a cross member. Cross Member 11 60” Approx. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 WELDING TO FLATBED Remove the seven foot long pipe that is strapped to this column of the lift gate (two pipes if lift has hydraulic platform closer), and weld to under side of floor cross members. End of pipe to be about two feet from the end of the truck body. Connect the four foot hoses to the end of the pipe(s) closest to the power unit and the other end through the pump box to the pump assembly. See the last page of “Power Pak Installation” for details. NOTE: Blow air through pipes and hoses before connections are made. App rox. 12 24” 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 HYDRAULIC PIPE INSTALLATION POWER PACK INSTALLATION Jack up the steel box containing the pump assembly until it touches at least two cross members under the floor, three if possible, and the back of the touches the truck chassis frame. Weld where instructed and remove jack. Leave room for tail lights. WELD WELD MAX. TRAILER BODIES FLOOR CROSS MEMBERS 20 feet WELD ALL SIDES OF ANGLE 8” (3 REQ’D, 2 SHOWN) 18” ANGLE BRACE POWE R UNIT BOX Jack up the steel box containing the pump assembly until it touches at least two cross members under the floor, three if possible and tack weld. Add braces provided to the back of the box and the side of the floor cross members. Weld both ends of braces and top of box. Use short pieces of angle iron provided to weld from the side of the floor cross members to the front of the box. Make sure the box is not in a position to interfere with the wheels of the trailer with sliding axle. Box can also be placed behind the wheels if room permits. 13 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 TRUCK BODIES Run 32 ft. power cable from the pump box, along the chassis frame to the positive terminal of the battery (assuming the negative is ground). Use frame clips to secure the cable. (Do not attach to the battery terminal until the other end is fastened on the pump). If the cable is too long, cut to proper length. POWER CABLE 3/8” CABLE END TERMINAL SHRINK TUBE 1/2” Strip about 1/2” of the insulation from the end and slide one of the pieces of shrink tube far enough down that it’s out of your way. Solder the terminal end firmly onto the cable. Always wear protective eye covering while you are doing soldering operations. When it’s cool, slide the shrink tube over the terminal end and heat with a heat gun til it shrinks tightly over the cable and terminal. NOTE: Proper cable connections are extremely important to insure a long and efficient life to all electrical components, therefore, solder type terminals, solder and shrink tubing are provided to insure proper connections. Please do not use the hammer smashing method since the constant bouncing and vibration of the vehicle can eventually cause these types of joints to loosen and deteriorate. This could also be true of crimping if not done properly or the wrong size tool is used. POWER CABLE FRAME CLIP 14 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 POWER PACK INSTALLATION - Continued TRUCKS ONLY Route the two hoses (3 if hydraulic closer) and the three conductor cord (two cords if hydraulic closer), that come out of the bottom of the lift gate main frame through the power pak box and connect as shown. TRAILERS ONLY Connect hydraulic hose coming out of bottom of lift gate to welded pipes under body. Tie the cord(s) and the low pressure line to the pipe and route through power unit box. 15 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 POWER PACK INSTALLATION - Continued ! WARNING Do not attach cable to battery until Liftgate is completely installed. SHORT END TO VEHICLE BATTERY 175 AMP REPLACEMENT FUSE KIT P/N 264687 BATTERY CABLE ASSEMBLY (38’ STD) (INCLUDES REPLACEMENT FUSE KIT) P/N 264422 LONG END TO MOTOR SOLENOID OPTIONAL POWER CABLE KITS DESCRIPTION PART NUMBER 40’ CABLE ASSEMBLY (WITH 200 AMP FUSE) 264848 10’ EXTENSION CABLE ASSEMBLY 264849 FIGURE (CABLE ASSEMBLY) (EXTENSION CABLE ASSEMBLY) 16 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FUSED POWER CABLE TOGGLE IDE S SWITCH EY ) K EF (R 1 2 BLK 3 GRN W HT +) LE ( AB YC R E T AT B TO GND POWER TO UP WHT. DOWN BLK. 17 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 PUMP WIRING CAM CLOSER 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 PUMP WIRING HYDRAULIC CLOSER 18 ADD HYDRAULIC FLUID Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination. NOTE: Use correct grade of hydraulic fluid for your location. +50 to +120 Degrees F - Grade ISO 32 Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606 See TABLES 20-1 & 20-2 for recommended brands. 1. Open pump box cover (FIG. 19-1). PUMP BOX 2. Remove the filler cap (FIG. 19-1). Add 4 quarts of hydraulic fluid to reservoir. (Refer to the NOTE above.) COVER PUMP BOX WITH OPEN COVER FIG. 19-1 3. Reinstall filler cap (FIG. 19-2). NOTE: To check oil level in the pump reservoir, platform must be at ground level. FILLER CAP 4. When Liftgate is ready to operate, unfold and lower the platform to ground level. (See Operation Manual.) 5. Remove the filler cap (FIG. 19-2). Check if hydraulic fluid is at the top of the GRAVITY DOWN bar on the decal (FIG. 19-1). If necessary, add fluid to the top of the bar. 6. Reinstall filler cap (FIG. 19-2). DECAL (FLUID FILL) CHECKING FLUID LEVEL (GRAVITY DOWN PUMP SHOWN - USED ON RC WITH CAM PLATFORM CLOSER) FIG. 19-2 19 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 CAUTION ISO 32 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER AMSOIL AWH-05 CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 V32 EXXON UNIVIS N-32 MOBIL DTE-13M, DTE-24, HYDRAULIC OIL-13 TABLE 20-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER AMSOIL AWF-05 CHEVRON FLUID A, AW-MV-15 KENDALL GLACIAL BLU SHELL TELLUS S2 V15 EXXON UNIVIS HVI-13 MOBIL DTE-11M ROSEMEAD THS FLUID 17111 TABLE 20-2 20 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 ADD HYDRAULIC FLUID - Continued Fill the system with fluid by activating the raise control switch until the runners hit the stops. Unlatch Chain before activating liftgate. Slide Block must be in its retracted position. Remove platform holding chain and activate switch to let unit down until platform rests on ground. Weld 2” long fillets along threshold/floor about every 8 to 10 inches. No welding is necessary on the bottom. 21 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FINAL ADJUSTMENTS Adjust Flow Control valve on power pak so that platform opens from a vertical position just slow enough so as not to create a banging condition. To ensure that the platform brakes are working properly, perform the following simple test: 1. Open Platform and let unit down so that the bottom of the Runner on one side rests on a floor jack. 2. Raise the jack about 3” or so and let the jack down. 3. The Runner should stay in the position that it was jacked up to. If it falls down to its origional position resting on the jack, then the brake is not working and must be checked. 4. To release engaged brake, raise unit. Perform test on opposite side as well. If platform raises uneven from side to side, adjust per instructions in maintenance manual. Install lights and add decals. 22 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FINAL ADJUSTMENTS - Continued PAINT DECAL (2 PLACES) P/N 267338-01 SERIAL PLATE (REF) DECAL “F” OR DECAL “G” DECAL “C” DECAL “D” DECAL “B” DECAL “E” DECAL “A” DECAL “H” DECAL “I” 23 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 ATTACH DECALS DECAL SHEET MODEL ORDER P/N MODEL ORDER P/N RC-2 CAM CLOSER 268385-01 RC-2 HYD CLOSER 268386-01 RC-3 CAM CLOSER 268385-02 RC-3 HYD CLOSER 268386-02 RC-4 CAM CLOSER 268385-03 RC-4 HYD CLOSER 268386-03 RC-5 CAM CLOSER 268385-04 RC-5 HYD CLOSER 268386-04 RC-6 CAM CLOSER 268385-05 RC-6 HYD CLOSER 268386-05 DECAL SHEET PART NUMBERS 24 DECAL SHEET PART NUMBERS 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 (FOR HYDRAULIC CLOSER, ONLY) ALL RCT UNITS INCLUDE BACK LIGHTS 25 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 OPTIONS RCT LIGHT INSTALLATION WHT RED GRN BLK 26 RED GRN WHT RIGHT HAND -01 WHT RED BLK RED WHT WHT BLK GRN GRN BLK CONNECTOR P/N 030488 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 TAIL LIGHT BLK STOP/TURN LIGHT WHT RED LICENSE PLATE WHT BLK WHT BACK-UP LIGHT RED TAIL LIGHT LEFT HAND BASIC RED RED STOP/TURN LIGHT BLK LICENSE PLATE WHT BACK-UP LIGHT RCT LIGHT INSTALLATION - Continued OPTIONS The procedure for lifting the platform using the hand pump is as follows: 1. Check if the relief valve is closed by using the handle to turn it clockwise until complete stop. 2. Close the flow control valve by turning the knob clockwise until it is fully closed. 3. Locate the handle in the hand pump and operate with an up and down motion. To lower the platform, open the hand pump relief valve slowly to be able to control the down speed with this valve. NOTE: When going back to normal operation, a. Be sure to have the hand pump closed. b. Open and adjust the flow control valve. HANDLE FLOW CONTROL KNOB RELIEF VALVE HAND PUMP 27 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 HAND PUMP OPTION FOR CAM CLOSER Mount the battery pak on either side of the trailer body, as close to the power source as possible. Using a floor jack or other lifting device, raise the box so that it’s top touches the underside of the cross members and tack weld to the crossmembers (unless the cross members are aluminum). Place the four plates (included with this kit) against the cross members and slide down against MOUNTING the battery pak. Weld PLATES to both structures. (NOTE: Holes are provided in the mounting plates to allow bolting CROSS MEMBERS to aluminum cross members). Make sure the box is not in a position to interfere with the wheels BATTERY PAK of the trailer with sliding axle. NOTE: These boxes can also be installed behind the wheels if room permits. For easier service, mount boxes so that the front of each box is recessed one foot from the side wall of the vehicle body. 28 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 BATTERY PAK INSTALLATION (For Trailers) OPTIONS NOTE: Make sure the Liftgate power unit, and all batteries on the vehicle for the power unit, are connected correctly to a common chassis ground. 1. Liftgate, pump box, and additional battery box are typically installed on trailers as shown in FIG. 29-1 and on trucks as shown in FIG. 29-2. See the following page for battery and cable connections. TRACTOR BATTERIES, TYPICAL LOCATION MASTER DISCONNECT SWITCH LIFTGATE LIFTGATE PUMP BOX TRACTOR BATTERY CIRCUIT BREAKER, REQUIRED LOCATION CHARGE LINE POWER CABLE CIRCUIT BREAKER OPTIONAL BATTERY BOX, TYPICAL LOCATION TRAILER-MOUNTED CIRCUIT BREAKER, ADDITIONAL RECOMMENDED LOCATION RECOMMENDED LIFTGATE & BATTERY BOX INSTALLATION ON TRAILER FIG. 29-1 TRUCK BATTERY CIRCUIT BREAKER, REQUIRED LOCATION MASTER DISCONNECT SWITCH LIFTGATE LIFTGATE PUMP BOX POWER CABLE CIRCUIT BREAKER TRUCK BATTERIES, TYPICAL LOCATION OPTIONAL BATTERY BOX, CHARGE LINE TYPICAL LOCATION RECOMMENDED LIFTGATE & BATTERY BOX INSTALLATION ON TRUCK FIG. 29-2 29 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 RECOMMENDED LIFTGATE POWER CONFIGURATION NOTE: Always connect fused end of power cable to battery positive (+) terminal. 2. Recommended battery box setup for 6 volt batteries is shown in FIG. 30-1. (+) BATTERY CABLES 150 AMP CIRCUIT BREAKER 150 AMP CIRCUIT BREAKER (NEAR TRUCK OR TRACTOR BATTERY AND/OR NOSE OF TRAILER) 175 AMP FUSED POWER CABLE (SEE NOTE) CHARGE LINE TO TRUCK OR TRACTOR BATTERY POWER CABLE TO PUMP BOX (-) BATTERY CABLE GROUND CABLE TO PUMP BOX 6 VOLT BATTERY CONNECTIONS FIG. 30-1 NOTE: Always connect fused end of power cable to battery positive (+) terminal. 3. Recommended battery box setup for 12 volt batteries is shown in FIG. 30-2. 175 AMP FUSED POWER CABLE (SEE NOTE) 150 AMP CIRCUIT (+) BREAKER BATTERY CABLES 150 AMP CIRCUIT BREAKER (NEAR TRUCK OR TRACTOR BATTERY AND/OR NOSE OF TRAILER) CHARGE LINE TO TRUCK OR TRACTOR BATTERY POWER CABLE TO PUMP BOX GROUND CABLE TO PUMP BOX (-) BATTERY CABLES 12 VOLT BATTERY CONNECTIONS FIG. 30-2 30 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued OPTIONS CIRCUIT BREAKER FROM CONNECTOR PLUG GROUND CABLE + + T OL 6 V ERY TT BA T OL Y V 6 ER TT BA MOTOR SOLENOID CABLE MOTOR SOLENOID 31 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 BATTERY CABLE MOUNTING, 6 VOLT SYSTEM CIRCUIT BREAKER FROM CONNECTOR PLUG GROUND CABLE + + LT VO 12 TERY T BA LT VO 12 TERY T BA MOTOR SOLENOID CABLE MOTOR SOLENOID 32 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 BATTERY CABLE MOUNTING, 12 VOLT SYSTEM OPTIONS Lower the platform to level ground. Line up top edge of ramp with the front edge of the platform. Weld 1/8” beads two inches long about every 6 or 8 inches along the entire length of the platform. Repeat procedure for the underside of the platform. WELD WELD 33 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FIXED RAMP INSTALLATION, 6” Lower the platform to level ground. Line up top edge of ramp with the front edge of the platform. A Cut rear edges of ramp as shown: Single piece platform “A” = 3/8” Folding platforms “A” = 1/2” WELD WELD Weld 1/8” beads two inches long about every 6 or 8 inches along the entire length of the platform. Repeat procedure for the underside of the platform. Weld gussets full length. 34 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 FIXED RAMP INSTALLATION, 12” 1. With the platform on the ground, center the Cart Stop Ramp against the butt end of the platform. Rest the Ramp Blocks on top of the platform and let the Ramp Tip touch the ground. Weld both sides into place. Cart Stop Ramp Ramp Blocks Platform 1/4” Weld Cart Stop Ramp Tip to be flush with bottom surface of Platform. 2. Pop open the Cart Stop Section of the ramp for ease of welding. Weld the top & bottom of the Ramp to the Platform with 2” long welds on approximately 12” centers. Grind all welds smooth and touch up with paint. Cart Stop Ramp NOTE: REPEAT THE STITCH WELD ON THE BOTTOM OF RAMP 1/4” 2”-12” Platform 35 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 CART STOP & DUAL CART STOP RAMP INSTALLATION HINGED RAMP INSTALLATION (STEEL) 3 5 1/8” Typ. 1/8” 1/8” Typ. 1/8” 6,7 8 Typ. 1/16”(Typ.) 4 C L 1-7/8” 7” (12” & 20” ramps) 3” (6” ramp only) 1/2”(Typ.) 6” 1 12” 2 46” 43-1/4” (Typ. 90” Ramp) (Typ. 90” Ramp) 38-1/4” (Typ. 80” Ramp) 7/8” 41” (Typ. 80” Ramp) 2 1/2” 8 1/8” 4 1 1/8” Item Qty. 1 12” & 20” RAMPS 8 1 Part No. Description 225989-1 12"x 90" RAMP & HINGE ASSY. 225989-2 6"x 90" RAMP & HINGE ASSY. 225989-3 12"x 80" RAMP & HINGE ASSY. 225989-4 6"x 80" RAMP & HINGE ASSY. 225989-5 20"x 90" RAMP & HINGE ASSY. 225989-6 20"x 80" RAMP & HINGE ASSY. 2 4 092143-01 TUBE 1.5 OD x1.015 ID x1.75LG. 3 1 4 2 225998 BAR RD. 3/4" DIA. x 8" LG. 5 2 201020 FLAT, 3/8 x 1 x 1-1/2" LG 6 2 202698-41 CHAIN 18" LG. (12" & 20" RAMP ONLY) 7 2 202698-43 CHAIN 11" LG. (6" RAMP ONLY) 8 2 221739-1 LATCH PLT. WMT. 1PC PTFM. 221739-2 LATCH PLT. WMT. 2PC PTFM. 224342 LUBE FITTING 36 1 4 6” RAMPS 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 Locate Swivel this way on 36”, 42”, 48” pltfm. only. 5/8” 3 Locate Swivel this way on 60”, 72”, 76”, 84” pltfm. only. 1/8” 5 Typ. 1/8” 6 Typ. 1/8” 5/8” Typ. 1/8 4 1-1/2”(Typ.) 11-1/2” (36”,42”,48”Pfm) 9-1/2” (60”,72”,76”,80”Pfm) 1/16”(Typ.) 5/8” 10” 1 2 6-7/8” (Typ. 80” Pltfm.) 3-13/32” (Typ. 70” Pltfm.) 1/2” Item Qty. Part No. 221543 1/8” 1-10 221543-1 4 1 1 229569 229569-01 1 Description 16"x 80" RAMP ASSY. 16"x 80" REINFORCED ALUM. RAMP ASSY. 20"x 80" ALUM. RAMP ASSY. 20"x 80" REINFORCED ALUM. RAMP ASSY. 221543-100 16"x 70" RAMP ASSY. 2 1 092143-01 TUBE 1.5 OD x1.015 ID x1.75LG. 3 1 221739-1 LATCH PLT. WMT. 1PC PTFM. 221739-2 LATCH PLT. WMT. 2PC PTFM. 4 1 225985 PIPE 3/4" SCH. 80 x 60" LG. 5 2 201020 FLAT, 3/8 x 1 x 1-1/2" LG 6 2 202698-41 CHAIN 18" LG. 37 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 HINGED RAMP INSTALLATION (ALUMINUM)
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