INSTALLATION MANUAL - MAXON Lift Corp. UK Limited
Contents
1. STEP 2 FIT LIFTGATE TO VEHICLE Continued NOTE The external control is pre wired to electrical controller box This control will be operable when power and ground cables for the liftgate are connected correctly in the pump box and at the battery External control can be used to help adjust the position of lift mechanism and tilt arms when connecting to platform 5 Remove pump cover Run the power cable through the sealing grommet to power unit FIG 14 2 TERMINAL LUG Leave enough cable to reach starter HEATSHRINK TUBING motor solenoid without putting tension on cable after connection Then run POWER CABLE power cable through sealing grom BARE WIRE END met to power unit FIG 14 2 Leave PLACING TERMINAL LUG 8 HEATSHRINK enough cable to reach motor ter TUBING ON POWER CABLE minal stud without putting tension on FIG 14 1 cable after connection 6 Put heatshrink tubing Parts Box item FIG 14 1 over each bare cable end leave room for terminal lug Crimp a terminal lug Parts Box item each bare end of TVPICAL POWER CABLE WITH power cable FIG 14 1 Then TERMINAL LUG INSTALLED shrink the heatshrink tubing over FIG 14 2 the barrel of the lug FIG 14 2 STEP 2 FIT LIFTGATE TO VEHICLE Continued NOTE Use dielectric grease on all electrical connections 7 Connect power cable to e terminal on starter switch FIGS STARTER2. To prevent possible injury stow platform and disconnect vehicle battery from power pack before working below platform 1 Stow the platform FIG 29 1 PLATFORM STOWED FIG 29 1 BATTERY WARNING BATTERY CABLE To prevent possible injurv dis CABLE connect power from Lift while BD working under vehicle bodv LA Lex 2 Disconnect and bat terv cables from batterv B FIG 29 2 ATTERY ls DISCONNECTING BATTERY CABLES FIG 29 2 3 Measure position L1 of the near side centre and offside parts of BUMPER underrun bumper FIG 29 3 NEARSIDE SHOWN MEASURING UNDERRUN BUMPER POSITION 8 GROUND CLEARANCE FIG 29 3 29 STEP 10 ADJUST UNDERRUN BUMPER Continued NOTE The centre part of the underrun bumper must be bolted to the main frame with 4 bolts For the nearside and offside parts of the bumper each part must be bolted to the main frame with 2 bolts Bolt pattern allows bumper position L1 to be shortened approximately 2 3 8 from shipping position 4 If adjustment is necessary unbolt the nearside cen tre and offside parts of underrun bumper Change bumper position L1 FIG 30 1 to the allowable di mensions shown in the VEHICLE REQUIREMENTS section sD OFFSIDE 2 PLACES NEA dentis 2 PLACES NEARSIDE CENTRE BUMPER M12 LOCK NUT 2 PLACES M12 FLAT WASH
3. OPTIONAL 236 ove BLUE O59 X939 YEL BROWN GREEN YELLOW INTERNAL 2 HAND CONTROL CONTROL o yg 5 62 NOT PARKED CAB LAMP amp B I 8 WIRING CUSTOMER SUPPLY gt B al 14 4 INTENSIFIER CHANGE OVER VALVE LIVE RELEASE SOLENOID YELLOW LUE T STARTER 12V 24V 1504 FUSE 24V ONLY POWER PACK 200A FUSE 12V ONLY FIG 42 1 42
4. 15 1 or 14 2 Next connect SWITCH ground cable to terminal on pump Motor Then apply dielectric grease to electrical connections If equipped position rubber boots to TERMINAL cover the terminal on the motor STUD 8 and starter switch and the ground terminal on the motor PUMP 4 TERMINAL STUD amp BOOT 2 GA 2 CONNECTING 8 POWER CABLES HALDEX BRAND POWER UNIT FIG 15 1 STARTER TERMINAL TERMINAL STUD 2 2 PUMP MOTOR CONNECTING 8 POWER CABLES TO BUCHER BRAND POWER UNIT FIG 15 2 STEP 2 FIT LIFTGATE TO VEHICLE Continued WARNING Prevent possible injurv and damaged equipment Ensure power cable ground cable and control switch are connected to power unit before reconnecting vehicle batterv cables BATTERV CABLE NOTE Use dielectric grease on BATTERY all electrical connections CABLE l 8 Connect and batterv cables to TA vehicle battery FIG 16 1 Tighten E the connector nuts securely BATTE NUTS RECONNECTING VEHICLE NOTE Mounting plates can be adjusted to fit Mb m vehicle frames 29 1 2 to 34 1 2 wide 9 Position mounting plates for a snug fit against ve hicle as follows Loosen the 2 lock nuts at the base of each mounting plate FIG 16 2 Keep liftgate centered on re
5. LIFT CVLINDER 8 LIFT ARM LUBRICATION DIAGRAM FIG 34 1 2 Pump multi purpose lithium grease in each lube fitting on the cylinders and arms until grease starts oozing from ends of the bearings Refer to lubrica tion diagram in FIG 34 1 Wipe off excess grease with a clean lint free cloth 34 STEP 14 ATTACH EXTERNAL BRACKET 8 CONTROLS CAUTION Prevent damage to control box Make sure installed control box does not protrude from the vehicle body 1 Position external control bracket crossmembers at nearside of vehicle body as shown FIG 35 1 REAR SILL BRACKET REF 1 l 8 8 IT 2 Bolt external control bracket in position with 4 self tapping CROSSMEMBER FIG 35 1 2 CONTROL M6 X 16 TAP TITE SCREWS EXTERNAL 4PLACES CONTROL NOTE Secure excess lengths of control cables behind power pack awav from moving parts on liftgate and vehicle 3 Attach external control to bracket as follows FIG 35 1 Remove control face from rear housing of external control bv loosening 4 screws Next bolt external con trol rear housing to bracket with M4 screws washers and lock nuts provided Then reattach control face to rear housing with 4 screws for the 2 hand POSITIONING 8 BOLTING EXTERNAL CONTROL control BRACKET UNDER VEHICLE BODV FIG 35 1 35 STEP 15 ATTACH INTERNAL BRACKET 8 CONTROL 1 Position
6. i persons to stand in i the area af tail lift movement IMPOIV TANT Pret meme inti merical enirn minsi Gall Eur be yla Ga paola 2E2887 0 Lewd 22 Lead air an oa Peeper 0800 195 2048 4 0 MERA X MIL rene Anima Svar DI fin ema Sed IEFEPI IMPORTANT External Poner mudo on Internal must selecied before taf can be dparuled yin ihe cuntiols anzi chose ibe pintiomm anij at vehicle fici iewal F External Control Decal MAX20C ONLV P N 282887 03 MAXON CN Lift Carp Lid Lini 3 5 Busing Park MA Lilt 41 4 Fini PES SG BANT 54 OF MPR MAGE HELE FOR MHRA BREAKDOWN ASSISTANCE 8 n 0800 195 2048 Serial Plate Ref FIG 38 1 38 SVSTEM DIAGRAMS PUMP 8 MOTOR SOLENOID OPERATION HALDEX PUMP ONLV STARTER SOLENOID VALVE POWER UNIT MOTOR 8 SOLENOID OPERATION SOLENOID OPERATION PORT LOGIC LOGIC LOGIC LOGIC INTENSIFIER MOTOR VALVE A VALVE VALVE VALVE VALVE CHANGEOVER LIFT 1 LIFT 2 TILT 1 TILT 2 VALVE TAIL LIFT FUNCTION REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC HALDEX PUMP ONLY T
7. 1 Run the 2 gauge live cable and black earth cable Kit items along RED FUSED POWER CABLE TO BATTERY FUSE UEM V E H L FRAME vehicle frame from the vehicle batterv to the rear of vehicle where Liftgate will be mounted Clip cables to vehicle frame at intervals shown FIG 8 1 Leave sut ficient cable to reach the power pack on the Liftgate Wim ium NUM TERES TE d 22 RO N NIS Qu Ei FRONT OF VEHICLE REAR OF VEHICLE N VEHICLE BATTERY 2 GA CABLE 2 GA CABLE STEP 1 RUN POWER 8 GROUND CABLES Continued A WARNING Prevent possible injurv and damaged equipment Ensure batterv cables remain disconnected from batterv until safe to reconnect Reconnect batterv cables only as instructed in this manual 2 In the vehicle batterv compartment disconnect the and batterv ie cables as shown in FIG 9 1 BATTERY CABLE DISCONNECTING BATTERY CABLES FIG 9 1 3 Connect the power cable and ground cable to the battery cables disconnected from battery as shown in FIG 9 2 CABLE CONNECTING POWER amp GROUND CABLES TO DISCONNECTED BATTERY CABLES FIG 9 2 STEP 1 RUN POWER amp GROUND CABLES Continued WARNING To prevent personal injury and damage to equipment tail lift battery must be disconnected while fitting the in line fuse 4 Fit the in line fuse holder
8. 1148 1098 400 1153 1087 389 1161 1381 1368 0 m gt JJ gt 2 O m 569 1359 56 fusi 564 tot 643 1349 5 3 2 89 76 64 1335 1323 1310 1298 1284 1272 1259 1247 1234 962 MIN BED HT LADEN 950 MM MIN BED HT LADEN z 1075 MM MIN BED HT LADEN 1329MM LIFTGATE CLEARANCE DIMENSIONS IN INCHES TABLE 6 1 BODV CORNER POST PLATFORM STOWED INBOARD 29 4 MM THK FLOOR SEAL CLEARANCE FOR SPACERS SEE WORKSHEET TABLE 6 1 FLOOR LEVEL M OOR LEVEE REAR SILL a FLOOR VEHICLE CLEARANCE TABLE 6 1 ARM LENGTH X BED HEIGHT S 2 i TABLE 6 1 i 305 GROUND CLEARANCE BEAM HEIGHT GROUND LEVEL LIFTGATE CLEARANCE DIMENSIONS FIG 6 1 6 VEHICLE REQUIREMENTS Continued CAUTION To prevent Liftgate and or vehicle from being damaged check for possible interference from rear sill that is 102 mm or more in height Lift arms and or tilt cylinder rods could hit the rear sill when platform approaches bed height e Installer is responsible for ensuring that vehicle body and frame modifications do not adversely affect the integrity of the body and frame NOTE Rear sill height and resulting clearance for tilt cylinder rods and lift arms can differ greatly from installation to installation Height depth and angle of notches will vary for different vehicle bodies and lengths of lift a
9. COVER WRAP parts stores box as fol PRINT FACES VEHICLE lows See FIG 10 1 for FRAME position and electrical connections Ensure fuse holder is positioned so power cable will reach batterv and fuse holder Use self tapping screws to attach fuse holder and cover wrap parts stores box to vehicle frame near battery VELCRO 150A FUSE 24V POWER 200A FUSE 12V POWER SCREW 2 PLACES x TERMINAL STUD 2 PLACES 5 Position tail lift power cable next to fuse holder FIG 10 1 Cut cable midway between the 2 terminal studs on fuse holder FIG 10 1 CONNECTING IN LINE FUSE FIG 10 1 PROTECTIVE VELCRO COVER TERMINAL LUG 6 Strip insulation from the 2 cut HEATSHRINK TUBING cable ends Then crimp or 7 solder a lug to each cut end POWER CABLE 2 FIGS 10 2 and 10 3 BARE WIRE END PLACING TERMINAL LUG amp HEATSHRINK TUBING ON POWER CABLE FIG 10 2 7 Ensure correct fuse is installed FIG 10 1 Then close the protec tive cover wrap FIG 10 1 Use the Velcro strips on cover wrap to TYPICAL POWER CABLE WITH secure it around fuse holder TERMINAL LUG INSTALLED FIG 10 3 10 STEP 2 LIFTGATE TO VEHICLE NOTE Ensure both installation jigs fit snug against the top and side of the rear sill If rear sill spacers are necessary ensure correct thickness of spacers is fit ted in snug between the rear sill and jigs Lift mechanis
10. CUT TO PLATFORM WIDTH FIG 23 1 23 STEP 7 ATTACH DOOR SEALS 8 PLATFORM BUFFERS 1 Measure height H from bot tom of rear sill to top of door opening on vehicle body FIG 24 1 2 Cut 2 door seal mounting strips FIG 24 2 and door seals FIG 25 2 Kit items to measured length H FIG 24 1 DOOR OPENING 3 Place mounting strip Kit item in position on LH side amp RH side of door opening FIG 24 2 Fasten each mounting strip to vehicle body with 7 14 self tapping screws Kit item REAR IE id J TE TELA Ls TITU MEASURING DOOR HEIGHT PLATFORM ON THE GROUND FIG 24 1 inn 14 SELF m TAPPING i SCREWS i 7 PLACES e Eur MOUNTING STRIP END VIEW gt ATTACHING MOUNTING STRIPS FIG 24 2 24 STEP 7 ATTACH DOOR SEALS 8 PLATFORM BUFFERS Continued 4 Measure width W2 of the rear door opening to the outboard edges of the door seal mounting MOUNTING STRIP SIDE VIEW MOUNTING STRIP 14 SELF TAPPING SCREWS 7 PLACES i MOUNTING STRIP TAI 5 Place mounting strip Kit ATTACHING TOP MOUNTING STRIP item in position at top of FIG 25 1 door opening FIG 25 1 Fasten mounting strip to vehicle bodv with 7 4 self tapping screws Kit item 6 Slide rubber door seals all the through
11. VIEW FIG 37 1 PRESSURE RELIEF VALVE ADJUSTMENT COVER ADAPTER BLOCK PRESSURE TEST REF CONNECTOR REF M a kell BUCHER POWER PACK PRESSURE TEST 8 ADJUSTMENT TOP VIEW FIG 37 2 3 ATTACH DECALS 50086 6868 NOTE Ensure there is residue dirt or corrosion px where decals are attached If necessary KRIET clean surtace before attaching decals Meira iis gt 7 dm Casi se IMPORTANT tal Power mode fal must bs ankirtad batons tajl lift eap ba operated dis Ea a arrk l 8 External Control Decal MAX10C ONLV P N 282887 01 ing i Load Uu Internal External 2Button ternal Control Raise Button Operation 1 Lower Button Genera eer ca 1 il 0800 195 2048 uae 15008 S MEL Capacity 0800 195 8 Fower Raise Lift Lower Lift Power On Only ONE operator Internat Control i Externat Control May travel on the Keep feet away from the rear of the IMPORTANT External Power mode on internal control must Part be selected before tail lift can be operated via the external controls 2 Internal Control Decal External Control Decal P N 5 90052 MAX15C ONLV P N 282887 02
12. internal control bracket Kit item by nearside rear vehicle body vertical post as shown in FIG 36 1 INTERNAL l 1 CONTROL SWITCH PE BRACKET 9 26 INTERNAL N CONTROL VERTICAL POST NEARSIDE M6 X 16 TAPTITE SCREWS 4 PLACES 2 Use bracket to mark and drill 4 holes for M6 tapping screws Then bolt internal control bracket to vehicle body with 4 self tapping screws Kit item FIG 36 1 BOLTING INTERNAL SWITCH amp BRACKET TO VEHICLE BODV 3 Attach internal control to bracket FIG 36 1 as follows FIG 36 1 Remove control from rear housing of internal control bv loosening 4 screws Next bolt internal control rear housing to bracket with M4 screws washers and lock nuts provided Then reattach con trol face to rear housing with 4 screws STEP 16 LOAD TEST 8 CERTIFY TAIL Note To finish installation the installer must do the Tail Lift Load Testing procedure and complete the Tail Lift Test Certificate P N 5 90028 The pressure relief valve is located on the adapter block FIGS 37 1 or PRESSURE RELIEF VALVE 37 2 Adjustment is performed as part of the Lift Load Testing procedure ADAPTER BLOCK PRESSURE TEST P N 5 90020 and recorded on Tail Lift REF CONNECTOR REF Test Certificate P N 5 90028 The in structions and certificate are supplied lt PR with the document kit 8 ADJUSTMENT
13. tilt the tip down 2 Unlatch and open pump cover FIG 32 1 3 Check the hydraulic fluid level in reservoir as follows With platform on ground level should be as shown in FIG 32 2 PUMP UNIT NOTE If the hydraulic fluid in the reservoir is contaminated do the CHANGING HVDRAULIC LATCHES IN FLUID procedure in this section 2 PLACES PUMP COVER 4 If needed add fluid to the reservoir UNLATCH LATCH PUMP COVER as follows Remove filler oreather FIG 32 1 cap FIG 32 2 Fill the reservoir with fresh ISO VG22 hydraulic fluid up to 6L mark FIG 32 2 Reinstall Cap FIG 32 2 6L MARK FILLER BREATHER RESERVOIR CAUTION Pump cover must be correctly secured to prevent it from becom ing a hazard Ensure pump cover is latched to pump box 5 Close and latch the pump cover as shown in FIG 32 1 POWER UNIT FLUID LEVEL FIG 32 2 32 STEP 12 CHECK HYDRAULIC FLUID Continued BUCHER PUMP ONLY CAUTION Keep dirt water and other contaminants from entering the hydraulic system Before opening the hydraulic fluid reservoir filler cap drain plug and hydrau lic lines clean up contaminants that can get in the openings Also protect the openings from accidental contamination 1 Tilt platform down to bed level Then PUMP COVER lower platform to the ground and tilt LATCHES the tip down 2 PLACES 2 Unlatch and open pump cover FIG 33 1 3 Check the hydraulic
14. 4 REV A MARCH 2013 MAXON MAX10C MAKTSC 4 MANZOB INSTALLATION MANUAL MAXON Lift Corp UK Ltd Unit 3 Saracen Business Park lli Wav Peterborough Cambridgeshire 1 5 24hr breakdown service 0800 195 2048 Tel 444 0 1733 567681 Fax 44 0 1733 898026 MAXON Lift Corp UK Ltd 2013 TABLE OF CONTENTS 3 3 SAFETY INSTRUG HONS MAX10C 156 8 20C INSTALLATION COMPONENTS amp KITS 4 5 VERMILE STEP 1 RUN POWER amp GROUND 55 8 TOVERI E 11 PI ie 17 STEP 3 MOUNT LIFTGATE ON VEHICLE 19 STEP 4 REMOVE eee ae 20 SIEP FLOOR G BA 22 STEP 7 ATTACH DOOR SEALS amp PLATFORM BUFFERS 24 TORS tres errr terre d 27 STEP 9 ADJUST PLATFORM SOS eee 28 STEP 10 ADJUST UNDERRUN BUMPER 29 STEP 11 ATTACH MARKER FEAOG Tc 31 STEP I CHECK FI DRAWLIC FEUD ii 32 2 32 33 34 STEP 13 LUBRICATE BEARINGS AT GREASE FITTINGS STEP 14 ATTACH EXTERNAL BRACKET amp CONTROLS 6 35 STEP 15 ATTACH INTERNAL BRACKET amp GON
15. ABLE 39 1 39 SYSTEM DIAGRAMS Continued PUMP amp MOTOR SOLENOID OPERATION BUCHER PUMP ONLY LOWERING VALVE STARTER SOLENOID d PORT P INTENSIFIER CHANGEOVER VALVE POWER UNIT MOTOR 8 SOLENOID OPERATION SOLENOID OPERATION v MEANS ENERGIZED liegi LOGIC LOGIC LOGIC LOGIC INTENSIFIER FUNCTION LOWERING MOTOR VALVE VALVE VALVE VALVE VALVE CHANGEOVER LIFT 1 LIFT 2 TILT 1 TILT 2 VALVE REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC BUCHER PUMP ONLY TABLE 40 1 40 HVDRAULIC SCHEMATIC NOTE LOGIC VALVES ARE DOUBLE LOCK SEAT NC FLOW RATE IS 19 LPM 5 GPM EN 6 9 DO ODO LIFT CYL e LIFT CYL LOGIC LOGIC VALVE VALVE 16 39 6 9 1 OO L I TILT CVL 5 1 mm 2 TILT CVL LOGIC LOGIC VALVE si VALVE 3 21117 CHANGEOVER 2 P VALVE PORTA 7 6 LPM 2 GPM FLOW CONTROL TEST PORT 2 POS 2 POLE SOL VALVE CHECK VALVE 100 BAR 1450 PSI PRESSURE RELIEF FIG 41 1 41 SYSTEM DIAGRAMS Continued ELECTRICAL SCHEMATIC EXTERNAL CONTROL GREEN LINK LINK JUMPER JUMPER TILT RAM LOGIC SOLENOID VALVE BLUE BROWN BLUE BROWN TILT RAM LOGIC GREEN SOLENOID VALVE BLUE YELLOW LIFT RAM LOGIC SOLENOID VALVE BROWN RED BLACK LIFT RAM LOGIC SOLENOID VALVE WANDER LEAD JUMPER
16. ATE AEM 3 Lower platform to ground level Then raise platform to floor level to verifv platform is in cor rect position when the lift arms come in contact with the stops FIG 27 2 TVPICAL OFF SIDE 8 NEAR SIDE LIFT STOPS TACK IN POSITION THEN FULLV WELD 4 When stop and gusset are in correct position fullv weld plate stop and gusset FIG 27 2 Repeat this step for off LIFT STOP amp GUSSET WELDED side lift arm TO VEHICLE FRAME FIG 27 2 27 STEP9 ADJUST PLATFORM TILT STOPS Stow platform FIG 28 1 PLATFORM POINTS STRAIGHT UP WITHOUT LEANING Ensure platform is pointed straight up and not leaning towards the vehicle bodv FIG 28 1 NOTE There is a tilt stop adjust ment screw where each lift arm connects to platform 5 O platform leans toward vehicle body B 4 turn stop screws clockwise at near 192 side and offside of the platform FIG ifi 28 2 Turn screws evenly until platform 1 2 points straight up without leaning PLATFORM STOWED FIG 28 1 PLATFORM HEEL TILT ADJUST SET SCREW 7 Tilt platform down to bed level Then tilt platform up to stowed position FIG 28 1 Ensure platform is not leaning If necessarv repeat adjustment instruc PLATFORM WITH NEARSIDE TILT tion 3 STOP SHOWN FIG 28 2 28 STEP 10 ADJUST UNDERRUN BUMPER A WARNING
17. ER 4 PLACES M12 BOLT 2 PLACES VA PLACES M12 BOLT 4 PLACES UNBOLTING UNDERRUN BUMPER TO CHANGE POSITION FIG 30 1 5 When each of the 3 bumpers are in correct position bolt each bumper to bracket with specified number of bolts FIG 30 1 Torque each of the 12 lock nuts to 116NM 6 Reconnect and batterv cables to batterv Tighten the connector nuts securelv 30 STEP 11 ATTACH MARKER FLAGS 1 Stow platform FIG 31 1 MARKER FLAG 2 PLACES MOUNTING FLAT 2 PLACES POP RIVETS 6 PLACES ATTACHING FLAGS PLATFORM ALUMINUM SHOWN FIG 31 1 2 Use mounting flats to mark and drill 6 holes to fasten flags and flats to platform FIG 31 1 NOTE Aluminum pop rivets and self tapping screws are provided with marker flag kit Use the 6 aluminum rivets to attach flags to aluminum platform To attach marker flags to steel platform use the 6 self tapping screws 3 Attach marker flags Kit items as shown in FIG 31 1 31 STEP 12 CHECK HYDRAULIC FLUID HALDEX PUMP ONLY CAUTION Keep dirt water and other contaminants from entering the hydraulic system Before opening the hydraulic fluid reservoir filler cap drain plug and hydrau lic lines clean up contaminants that can get in the openings Also protect the openings from accidental contamination 1 Tilt platform down to bed level Then lower platform to the ground and
18. M FRAME E 40MM EXISTING HOLES IN 8 BOLT PATTERN FOR BOLTING MAX20C TO VEHICLE FRAME FIG 18 1 STEP 4 REMOVE INSTALLATION JIGS 1 Remove lift arm pins and jigs FIGS 19 1 and 19 2 L JIG 2 PLACES 47 23 LIFT ARM N gt 2 PLACES 17 x LIFT ARM PINS AN REMOVING PLATFORM PINS CLAMPS amp JIGS FIG 19 1 ED fi 7 98 BE UP 1 50 5 H LIFT ARMS FREED FROM INSTALLATION JIGS FIG 19 2 2 Lower forklift or jack and remove from under liftgate STEP 5 ATTACH PLATFORM 8 ROLLERS WARNING To prevent possible injury never work in the area directly under the platform Gain access to lift arm and tilt cylinder rod connection points at heel of platform 1 Support platform in horizontal position FIG 20 5 2 Use external control to raise or lower lift arms in position on the platform heel UP BUTTON DOWN BUTTON FIGS 20 1 20 2 and 20 5 Next RAISE LIFT ARMS LOWER LIFT ARMS insert pins to connect lift arms to platform FIG 20 1 FIG 20 2 Then bolt both pins securely 3 Use external control to extend or retract tilt cylinder rods to correct position on the platform heel FIGS 20 3 20 4 TILT UP EXTEND TILT TIL
19. ME CLEAR SPACE FLOOR HEIGHT M BED HEIGHT MUD GUARDS UNLADEN OR OTHER BARRIER AS EQUIPPED GROUND LEVEL VEHICLE DIMENSIONS FIG 5 1 BODY CORNER ES PLATFORM Measure length of lift STOWED arms FIG 5 2 to verifv ELO ENSENT that the length is opti mum for the range of bed VEHICLE FLOOR LEVEL heights and clearances shown in FIG 6 1 and TABLE 6 1 amp VEHICLE FRAME pom a 6 NX l MA S z UNLADEN Use FIG 6 1 and clearance dimensions in TABLE 6 1 to MAIN BEAM UNDERRIDE determine the initial mount ing position for Liftgate one ee MEASURING ARM LENGTH FIG 5 2 VEHICLE REQUIREMENTS Continued SHORT LIFT ARM 750 MM MEDIUM LIFT ARM 875 ILONG LIFT ARM 1000 MM MAX BEAM HEIGHT 695 MM MAX BEAM HEIGHT 781 MM MAX BEAM HEIGHT 787 MM INBOARD ien MAX BED HT MIN FLOOR INBOARD UNLADEN CLEARANCE CLEARANCE UNLADEN CLEARANCE CLEARANCE 1260 564 1024 1437 1181 1251 553 1030 1427 1242 543 1041 1415 1219 83 5 5 5 2 20 gt gt lt UJ m amp TI J gt gt lt UJ 25 1207 1232 536 1051 1405 1140 1229 1223 526 1059 1394 1148 1213 516 1069 1204 505 1076 1194 495 1084 1183 485 1095 1173 4 5 1097 1163 465 1110 1152 454 1118 1142 445 1126 1130 434 1132 1120 421 1140 1109 411
20. T DOWN RETRACT and 20 5 Next insert pins to connect CYLINDER ROD TILT CYLINDER ROD tilt cylinder rods to platform FIG 20 FIG 20 3 FIG 20 4 5 Then bolt both pins securely PLATFORM LOCK WASHER 4 PLACES HEX HEAD SET SCREW N LIFT 2 PLACES LIFT ARM PINS TILT CVLINDER TILT CVLINDER ROD 2 PLACES 8 ROLLER PINS CONNECTING LIFT ARMS 8 TILT ARMS TO HEEL OF PLATFORM ALUMINUM PLATFORM SHOWN FIG 20 5 20 STEP 5 ATTACH PLATFORM 8 ROLLERS Continued 4 Attach anti skid rollers with flat washers and roll pins Kit items to tilt cylinder pins FIG 21 1 PLATFORM 30MM FLAT WASHER 4 PLACES ANTISKID ROLLER 2 PLACES CYLINDER ROLL PIN TILT PIN 2 PLACES CYLINDER PIN ATTACHING ANTI SKID ROLLERS TO CYLINDER PINS ALUMINUM PLATFORM SHOWN FIG 21 1 5 Remove platform supports 6 Use external control to lower platform FIG 22 1 to ground level and raise platform FIG 22 2 to vehicle floor level Watch for interference between moving parts on the liftgate and the vehicle body and frame 21 STEP 6 ATTACH FLOOR SEAL 1 Lower platform to the ground DOOR OPENING FIG 22 1 NOTE If door seals are required for top and sides of the door opening measure width of door opening 2 Measure width of the platform FIG 22 1 or width D of door Opening MEASURING
21. TROL L 36 eem 37 OO TESTE E a 38 eto 39 DIAGRAMS PUMP 8 MOTOR SOLENOID OPERATION HALDEX PUMP 39 PUMP 8 MOTOR SOLENOID OPERATION BUCHER PUMP ONLY 40 HYDRAULIC 41 ELECTRICAL SE EMA 42 Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates Refer to WARNING CAUTION and SAFETY INSTRUCTIONS decals on Liftgate AWARNING e Do not stand or allow obstructions under the platform when lowering the Liftgate Be sure your feet are clear of the Liftgate e 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 e Disconnect Liftgate power cable from battery before repairing or servicing Liftgate e f it is necessary to stand on the platform while maintaining 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 vehicle body Never perform unauthorised modifications on the Liftgate Modifications may result in early failure of the Liftgate and may create ha
22. WIDTH OF PLATFORM OR NOTE If door seals are to be installed DOOR WIDTH ON THE BODY at top and sides of door open PLATFORM ON THE GROUND ing cut floor seal to width D FIG 22 1 of door opening NOTE Rubber floor seal may stretch when inserted If door seals will not be installed cut the rubber floor seal 1 2 longer than mount ing strip Rubber should relax to length of strip after a time 8 SELF DRILLING SCREWS 8 PLACES 3 Cut the floor seal mounting strip FIG 22 2 and floor seal FIG 23 1 Kit items ee oe to measured length P or D FIG 22 1 4 Place mounting strip in position so top is flush with top of rear sill and centered on the body FIG 22 2 Fasten mounting strip to vehicle body with 8 8 18 drilling screws buffer kit item MOUNTING STRIP FLUSH WITH REAR SILL Ka 3 i FI ODRI 3 E i M 5 1 1 5 hl um MOUNTING STRIP END VIEW ATTACHING MOUNTING STRIP STRIP SHOWN CUT TO PLATFORM WIDTH FIG 22 2 22 STEP 6 ATTACH FLOOR SEAL Continued NOTE Seal can be captured by staking each end of the mounting strip 5 Slide rubber floor seal all the way in the mounting track FIG 23 1 FLOOR SEAL END VIEW 1 FLOOR SEAL FLOOR SEAL INSERTED SEAL IS SHOWN
23. ar sill of vehicle bodv Butt both mounting plates against vehicle frame Tighten lock nuts FIG 16 2 to 170NM RH MOUNTING LH MOUNTING PLATE PLATE VEHICLE FRAME 2 PLACES MAIN FRAME REPOSITIONING MOUNTING PLATES REAR VIEW OF MAIN FRAME FIG 16 2 16 STEP 3 MOUNT LIFTGATE ON VEHICLE FRAME A WARNING Never operate the liftgate with loaded platform until mounting plates are complete ly bolted to the vehicle frame Personal injury and equipment damage can result 1 Measure mark and drill 14 2mm bolt holes in nearside mounting plate as shown in FIGS 17 1 and 18 1 Repeat for offside mounting plate EXISTING HOLES IN VEHICLE FRAME 220MM MIN EXISTING HOLES IN A VEHICLE FRAME 7 50MM MIN MIN MOUNTING PLATE 4 50MM gt 50MM gt MIN MIN FLANGE EB 40MM VEHICLE FRAME 6 BOLT PATTERN FOR BOLTING MAX10C amp MAX15C TO VEHICLE FRAME FIG 17 1 Bolt nearside mounting plate to vehicle frame with 14mm grade 8 8 bolts 14mm flat washers and 14mm nvlon lock nuts Repeat for offside mounting plate Torque each 14mm lock nut to 155NM 17 STEP 3 MOUNT LIFTGATE ON VEHICLE FRAME Continued EXISTING HOLES IN VEHICLE FRAME 220MM MIN FLANGE 9 a VEHICLE FRAME 50MM 50MM MIN MIN MOUNTING PLATE 5OMM 50MM gt MIN MIN VEHICLE 5OM
24. fluid level in reservoir as follows With platform on ground level should be as shown in FIG 33 2 NOTE If the hydraulic fluid in the reservoir is contaminated do the CHANGING HYDRAULIC FLUID procedure in this section CAUTION UNLATCH LATCH PUMP COVER Do not fill reservoir to the FULL FIG 33 1 mark on the dipstick Hydraulic fluid can overflow from the reser voir 4 If needed add ISO 22 hydraulic fluid to the reservoir as follows Remove filler cap FIG 33 2 Fill the reser FILLER BREATHER voir with hydraulic fluid to scribe mark RESERVOIR CAP 19MM above bottom of dipstick FIG 33 2 Reinstall filler cap FIG 33 2 SCRIBE MARK FLUID LEVEL CAUTION Pump cover must be correctly secured to prevent it from becom ing a hazard Ensure pump cover is latched to pump box 0 TE 5 oe a Lite fi FI DRAIN PLUG 5 Close and latch the pump cover POWER UNIT FLUID LEVEL FIG 33 1 FIG 33 2 33 13 LUBRICATE BEARINGS AT GREASE FITTINGS NOTE Lube fittings are shown for the nearside tilt cvlinder nearside lift cvlinder and nearside arm of the lift frame There are also lube fittings at the same places on the offside tilt cvlinder offside lift cvlinder and offside arm of the lift frame 1 Position the platform as shown in FIG 34 1 CVLINDER LIFT CVLINDER 8 LIFT ARM OFFSIDE TILT CVLINDER
25. m must be centered within the opening on the rear sill 1 Position the 2 installation jigs Kit items on the rear sill of the vehicle body as shown in FIG 11 1 Clamp or tack weld jigs to rear sill 490 MM gt lt 490 MM JIG REAR BUTTED TO REAR SILL BUTTED TO REAR SILL SEE NOTE SILL SEE NOTE CENTER INSTALLATION JIGS POSITIONED ON REAR SILL OF VEHICLE BODV FIG 11 1 11 STEP 2 LIFTGATE TO VEHICLE Continued 2 Raise and support platform enough to remove the 2 lift arm pins and 2 tilt arm pins FIG 12 1 LIFT ARM PINS TILT ARM PINS SET SCREW 4 PLACES LOCK WASHER 4 PLACES REMOVING LIFT ARM 8 TILT ARM PINS PROVIDED WITH PLATFORM FIG 12 1 3 Use the 2 lift arm pins removed from platform to pin each lift arm to a jig clamped to rear sill FIG 12 2 JIG 2 PLACES 2 PLACES LIFT ARM PINS PINNING ARMS JIGS FIG 12 2 12 STEP 2 LIFTGATE TO VEHICLE Continued 4 Position the liftgate as shown in FIGS 13 1 and 13 2 and the ap plicable dimensions from VEHICLE REQUIREMENTS Keep liftgate from moving out of position while bolting mounting plates to vehicle frame MAIN BEAM LIFT MECHANISM POSITIONED ON VEHICLE FIG 13 1 VEHICLE FRAME SPACERS Nl PACKERS LIFT MECHANISM POSITIONED ON VEHICL FORKLIFT NOT SHOWN FIG 13 2
26. rms 4 If rear sill is likely to interfere with tilt cylinder rods and or lift arms measure and mark the areas to be modified on the rear sill as shown in FIG 7 1 Dimension N is the distance to top of the notch A side view of notch s is shown in FIG 7 2 CENTER LINE gt 667 MM gt 667 MM 4 487 MM 4 487 MM 310553 HEEN 4 102 MM l FRAME AREAS INBD MODIFY 4 PLACE NOTCH OUTBD 70 OUTBD NOTCH NOTCH INBD 2 PLACES 2 PLACES FRONT VIEW REAR SILL NOTCH POSITIONS LIFTGATE NOT SHOWN FIG 7 1 102 MM OR MORE NOTCH DEPTH BODY FRAME RH SIDE VIEW REAR SILL NOTCH FIG 7 2 STEP 1 RUN POWER 8 GROUND CABLES A WARNING Never route an energized wire Make sure the vehicle battery is disconnected Always route electrical wires clear of moving parts brake lines sharp edges and exhaust systems Avoid making sharp bends in wiring Keep adequate distance between and cables that connect to battery Attach securely If drilling is necessary first check behind the drilling surface so you do not dam age any fuel lines vent lines brake lines or wires NOTE The fuse end of the red power cable will be connected to ter minal on vehicle battery BLACK GROUND CABLE TO BATTERY
27. tch 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 Listen for scraping grat ing and binding noises and correct the problem before continuing to operate Liftgate e Use only Maxon Authorised Parts for replacement parts Provide Liftgate model and serial num ber information with your parts order 10 156 8 20C INSTALLATION COMPONENTS 8 KITS HYDRAULIC LIFT MECHANISM WITH BOXED SMALL ITEMS KIT BUMPER DOCUMENT KIT amp PARTS STORES PLATFORM ASSEMBLY ALUMINUM WITH DUAL CART STOPS SHOWN FLOOR SEAL KIT 2 GA BATTERY CABLE 20M LG LARGE ITEMS KIT LARGE ITEMS KIT P N PLO0133 P N 226781 VEHICLE REQUIREMENTS CAUTION The sliding axle assembly on a trailer can collide with a Liftgate mounted on the slide rails To prevent damage to Liftgate and trailer install stops on the slide rails to keep the sliding axles from hitting Liftgate Refer to Liftgate clearance dimensions in this section of the manual NOTE Make sure vehicle is parked on level ground while verifying dimensions preparing vehicle and installing Liftgate NOTE Dimensions are provided as reference for fitting Liftgate to vehicle body Check and record dimen sions of vehicle where VEHICLE FLOOR liftgate will be mounted FIG 5 1 BODY OVERHANG AVAILABLE SPACE VEHICLE FRA
28. the 3 mounting tracks FIG 25 2 DOOR SEALS INSERTED FIG 25 2 25 STEP 7 ATTACH DOOR SEALS 8 PLATFORM BUFFERS Continued 7 Position rubber buffers Kit item on vehicle body corner posts at outboard side of door DOOR SEAL seals as shown in FIG 26 1 Ensure each buffer is below the seal at the top of the door LH BUFFER RH BUFFER and makes contact with plat POSITION POSITION form below the tip LH DOOR SEAL RH SEAL 8 Use each rubber buffer Kit item as a template for marking VEHICLE DOOR OPENING and drilling 2 pilot holes 4 screws in each vehicle body corner post FIG 26 1 POSITIONING BUFFERS ON VEHICLE BODY FIG 26 1 14 SELF TAPPING SCREW 9 Bolt each buffer to vehicle corner post with bolts and lock nuts provided with kit FIG VEHICLE DOOR OPENING 26 2 BOLTING BUFFERS TO VEHICLE BODY FIG 26 2 26 STEP 8 ATTACH LIFT STOPS 1 Raise open platform to vehicle floor level FIG 27 1 ERE R 2 Find area free of obstructions on vehicle frame bv nearside LU lift arm Position lift stop chan 7 nel with gusset and plate Kit l 77 items so channel is in contact 7 A with nearside lift arm and as close as possible to underside PLATFORM RAISED TO FLOOR LEVEL of vehicle bodv FIG 27 2 FIG 27 1 Tack weld in position Repeat this step for offside lift arm CHANNEL STEEL PL
29. zards for Liftgate operators and maintainers SAFETY INSTRUCTIONS e Read and understand the instructions in this Maintenance Manual before performing mainte nance on the Liftgate e Before operating the Liftgate read and understand the operating instructions in Operation Manual e Comply with all WARNING and instruction decals attached to the Liftgate e Keep decals clean and legible decals are illegible or missing replace them Free replacement decals are available from Maxon Customer Service e 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 e Do not allow untrained persons to operate the Liftgate e 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 e 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 e f an emergency situation arises vehicle or Liftgate while operating the Liftgate release the con trol swi
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