M-91-17 REV. E AUGUST 2012 INSTALLATION MANUAL RCM-1250 C RCM-1250 C AB RCM-1600 RCM-1600 C AB LIFT CORP. © MAXON Lift Corp.
TABLE OF CONTENTS WARNINGS ........................................................................................................................... 3 SAFETY INSTRUCTIONS .................................................................................................... 3 RCM-1250 C INSTALLATION PARTS BOX ......................................................................... 4 RCM-1600 C INSTALLATION PARTS BOX .........................................................................
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.
RCM-1250 C INSTALLATION PARTS BOX REF PARTS BOX, RCM-1250C QTY PART NUMBER 1 251813-01 1 FRAME CLIP, 1/2” X 1-3/8” 7 050079 2 TAPPING SCREW, #10 x 1/2” LG. 4 030458 3 FUSED POWER CABLE, 175 AMP, 38’ LG. 1 264422 4 JIFFY CLAMP, #130 1 125674 5 BUTT CONNECTOR, 14AWG 1 030491 6 FLAT WASHER, 3/8” 2 030556 7 BRASS ELBOW, 1/4” X 1” LG. 1 202406 8 LOOM CLAMP, #8 RUBBER 3 214663 9 ELBOW, 3/8” FEM-3/8” FEM 1 228950 PUMP BOX KIT (RCM) 1 251738-02 A.
RCM-1600 C INSTALLATION PARTS BOX REF PARTS BOX, RCM-16C QTY PART NUMBER 1 251814-01 1 FRAME CLIP, 1/2” X 1-3/8” 7 050079 2 TAPPING SCREW, #10 x 1/2” LG. 4 030458 3 FUSED POWER CABLE, 175 AMP, 38’ LG. 1 264422 4 JIFFY CLAMP, #130 1 125674 5 BUTT CONNECTOR, 14AWG 1 030491 6 FLAT WASHER, 3/8” 2 030556 7 BRASS ELBOW, 1/4” X 1” LG. 1 202406 8 LOOM CLAMP, #8 RUBBER 3 214663 9 ELBOW, 3/8” FEM-3/8” FEM 1 228950 PUMP BOX KIT (RCM) 1 251738-02 A.
! WARNING This unit cannot be used with swing type doors. Do not remove banding from shipping pallet or attempt to move the platform, until: 1. The unit is welded to the vehicle. 2. The pump installation is complete and motor wiring cable installation thru vehicle battery is complete, and pump is filled with oil and operating. NOTE: BODIES WITH ALUMINUM CORNER POSTS. The Aluminum corner posts must be re-inforced before installing unit. NOTE: FOR AB UNITS.
PREPARING VEHICLE BODY - Continued The ideal installation, when the rear of the column assemblies are touching the body corner posts, and the rear of the main frame is touching the sill. On some body configurations this is not possible, therefore the following examples must be taken into consideration before hoisting the unit up to the body. VEHICLES WITH ALUMINUM FRAMES. These bodies are covered on pages 13, 14 and 15.
The center line of the unit must be in line with the center line of the body rear door opening (FIG. 8-1). The columns and main frame assembly must be touching the corner post and sill. The temporary support angles will be resting on the floor and the top surface of the main frame should be flush and level with the body floor. CENTER LINE OF THE UNIT. CENTER LINE OF BODY TEMPORARY SUPPORT ANGLES RESTING ON THE FLOOR CENTER LINE OF LIFTGATE MUST BE IN LINE WITH THE CENTER OF BODY REAR DOOR OPENING FIG.
WELDING LIFTGATE TO VEHICLE 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-engaging the fork lift. Tack weld on both columns as shown in FIG. 9-1. See page 10. If an overhead chain hoist was used, it should remain hooked to the unit until the welding procedure is completed. If the hoist needs to be removed before welding, tack weld as shown in FIG. 9-1 before removing hoist.
WELDING LIFTGATE TO VEHICLE - Continued Right hand and left hand column assemblies (FIG. 10-1) are welded to right and left hand corner posts. Welds shall be 1/4” fillets welds spaced as shown in FIG. 10-1 (except where noted). ! WARNING When welding operations are in progress NEVER allow flame, heat or sparks to come in contact with lift chain. BOTH SIDES OF COLUMN, 2” LG. (TYPICAL) 1/4” 2” 1/4” ALL UNITS: APPROX. HALF WAY DOWN THE COLUMN.
20” 20” 20” 20” 1” - 20” 1/8” WELD REAR OF LIFTGATE MAIN FRAME TO VEHICLE SILL (UNDER BODY VIEW) FIG. 11-1 11 11921 Slauson Ave. Santa Fe Springs, CA.
WELDING LIFTGATE TO VEHICLE - Continued The column assemblies are tied in to the flat bed side rails with two lengths of channel as shown in FIG. 12-1A. Weld column assembly to its corresponding side rail to a distance of 60” approximately, just above a cross member (FIG. 12-1A). If side rail is less than 1/4”, weld a 1/4” plate to side rail, then weld channel to 1/4” plate as shown in FIG. 12-1B. NOTE: Mounting channel is not supplied by MAXON. 1/4” 3” LG.
WELDING LIFTGATE TO VEHICLE - Continued Four steel mounting channels will need to be fabricated before hoisting unit up to vehicle. The mounting channels will be riveted to the aluminum frame before installing the unit. The required mounting dimensions are shown in FIG. 13-1. To fill gap between body and rear of main frame, fabricate 2 pieces of 10 GA 8” x 4”(FIG. 13-1). See pages 14 and 15 for details of installation. NOTE: Mounting channel is not supplied by MAXON.
WELDING LIFTGATE TO VEHICLE - Continued Steel mounting channels shall be 10 gauge material, 8” in length (FIG. 14-1). All other dimensions 1-3/4” shall suit dimensions of vehicle corner posts. Drill 10 holes to 1-3/4” larger side of mounting channel, 1-3/4” and 5 to smaller face. Drillings should be suitable to accept 1/4” 1-3/4” drive rivets. FIG. 14-1 shows 1/2” locations for drillings. 1/2” 1-3/4” 1-3/4” 1-3/4” 1-3/4” 1/2” 1/2” 1/2” DRILLINGS LOCATIONS ON STEEL MOUNTING CHANNELS FIG.
INSIDE OF COLUMN ASSEMBLY Weld two 1/8” gussets to channels and column assembly as shown in FIG. 15-1. The channel located at bottom of the column assembly is gusseted in an identical manner. Repeat for right head column assembly. 1/8” WELDING GUSSETS TO COLUMN ASSEMBLY AND CORNER POST (LH COLUMN ASSY IS SHOWN, INSIDE UPPER FACE) FIG. 15-1 WELDING MAIN FRAME TO SILL The rear of the main frame shall be welded to sill as illustrated in FIG. 15-2. Main frame upper side must be flush to sill upper side (FIG.
WELDING LIFTGATE TO VEHICLE - Continued The lower portion of the column can be cut off 18” (maximum) above the ground 18” (FIG. 16-1) to improve the entry and exit angle of the vehicle. NOTE: Vehicles with air ride suspension must have air bags fully inflated before columns are cut 18” from ground. 18” ENTRY/EXIT ANGLE CUTTING OFF LOWER PORTION OF COLUMN FIG. 16-1 16 11921 Slauson Ave. Santa Fe Springs, CA.
INSTALLING PUMP & PUMP BOX PUMP PUMP BOX PUMP MOUNT 1/4” VEHICLE FRAME 1/4” 2 PLACES PUMP MOUNT 13/16” 10-7/8” 3-3/4” 251817 MOUNT BRACKET 17 11921 Slauson Ave. Santa Fe Springs, CA.
INSTALLING PUMP & PUMP BOX - Continued 251681 COVER 251741 PUMP BOX ASSY PUMP ASSY (REF) 251680 BOX BOLT 3/8”-16 X 1-1/4” LG PUMP MOUNT (REF) 3/8” LOCK WASHERS (2 PLACES) MOUNT BRACKET (REF) 3/8” LOCK WASHERS (2 PLACES) 3/8” FLAT WASHERS (2 PLACES) 3/8”-16 HEX NUT (2 PLACES) 18 BOLT 3/8”-16 X 1” LG (2 PLACES) 11921 Slauson Ave. Santa Fe Springs, CA.
1. Select holes on top of battery box frame to align mounting brackets flush to cross members. Refer to FIGS. 19-1A & 19-1B for trailers and FIG. 19-2 for trucks. Bolt mounting brackets to battery box frame as shown in FIG. 19-1C. Torque each bolt and lock nut to 85-128 lb-ft. LOCK WASHER LOCK NUT WASHER CROSS MEMBER MOUNTING BRACKETS WASHER CAP SCREW BOLTING BRACKETS (8 PLACES) FIG.
ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued 2. Using mounting brackets as a template mark and drill holes through cross members (FIG. 20-1). Bolt mounting brackets to cross members as shown in FIGS. 20-2A and 20-2B. Torque bolts and lock nuts to 85-128 lb-ft. CROSS MEMBER MOUNTING BRACKETS 1/2” HOLES MARK AND DRILL FIG.
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.
! WARNING Remove all rings, watches and jewelry before doing any electrical work. NOTE: Always connect fused end of power cable to battery positive (+) terminal. NOTE: To connect charge lines, refer to instructions provided with each charge line kit. NOTE: MAXON recommends using dielectric grease on all electrical connections. 4. Connect battery cables, fused cables, and ground cables as shown in FIG. 22-1. ELECTRICAL COMPONENTS - BATTERY BOX (GROUND CABLE TO PUMP BOX OR COMMON CHASSIS GROUND) 74” LG.
! 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. 23-1 23 11921 Slauson Ave. Santa Fe Springs, CA.
ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued PAN HEAD SCREW 1/4”-20 X 1” LG. FLAT WASHER 1/4” REFER TO BATTERY BOX LOCK NUT 1/4”-20 HEX NUT 5/16”-18, GR8 (3 PLACES) L-SHAPE ROD LOCK WASHER #10 (3 PLACES) FLAT WASHER 5/16” (3 PLACES) CAP SCREW 1/2”-20 X 2 1/4” LG. GR8 (4 PLACES) ROD (2 PLACES) HEX NUT 5/16”-18 (2 PLACES) FLAT WASHER M8 (2 PLACES) BRACKET MOUNTING PLATE LOCK NUT 5/16”-18 (2 PLACES) LOCK WASHER 9/16” (4 PLACES) FIG.
RUNNING POWER CABLE CAUTION 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. Attach securely. If drilling is necessary, first check behind the drilling surface to prevent damage to any fuel lines, vent lines, brake lines or wires.
RUNNING POWER CABLE - Continued ! CAUTION 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. Attach securely. If drilling is necessary, first check behind the drilling surface to prevent damage to any fuel lines, vent lines, brake lines or wires.
RUNNING POWER CABLE - Continued ! CAUTION 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. Attach securely. If drilling is necessary, first check behind the drilling surface to prevent damage to any fuel lines, vent lines, brake lines or wires.
CONNECT POWER CABLE 2. On the bare wire end of fused power cable, keep enough length to attach copper terminal lug and reach motor solenoid without putting tension on cable (after connection) (FIG. 28-1A). Measure (if needed), and then cut excess cable from bare wire end of cable. Put heatshrink tubing (Parts Box item) (FIG. 28-1B) on the end of the cable and leave room for terminal lug. Crimp copper terminal lug (5/16” ring, Parts Box item) on the fused power cable and shrink the heatshrink tubing (FIG.
NOTE: To ensure power unit is correctly grounded, MAXON recommends connecting 2 gauge ground cable from grounding bolt on pump manifold to grounding point on vehicle frame. Use remaining length of 2 gauge cable (Parts Box item) and 2 copper lugs (Parts Box item) to make ground cable. 1. Put heatshrink tubing (Parts Box item) (FIG. 29-1) on each end of ground cable and leave room for terminal lug.
NOTE: If there is a grounding point on the frame, use it to connect ground cable. Then, skip the step for drilling a hole. NOTE: Clean the ground cable connection point on the frame down to bare metal. 4. Extend the ground cable to reach vehicle frame (FIG. 30-1) without putting tension on cable (after connection). Connect to existing grounding point if available. 5. If necessary, drill a 11/32” (0.343”) hole in vehicle frame for bolting the ground cable terminal lug (FIG. 30-1).
1. Extend the control switch cable through hole in pump box wall (FIG. 31-1). Connect 3 control wires to solenoid valve and starter switch (FIG. 31-1). Ensure wiring has slack after connections are made. BLACK (SOL. VALVE) BUTT CONNECTOR GROUND CABLE (REF) GREEN (BATTERY+) WHITE (START SWITCH COIL+) POWER CABLE (REF) CONNECTING CONTROL SWITCH CABLE TO PUMP ASSEMBLY FIG. 31-1 2. Connect 3 control wires to solenoid valve and starter switch as follows (FIG. 31-1).
CONNECT RETURN HOSE ELBOW (1/4” X 1/4”) PLASTIC HOSE (1/4” O.D.) RESERVOIR BUSHING (3/8” TO 1/4”) RETURN PORT RETURN HOSE CONNECTED TO PUMP RESERVOIR FIG. 32-1 NOTE: Apply thread sealant (Parts Box item) to hydraulic line connections. 2. Connect bushing and 1/4” x 1/4” elbow (Parts Box items) to return port on reservoir (FIG. 32-1). 3. Connect return hose to elbow (FIG. 32-1). 32 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1.
CONNECT POWER CABLE TO BATTERY ! WARNING To prevent accidental personal injury and equipment damage, make sure power is disconnected from Liftgate while installing parts. NEGATIVE (-) BATTERY CABLE NEGATIVE (-) POST 1. Disconnect power from Liftgate by disconnecting negative (-) cable from negative (-) post on battery (FIG. 33-1). DISCONNECTING BATTERY FIG. 33-1 2. Remove nut from positive (+) battery terminal connector. Connect power cable to the positive (+) battery terminal connector (FIG. 33-2).
NOTE: To set pressure relief valve, hydraulic pressure gauge must be connected to lifting port on pump manifold. Do the pump pressure relief valve adjustment before connecting pressure hose from cylinder. 1. Remove shipping plug from pressure port on pump manifold (FIG. 34-1). Then, connect 5000 psi pressure gauge to pressure port. PRESSURE GAUGE PRESSURE PORT MANIFOLD RELIEF VALVE ADJUSTMENT ADJUSTING PRESSURE RELIEF VALVE FIG. 34-1 2. Remove relief valve cover from manifold (FIG. 34-1). 3.
CONNECT PRESSURE LINE 1. Connect pipe nipple and swivel elbow (Parts Box items) to pressure port on pump manifold (FIG. 35-1). SWIVEL PRESSURE HOSE ELBOW 2” LG PIPE NIPPLE MANIFOLD PRESSURE PORT PRESSURE HOSE CONNECTED TO PUMP MANIFOLD FIG. 35-1 2. Connect pressure hose to swivel end of pipe nipple (FIG. 35-1). 35 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 NOTE: Apply thread sealant (Parts Box item) to hydraulic line connections.
NOTE: Vehicle body must be empty (unloaded) before performing the following adjustment. ADJUSTING RODS 1. Adjust drive chains as follows. ADJUSTING NUTS CYLINDER LOCK NUTS 2. Remove cover from cylinder housing. Loosen the lock nut on each chain adjusting rod (FIG. 36-1). Then lower platform to ground level. ADJUSTING DRIVE CHAIN FIG. 36-1 3. Turn each chain adjusting nut (FIG. 36-1) an equal amount of clockwise turns (alternate from chain to chain) until hydraulic cylinder is fully compressed.
CHECKING 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 38-1 and 38-2 for recommended brands. 1.
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 38-1 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 38-2 38 11921 Slauson Ave. Santa Fe Springs, CA.
NOTE: Ensure there is no residue, dirt, or corrosion where decals are attached. If neccessary, clean surface before attaching decals. CONTROL SWITCH DECAL P/N 250993 MAXPRO DECAL P/N 265388-01 CAPACITY DECAL (RCM-1600 ONLY) P/N 224751 CAPACITY DECAL (RCM-1250 ONLY) P/N 226006 INSTRUCTION DECAL P/N 252899 WARNING DECAL P/N 282479-01 WARNING DECAL P/N 282847-01 39 11921 Slauson Ave. Santa Fe Springs, CA.
TOUCHUP PAINT Damaged cylinder seals and contaminated hydraulic fluid 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 touchup paint kit, P/N 908134-01. 40 11921 Slauson Ave. Santa Fe Springs, CA.
HYDRAULIC CYLINDER 2 GPM FLOW CONTROL VALVE AUX. TANK PORT (PLUGGED) VENT PORT PRESSURE PORT “A” VALVE CHECK VALVE PRESSURE RELIEF VALVE (SET AT 2250 +/- 50 PSI) PUMP MOTOR (REF) FILTER 41 HAND PUMP PORT (PLUGGED) HAND PUMP PORT (PLUGGED) 11921 Slauson Ave. Santa Fe Springs, CA.
CONTROL SWITCH WHITE GREEN BLACK CABLE ASSY STARTER SOLENOID SOLENOID, VALVE “A” BLACK MOTOR CABLE WITH 175 AMP FUSE BATTERY 42 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION PART NO CAB CUT-OFF SWITCH 250477 CIRCUIT BREAKER (150 AMP) 251576 AUXILIARY HAND PUMP KIT 251849 LVS, RCM 282991-01 TRAFFIC CONE KIT 268893-01 EXTRA CONTROLS & CONTROL KITS HAND HELD CONTROL 053513 HAND HELD CONTROL WITH COILED CORD 053513-200 TOUCH-UP PAINT KIT TOUCH-UP PAINT (BCG) WITH ALUMINUM PRIMER, SMALL 43 908134-01 11921 Slauson Ave. Santa Fe Springs, CA.
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 and additional battery box are typically installed on trailers as shown in FIG. 44-1 and on trucks as shown in FIG. 44-2. See the following page for battery and cable connections.
NOTE: Always connect fused end of power cable to battery positive (+) terminal. 2. Recommended battery box setup for 12 volt batteries is shown in FIG. 45-1. GROUND CABLE TO PUMP BOX OR GROUND COMMON CHASSIS (-) BATTERY CABLE (-) BATTERY CABLE TO COMMON GROUND POWER CABLE TO PUMP BOX 150 AMP CIRCUIT BREAKER FUSED CABLE (SEE NOTE) (+) BATTERY CABLES FUSED CABLE (SEE NOTE) 12 VOLT BATTERY CONNECTIONS FIG. 45-1 45 11921 Slauson Ave. Santa Fe Springs, CA.
NOTE: Always connect fused end of power cable to battery positive (+) terminal. 3. Recommended battery box setup for getting +24 volt dc power from 12 volt batteries is shown in FIG. 46-1. GROUND CABLE TO PUMP BOX OR COMMON CHASSIS GROUND (-) BATTERY CABLE TO COMMON GROUND 150 AMP CIRCUIT BREAKER FUSED CABLE (SEE NOTE) (+) BATTERY CABLE FUSED CABLE (SEE NOTE) 12 VOLT BATTERY CONNECTIONS FOR +24 VDC POWER FIG. 46-1 46 11921 Slauson Ave. Santa Fe Springs, CA.
