M-91-17 REV. E AUGUST 2012 INSTALLATION MANUAL RCM-1250 C RCM-1250 C AB RCM-1600 RCM-1600 C AB 11921 Slauson Avenue Santa Fe Springs, CA 90607 (800) 227-4116 LIFT CORP. © MAXON Lift Corp. 2012 TABLE OF CONTENTS WARNINGS ...........................................................................................................................3 SAFETY INSTRUCTIONS ....................................................................................................3 RCM-1250 C INSTALLATION PARTS BOX .........................................................................4 RCM-1600 C INSTALLATION PARTS BOX .........................................................................5 PREPARING VEHICLE BODY ..............................................................................................6 POSITIONING LIFTGATE .....................................................................................................8 WELDING LIFTGATE TO VEHICLE......................................................................................9 INSTALLING PUMP & PUMP BOX .....................................................................................17 ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) ................19 RUNNING POWER CABLE ................................................................................................25 FRAMELESS - REFRIGERATION/SMOOTH UNDERSIDE TRAILER ...............................26 FRAMELESS - DRY VAN TRAILER ....................................................................................27 CONNECT POWER CABLE ...............................................................................................28 CONNECT GROUND CABLE .............................................................................................29 CONNECT CONTROL WIRING ..........................................................................................31 CONNECT RETURN HOSE ................................................................................................32 CONNECT POWER CABLE TO BATTERY ........................................................................33 ADJUST DRIVE CHAINS (ABOVE BED MODELS) ............................................................36 CHECKING HYDRAULIC FLUID ........................................................................................37 ATTACHING DECALS .........................................................................................................39 TOUCHUP PAINT ...............................................................................................................40 HYDRAULIC SYSTEM DIAGRAM ......................................................................................41 ELECTRICAL SYSTEM DIAGRAM .....................................................................................42 OPTIONS ............................................................................................................................43 RECOMMENDED LIFTGATE POWER CONFIGURATION ................................................44 Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates. See Operation Manual for operating safety requirements. WWAARRNNININGGSS ! WARNING • Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your 3 feet are clear of the Liftgate. 1 7 7 • Keep fi ngers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform 1- 7 edges) when operating the Liftgate. 7 ) • Correctly stow platform when not in use. Extended platforms could create a hazard for 8 8 8 people and vehicles passing by. ( X • Make sure vehicle battery power is disconnected while installing Liftgate. Connect vehicle A F battery power to the Liftgate only when installation is complete or as required in the installation instructions. 6 1 1 • If it is necessary to stand on the platform while operating the Liftgate, keep your feet and any 4 - 7 objects clear of the inboard edge of the platform. Your feet or objects on the platform can become 2 2 trapped between the platform and the Liftgate extension plate. ) 0 0 • Never perform unauthorized modifi cations on the Liftgate. Modifi cations may result in early failure 8 ( of the Liftgate and may create hazards for Liftgate operators and maintainers. 0 7 • Recommended practices for welding on steel parts are contained in the current AWS (American 6 0 Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and 9 personal injury can result from welds that are done incorrectly. . A C SAFETY SINASFTERTUYC INTSIOTNRSUCTIONS , s g n • Read and understand the instructions in this Installation Manual before installing Liftgate. ri p S • Before operating the Liftgate, read and understand the operating instructions in Operation e F Manual. a t • Comply with all WARNING and instruction decals attached to the Liftgate. n a S • Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement . decals are available from Maxon Customer Service. e v A • Consider the safety and location of bystanders and location of nearby objects when operating the n o Liftgate. Stand to one side of the platform while operating the Liftgate s u a • Do not allow untrained persons to operate the Liftgate. Sl 1 • Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while 2 9 performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact 1 1 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 con- trol 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 RCM-1250 C INSTALLATION PARTS BOX ITEM NOMENCLATURE OR DESCRIPTION QTY PART NUMBER REF PARTS BOX, RCM-1250C 1 251813-01 3 1 1 FRAME CLIP, 1/2” X 1-3/8” 7 050079 7 7 - 2 TAPPING SCREW, #10 x 1/2” LG. 4 030458 1 7 7 3 FUSED POWER CABLE, 175 AMP, 38’ LG. 1 264422 ) 8 4 JIFFY CLAMP, #130 1 125674 8 8 ( 5 BUTT CONNECTOR, 14AWG 1 030491 X A 6 FLAT WASHER, 3/8” 2 030556 F 7 BRASS ELBOW, 1/4” X 1” LG. 1 202406 6 1 1 8 LOOM CLAMP, #8 RUBBER 3 214663 4 - 7 9 ELBOW, 3/8” FEM-3/8” FEM 1 228950 2 2 PUMP BOX KIT (RCM) 1 251738-02 ) 0 0 A. PUMP BOX ASSY 1 251741 8 ( B. PUMP BOX BRACKET 1 251817 0 7 C. ANGLE, 2-1/2” X 2-1/2” 1 251815 6 10 0 9 D. BOLT, 3/8”-16 X 1-1/4” LG. 2 030074 . E. HEX NUT, 3/8”-16 2 030348 A C F. FLAT WASHER, 3/8” 2 030556 , s g G. LOCK WASHER, 3/8” 2 030555 n i r 11 ANGLE, 2-1/2” X 2-1/2” 1 251815 p S 12 BRACKET, PUMP MOUNT 1 251816 e F 13 INSTALLATION MANUAL 1 M-91-17 a t n 14 OPERATION MANUAL 1 M-91-19 Sa 15 MAINTENANCE MANUAL 1 M-91-18 . e v 16 INSTRUCTIONS, FUSED POWER CABLE 1 M-00-14 A n 17 DECAL, 1250 LB CAPACITY 1 226006 o s u 18 DECAL, UP & DOWN 1 250993 a l S 19 DECAL, OPER INSTRUCTION 1 252899 1 2 20 DECAL, WARNING 1 282479-01 9 1 1 21 DECAL, STOW WARNING 1 282847-01 22 HEATSHRINK TUBING, 3/4” X 1-1/2” LG. 1 253316-04 23 SEALANT (FOR THREADED HYDRAULIC FITTINGS) 1 260798-02 24 BUSHING, 3/8” X 1/4” LG. 1 800183 25 HEX CAP SCREW, 3/8”-16 X 1” LG, GRADE 8 2 900014-4 26 LOCK WASHER, 3/8” 2 902011-4 27 COPPER LUG, 2GA (5/16” I.D. RING) 1 906497-02 28 PIPE NIPPLE, 3/8” X 2” LG. 1 030304 4 RCM-1600 C INSTALLATION PARTS BOX ITEM NOMENCLATURE OR DESCRIPTION QTY PART NUMBER REF PARTS BOX, RCM-16C 1 251814-01 3 1 1 FRAME CLIP, 1/2” X 1-3/8” 7 050079 7 7 2 TAPPING SCREW, #10 x 1/2” LG. 4 030458 1- 7 3 FUSED POWER CABLE, 175 AMP, 38’ LG. 1 264422 7 ) 8 4 JIFFY CLAMP, #130 1 125674 8 8 ( 5 BUTT CONNECTOR, 14AWG 1 030491 X 6 FLAT WASHER, 3/8” 2 030556 A F 7 BRASS ELBOW, 1/4” X 1” LG. 1 202406 6 1 8 LOOM CLAMP, #8 RUBBER 3 214663 1 4 - 9 ELBOW, 3/8” FEM-3/8” FEM 1 228950 7 2 2 PUMP BOX KIT (RCM) 1 251738-02 ) 0 A. PUMP BOX ASSY 1 251741 0 8 ( B. PUMP BOX BRACKET 1 251817 0 C. ANGLE, 2-1/2” X 2-1/2” 1 251815 7 6 10 0 D. BOLT, 3/8”-16 X 1-1/4” LG. 2 030074 9 E. HEX NUT, 3/8”-16 2 030348 A. C F. FLAT WASHER, 3/8” 2 030556 , s G. LOCK WASHER, 3/8” 2 030555 g n i 11 ANGLE, 2-1/2” X 2-1/2” 1 251815 pr S 12 BRACKET, PUMP MOUNT 1 251816 e F 13 INSTALLATION MANUAL 1 M-91-17 a t n 14 OPERATION MANUAL 1 M-91-19 a S 15 MAINTENANCE MANUAL 1 M-91-18 . e v 16 INSTRUCTIONS, FUSED POWER CABLE 1 M-00-14 A 17 DECAL, 1600 LB CAPACITY 1 224751 on s 18 DECAL, UP & DOWN 1 250993 au l S 19 DECAL, OPER INSTRUCTION 1 252899 1 2 20 DECAL, WARNING 1 282479-01 9 1 1 21 DECAL, STOW WARNING 1 282847-01 22 HEATSHRINK TUBING, 3/4” X 1-1/2” LG. 1 253316-04 23 SEALANT (FOR THREADED HYDRAULIC FITTINGS) 1 260798-02 24 BUSHING, 3/8” X 1/4” LG. 1 800183 25 HEX CAP SCREW, 3/8”-16 X 1” LG, GRADE 8 2 900014-4 26 LOCK WASHER, 3/8” 2 902011-4 27 COPPER LUG, 2GA (5/16” I.D. RING) 1 906497-02 28 COPPER LUG, 2GA (3/8” I.D. RING) 2 226778 29 PIPE NIPPLE, 3/8” X 2” LG. 1 030304 5 PREPARING VEHICLE BODY ! WARNING 3 1 7 This unit cannot be used with swing type doors. 7 - Do not remove banding from shipping pallet or attempt to move the plat- 1 7 7 form, until: ) 8 1. The unit is welded to the vehicle. 8 8 2. The pump installation is complete and motor wiring cable instal- ( X lation thru vehicle battery is complete, and pump is fi lled with oil A F and operating. 6 1 1 NOTE: BODIES WITH ALUMINUM CORNER POSTS. 4 - 7 The Aluminum corner posts must be re-inforced before install- 2 2 ing unit. ) 0 0 8 ( NOTE: FOR AB UNITS. 0 See page 36 for platform travel (chain) adjustment. 7 6 0 9 . A C This unit must be installed as described in this Installation Manual. If any deviation , s g is deemed necessary by the installer, written permission must fi rst be obtained from n i MAXON. pr S e Any change in the installation method without written permission from MAXON, will F void any warranty issued with this unit. a t n a S Please read thru this Installation Manual before commencing the installation of this unit. e. v A The methods of hoisting or supporting the unit during installation are those found in most n o shops. If any other method of hoisting or supporting is used, precautions must be taken us a to ensure the support is adequate and does not endanger the personnel working on the l S installation of this unit. 1 2 9 1 Rear lights. In many cases the rear lights will need to be relocated. Relocate your rear 1 lights to satisfy your local codes and Federal Vehicle Safety Standard 108. 6 PREPARING VEHICLE BODY - Continued PREPARATION OF BODY INSTALLATION OF UNIT The ideal installation, when the rear of the column assemblies are touching the body 3 corner posts, and the rear of the main frame is touching the sill. On some body confi gu- 1 7 rations this is not possible, therefore the following examples must be taken into consider- 7 - 1 ation before hoisting the unit up to the body. 7 7 ) 8 VEHICLES WITH ALUMINUM FRAMES. These bodies are covered on pages 13, 14 8 8 and 15. The steel mounting channels will need to be fabricated and installed to the cor- ( X ner posts before the unit is hoisted up to the body. A F 6 1 1 4 FLAT BED VEHICLES. This installation is covered on page 12. - 7 The bracing channels for this installation cannot be cut until the unit is hoisted up to the 2 2 bed. ) 0 0 8 ( CORNER POST CONFIGURATIONS. In the CORNER POST 0 7 cases where the corner post is not square (VEHICLE) 6 0 or rectangular, a fi ller will need to be fabri- LIFTGATE 9 cated (FIG. 7-1A and 7-1B) to fi ll the space COLUMN A. C between the corner post and the unit column , assemblies. A typical example is illustrated gs n below. i r p S STEEL BAR STOCK 1/4” X 6” e F LG. BY REQUIRED WIDTH a t n a S . e v FILLER PLATE RUNNER A n o s TOP VIEW u a FIG. 7-1A Sl 1 2 9 1 1 THE FILLER PLATES WILL BE WELDED IN AFTER THE UNIT IS HOISTED INTO POSI- TION AND TACK WELDED TO THE BODY FIG. 7-1B 7 POSITIONING LIFTGATE The center line of the unit must be in line with the center line of the body rear door open- ing (FIG. 8-1). The columns and main frame assembly must be touching the corner post 3 and sill. The temporary support angles will be resting on the fl oor and the top surface of the 1 7 main frame should be fl ush and level with the body fl oor. 7 - 1 7 7 ) 8 8 8 ( X A F 6 1 1 4 - 7 2 2 ) 0 0 8 ( 0 7 6 0 CENTER LINE OF 9 THE UNIT. . A CENTER LINE OF C BODY , s g n i r p S e F a t n a S . e v A n o s u TEMPORARY a l S SUPPORT AN- 1 GLES RESTING 2 9 ON THE FLOOR 1 1 CENTER LINE OF LIFTGATE MUST BE IN LINE WITH THE CENTER OF BODY REAR DOOR OPENING FIG. 8-1 8 WELDING LIFTGATE TO VEHICLE WELDING PROCEDURE If a fork lift was used to hoist the unit and the fork lift is required for other work, the column assemblies must be tack welded to the vehicle corner posts (FIG. 9-1) before dis-engag- 3 ing the fork lift. Tack weld on both columns as shown in FIG. 9-1. See page 10. 1 7 7 If an overhead chain hoist was used, it should remain hooked to the unit until the welding - 1 7 procedure is completed. If the hoist needs to be removed before welding, tack weld as 7 shown in FIG. 9-1 before removing hoist. 8) 8 8 ( ! WARNING X A F When welding operations are in progress NEVER allow fl ame, 6 1 heat or sparks to come in contact with lift chain. 1 4 - 7 2 NOTE: Repeat procedure for right hand column. 2 ) 0 0 8 ( 0 7 6 0 9 . A C , s g n i r p S e TACK WELD (TYPICAL) F 1/2” LG. a t 1/4” n a S . e v A n o s u a l S 1 2 9 1 1 TACK WELD TO VEHICLE FRAME (LEFT HAND COLUMN SHOWN) FIG. 9-1 9 WELDING LIFTGATE TO VEHICLE - Continued WELDING PROCEDURE - STANDARD STEEL FRAME Right hand and left hand column assemblies (FIG. 10-1) are welded to right and left hand corner posts. Welds shall be 1/4” fi llets welds spaced as shown in FIG. 10-1 (except 3 1 7 where noted). 7 - 1 7 7 ) ! WARNING 8 8 8 ( When welding operations are in progress NEVER allow fl ame, X A heat or sparks to come in contact with lift chain. F 6 1 1 4 - 7 2 2 ) 0 0 8 ( BOTH SIDES OF 0 COLUMN, 2” LG. 7 6 (TYPICAL) 0 1/4” 9 . A C , s g 1/4” n ALL UNITS: i r p APPROX. S HALF WAY e 2” F 2” DOWN THE a t COLUMN. n a S 1/8” WELD . e v A n o s u a l S 1 2 9 1 1 WELD COLUMN ASSEMBLIES TO VEHICLE CORNER POSTS (LEFT HAND SHOWN) FIG. 10-1 10