Maxon BMR Series User manual

M-16-10
REV. D
MARCH 2020
• Warnings & Safety Instructions
• Requirements - Body Strength & Installed Liftgate
• Liftgate Installation Components
• Liftgate Component Installation Instructions
• Hydraulic Fluid Filling Instructions
• Decals
• Hydraulic & Electrical System Diagrams
• Pre-delivery Inspection Form
Installation Manual Contains:
© MAXON Lift Corp. 2020
To find maintenance & parts information for your BMR Liftgate, go
to www.maxonlift.com. Click the PRODUCTS, COLUMNLIFT &
BMR buttons. Open the Maintenance Manual in the PRODUCT
DOCUMENTATION window. For parts, click on the PARTS PORTAL,
COLUMNLIFT & BMR buttons.

TABLE OF CONTENTS
SUMMARY OF CHANGES: M-16-10, REVISION D............................................................. 5
WARNINGS........................................................................................................................... 6
SAFETY INSTRUCTIONS .................................................................................................... 7
VEHICLE REQUIREMENTS................................................................................................. 8
BODY STRENGTH................................................................................................................ 8
INSTALLED LIFTGATE ....................................................................................................... 12
LIFTGATE INSTALLATION COMPONENTS...................................................................... 13
COMPONENTS................................................................................................................... 14
STEP 1 - PREPARE VEHICLE IF REQUIRED ................................................................... 19
STEP 2 - CHOOSE METHOD OF INSTALLATION............................................................. 21
STEP 3 - POSITION LIFTGATE.......................................................................................... 22
METHOD 1 - PRE-INSTALL MOUNTING PLATES ............................................ 22
AND EXTENSION PLATE ON VEHICLE............................................................. 22
METHOD 2 - WELD BOLT-ON LIFTGATE TO BODY ......................................... 27
METHOD 3 - WELD LIFTGATE TO BODY.......................................................... 30
STEP 4 - BOLT LIFTGATE TO VEHICLE............................................................................ 33
STEP 5 - REMOVE LOWER SUPPORT FIXTURES .......................................................... 38
STEP 6 - POSITION PUMP BOX FRAME .......................................................................... 39
STEP 7 - ATTACH PUMP & BATTERY BOX FRAME TO VEHICLE ................................... 41
STEP 8 - RUN HYDRAULIC LINES & ELECTRIC CABLES............................................... 47
RUN GRAVITY DOWN HYDRAULIC LINES ....................................................... 48
TORQUE VALUES FOR HYDRAULIC CONNECTORS...................................... 50
RUN POWER DOWN HYDRAULIC LINES......................................................... 51
RUN ELECTRIC CABLES ................................................................................... 53
STEP 9 - GROUND PUMP TO VEHICLE FRAME.............................................................. 58

STEP 10 - RUN CHARGE LINES ....................................................................................... 59
RECOMMENDED POWER CONFIGURATIONS .............................................. 59
RUNNING CABLE FROM VEHICLE BATTERY ................................................ 61
STEP 11 - CONNECT CHARGE LINES & BATTERIES...................................................... 62
STEP 12 - PRESSURIZE HYDRAULIC SYSTEM .............................................................. 66
STEP 13 - OPTIMIZE HYDRAULIC FLUID LEVEL............................................................. 67
STEP 14 - REMOVE UPPER SUPPORT FIXTURES ........................................................ 72
STEP 15 - SECURING COLUMNS..................................................................................... 73
METHOD 1 & METHOD 2................................................................................. 73
METHOD 1 ONLY ............................................................................................. 74
STEP 16 - FINISH WELDING LIFTGATE TO VEHICLE ..................................................... 77
METHOD 2 & METHOD 3 - WELD LIFTGATE TO BODY................................. 77
STEP 17 - CHECK CLEARANCE OF CONNECTOR BAR SIDE BRACKETS &
STOP BLOCKS ................................................................................................................... 81
STEP 18 - CHECK CLEARANCE OF RUNNER PADS ...................................................... 83
STEP 19 - PLATFORM CHAIN ADJUSTMENT .................................................................. 88
STEP 20 - ADJUST PLATFORM ASSEMBLY ..................................................................... 90
STEP 21 - PLACE “ALIGN ARROWS” DECAL ................................................................... 91
STEP 22 - ACTIVATE PLATFORM LIGHTS........................................................................ 92
DECALS & PLATES ............................................................................................................ 93
TOUCH UP GALVANIZED FINISH ..................................................................................... 95
HYDRAULIC SYSTEM DIAGRAMS...................................................................................96
PUMP & MOTOR SOLENOID OPERATION - POWER DOWN.......................................... 96
PUMP & MOTOR SOLENOID OPERATION - GRAVITY DOWN........................................ 97
GRAVITY DOWN HYDRAULIC SCHEMATIC ..................................................................... 98
TABLE OF CONTENTS - Continued

TABLE OF CONTENTS - Continued
POWER DOWN HYDRAULIC SCHEMATIC....................................................................... 99
ELECTRICAL SYSTEM DIAGRAMS ............................................................................... 100
INTERCONNECTING ELECTRICAL SCHEMATIC - GRAVITY DOWN ........................... 100
GRAVITY DOWN SINGLE & DUAL PUMP ELECTRICAL SCHEMATIC .......................... 101
INTERCONNECTING ELECTRICAL SCHEMATIC - POWER DOWN ............................. 102
POWER DOWN SINGLE & DUAL PUMP ELECTRICAL SCHEMATIC ............................ 103
BMR ELECTRICAL VALUES............................................................................................. 104
PRE-DELIVERY INSPECTION FORM.............................................................................. 105

PAGE DESCRIPTION OF CHANGE
COVER Updated REV. and date of release.
6 Added California Proposition 65 WARNING.
26 Updated FIG. 26-1 extension plate and mounting plate weld dimensions.
53-57 Updated Run Electrical Cables step to include instructions for properly connecting
cables. Added taillight connector details (FIG. 57-1).
93 Added Parts QR Code decal.
94 Updated Operating Instructions decal (Decal F) with OR code link to operating instruc-
tions video.
105 Updated Pre-Delivery Inspection Form to include verifying all lights are operational.
SUMMARY OF CHANGES: M-16-10, REVISION D

6
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
WARNINGS
•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.
•Make sure vehicle battery power is disconnected while installing Liftgate. Connect vehicle
battery power to the Liftgate only when installation is complete or as required in the installation
instructions.
•Remove all rings, watches and jewelry before doing any electrical work.
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.
•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.
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
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.
!
•Recommended practices for welding galvanized steel are contained in the current AWS (Ameri-
can Welding Society) D19.0 Welding Zinc-Coated Steel. Damage to Liftgate and/or vehicle, and
personal injury can result from welds that are done incorrectly.
Installing and maintaining a liftgate can expose you to chemicals, including lead, which are known
to the State of California to cause cancer and birth defects or other reproductive harm. To mini-
mize exposure, install and maintain liftgate in a well-ventilated area and wear proper Personal
protective equipment (PPE). For more information go to www.P65Warnings.ca.gov.
WARNING
!

7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
•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.
•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.
•Do not allow untrained persons or children to operate the Liftgate.
• 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 con-
trol switch to stop the Liftgate.
•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.
• 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.

8
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
VEHICLE REQUIREMENTS
The BMR is a body-mounted Liftgate
that puts forces on the side walls of truck
and trailer bodies (FIG. 8-1). For cor-
rect installation, truck and trailer bodies
must be strong enough to withstand the
tension, compression and shear forces
shown in FIG. 8-1. Use TABLES 9-1,
9-2, 9-3, and 9-4 on the following page
to determine the forces that apply to the
type of platform, size of platform, and
load capacity of your Liftgate.
X= Tension on each sidewall
Y= Compression on each sidewall
Z= Shear on each sidewall
X
77”
BED HEIGHT
Y
Z
Consult vehicle body manufacturer for vehicle body strength data. Make sure the
forces created by the Liftgate are within the limits prescribed by the vehicle body
manufacturer.
WARNING
FIG. 8-1
BODY STRENGTH
NOTE: Maximum operating bed height for body is 56” (Unloaded). Minimum is 44”
(Loaded). Do not install this Liftgate on vehicle bodies equipped with swing
open doors.
!
NOTE: Installer is responsible for ensuring vehicle meets Federal, State, and Local
standards and regulations.

9
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
BODY STRENGTH - Continued
VEHICLE REQUIREMENTS - Continued
MODEL CAPACITY P/F
SIZE (X)(Y) LBS. (Z) LBS.
BMR-35
3500 LBS.
(ALUMINUM
PLATFORM)
84 1785 3683
72 1580 3649
60 1339 3619
48 1081 3533
42 964 3510
BMR-44
4400 LBS.
(ALUMINUM
PLATFORM)
84 2233 4358
72 1931 4324
60 1637 4294
48 1326 4208
42 1183 4185
MODEL CAPACITY P/F
SIZE (X)(Y) LBS. (Z) LBS.
BMR-55
5500 LBS.
(ALUMINUM
PLATFORM)
84 2725 5183
72 2360 5749
60 2001 5119
-- -
-- -
BMR-66
6600 LBS.
(ALUMINUM
PLATFORM)
84 3219 6008
72 2788 5974
60 2365 5944
-- -
-- -
TABLE 9-3 TABLE 9-4
MODEL CAPACITY P/F
SIZE (X)(Y) LBS. (Z) LBS.
BMR-35
3500 LBS.
(STEEL PLATFORM)
84 2101 4176
72 1780 4071
60 1475 3962
48 1180 3840
42 1043 3786
BMR-44
4400 LBS.
(STEEL PLATFORM)
84 2504 4851
72 2110 4746
60 1772 4637
48 1426 4515
42 1262 4461
MODEL CAPACITY P/F
SIZE (X)(Y) LBS. (Z) LBS.
BMR-55
5500 LBS.
(STEEL PLATFORM)
84 2998 5676
72 2559 5571
60 2137 5462
48 1726 5340
42 1529 5286
BMR-66
6600 LBS.
(STEEL PLATFORM)
84 3491 6501
72 2989 6396
60 2500 6287
48 2025 6165
42 1738 6111
TABLE 9-1 TABLE 9-2

10
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
VEHICLE REQUIREMENTS - Continued
NOTE: Maximum bed height is 56” (unloaded).
Minimum bed height (loaded) varies with type and size of platform.
Refer to FIGS. 10-1 & 10-2.
WELD-ON LIFTGATE
FIG. 10-1 BOLT-ON LIFTGATE FIG. 10-2
CLEARANCE DIMENSIONS
56” (MAX. BED HT.)
13-3/4” (INCLUDES 3/4” BUMPER)
56” (MAX. BED HT.)
13-1/4” (INCLUDES 3/4” BUMPER)

11
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
VEHICLE REQUIREMENTS - Continued
CLEARANCE DIMENSIONS
FIG. 11-1
97-1/8” (96” WIDE VEHICLE)
102-1/8” (102” WIDE VEHICLE)
95-5/8”
18-1/8”
82-1/8” (96” WIDE VEHICLE)
87-1/8” (102” WIDE VEHICLE)
77-5/8” (96” WIDE VEHICLE)
82-5/8” (102” WIDE VEHICLE)

12
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
INSTALLED LIFTGATE
LIFTGATE INSTALLED ON VAN BODY (COLUMNS
SHOWN PERPENDICULAR TO LEVEL GROUND)
FIG. 12-1
LEVEL
With the vehicle parked on level
ground, the columns of the BMR
must be perpendicular to the
ground (vertical) for the Liftgate
to operate correctly (FIGS. 12-1
and 12-2).
VEHICLE REQUIREMENTS - Continued
91° MAX.
LEVEL
LIFTGATE INSTALLED ON FLAT BED (COLUMNS & SUP-
PORTS SHOWN PERPENDICULAR TO LEVEL GROUND)
FIG. 12-2
NOTE: If Liftgate columns exceed a 91 degree angle from level ground when installed on
body, or if columns cannot be mounted flush against rear of vehicle, a steel filler
may be used to bridge gap between vehicle body and Liftgate columns. Make
sure the added materials and welds meet the BODY STRENGTH requirements
shown on the previous pages.
91° MAX.

13
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
FIG. 13-1
DESCRIPTION
1BMR Liftgate
2Hardware parts bag, mounting bracket parts bag, hydraulic lines & fittings, wiring
harness, power cable, molded switch control box
3A Mounting plates (bolt-on installation kit)
3B Extension plate (bolt-on installation kit)
4Pump box assembly
5A Pump installation kit (3’, 10’, 15’, 20’, or 28’)
5B Channel guard (for 10’, 15’, 20’ or 28’ installation kits only)
6Frame for pump box with optional battery box is shown. A shorter frame is also
available for mounting single pump box or an optional battery box.
7Battery box (optional)
8Optional equipment
9Installation and operation manuals.
TABLE 13-1
2
3B
5A
67
4
3A
3A 5B
1
8
9
LIFTGATE INSTALLATION COMPONENTS
Each BMR Liftgate includes items
shown in FIG. 13-1.

14
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
COMPONENTS
BMR
MODEL KIT, MANUALS
BOLT-ON
INSTALLATION KIT,
STAINLESS STEEL
BOLT-ON
INSTALLATION KIT,
STEEL
BOLT-ON
BOLT-ON
INSTALLATION KIT,
INSTALLATION KIT,
STEEL (BLACK)
STEEL (BLACK)
ALL 296912-01
288875-11
(96” WIDE VEHICLE)
288875-12
(102” WIDE VEHICLE)
288875-11-150
(96” W, PRE-INSTALLED)
288875-12-150
(102” W, PRE-INSTALLED)
288875-01
(96” WIDE VEHICLE)
288875-02
(102” WIDE VEHICLE)
288875-31
(96” WIDE VEHICLE)
288875-32
(102” WIDE VEHICLE)
288875-31-150
(96” W, PRE-INSTALLED)
288875-32-150
(102” W, PRE-INSTALLED)
TABLE 14-1
NOTE: Make sure you have components and parts before you start installing Liftgate.
Compare parts in the part box and each kit box with packing list enclosed in
each box. If parts and components are missing or incorrect, call:
Maxon Customer Service
Call [phone] or
Send e-mail to [email protected]
BMR
MODEL PART BOX 3 FT
PUMP BOX
INSTALL KIT
10 FT
PUMP BOX
INSTALL KIT
15 FT
PUMP BOX
INSTALL KIT
20 FT
PUMP BOX
INSTALL KIT
28 FT
PUMP BOX
INSTALL KIT
BMR-35 PD
BMR-44 PD
BMR-55 PD
BMR-66 PD
296805-02
(WELD-ON)
296805-12
(BOLT-ON)
296805-12-150
(BOLT-ON)
297060-11 297060-12 297060-13 297060-14 297060-15
BMR-35 GD
BMR-44 GD
BMR-55 GD
BMR-66 GD
296805-01
(WELD-ON)
296805-11
(BOLT-ON)
296805-11-150
(BOLT-ON)
297060-01 297060-02 297060-03 297060-04 297060-05
TABLE 14-2

15
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
COMPONENTS - Continued
TABLE 15-1
BMR
MODEL
OPTIONS
SINGLE
PUMP
ASSY
SECOND
PUMP
KIT
HYDRAULIC
OIL
UNIVIS HV1-
13
FRAME,
PUMP OR
BATTERY
BOXES
HEADER KIT
(ADJUST-
ABLE)
HEADER
KIT
(RECESSED
DOME LAMP)
BMR-35 GD
BMR-44 GD
BMR-55 GD
BMR-66 GD
296190-12
296445-12 284098-01
288180-11G
SINGLE FRAME
(GALVANIZED)
287980-11G
DUAL FRAME
2 BATT BOX
(GALVANIZED)
288810-11G
DUAL FRAME
3 BATT BOX
(GALVANIZED
289190-02
(GALVANIZED)
289188-11
(GALVANIZED,
96” WIDE VE-
HICLE)
289188-12
(GALVANIZED,
102” WIDE
VEHICLE)
BMR-35 PD
BMR-44 PD
BMR-55 PD
BMR-66 PD
296180-12
BMR
MODEL
OPTIONS
DOME LAMP
RECESSED
MOUNT
DOME TIMER
SWITCH AUXILIARY
CONTROL HAND HELD CONTROL CYCLE COUNTER
BMR-35 GD
BMR-44 GD
BMR-55 GD
BMR-66 GD
906589-01-100
(ONLY FOR
HEADER KITS
WITH RECESSED
MOUNTS FOR
DOME LAMPS)
295880-01
3’ REACH
295880-02
20’ REACH
297080-11
296169-01 289537-01
BMR-35 PD
BMR-44 PD
BMR-55 PD
BMR-66 PD
297080-12
TABLE 15-2

16
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
BMR
MODEL
OPTIONS
POWER & GROUND
CABLES
CONSPICUITY
(REFLECTIVE)
TAPE
PUMP
PRESSURE
GAUGE
STREET SIDE
CONTROL KIT
CAB CUTOFF
SWITCH
(TRUCK ONLY)
BMR-35 GD
BMR-44 GD
BMR-55 GD
BMR-66 GD
295263-01
BASIC
INSTALLATION
295263-11
EXTENDED
INSTALLATION
295261-01 295895-01
297080-01
297077-01
BMR-35 PD
BMR-44 PD
BMR-55 PD
BMR-66 PD
297080-02
COMPONENTS - Continued
TABLE 16-2
TABLE 16-1
BMR
MODEL
BATTERY BOX & CHARGING OPTIONS
BATTERY BOX
(BATTERIES NOT
INCLUDED)
BATTERY
12V, 1150 CCA,
BCI GROUP 31
BATTERY BOX MOUNTING
FRAME
TRUCK
CHARGE
LINE
BMR-35
BMR-44
BMR-55
BMR-66
269560-01
2 BATTERIES
289988-01
2 BATTERIES
(INCLUDES
DC-DC CON-
VERTER)
269950-01
3 BATTERIES
289988-02
BATTERIES
(INCLUDES
DC-DC CON-
VERTER)
907086
287990-01G
SINGLE GALVANIZED
FRAME FOR 2 BATTERIES
287929-01G
SINGLE GALVANIZED FRAME
FOR
3 BATTERIES
280290

17
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
TABLE 17-1
BMR
MODEL
BATTERY BOX & CHARGING OPTIONS
2/0 AWG CABLE
TRUCK
CHARGE LINE
TRAILER
CHARGE LINE
FOR USE WITHOUT
TRAIL
CHARGER
TRACTOR
CHARGE LINE
FOR USE WITH OR
WITHOUT TRAIL
CHARGER
BMR-35
BMR-44
BMR-55
BMR-66
285860-01
280275-01 SINGLE POLE
280275-02
DUAL POLE
280275-06 SINGLE/DUAL
POLE
FOR NOSE BOX
280275-08
1/0 AWG DUAL
POLE
WITH SINGLE
NOSE BOX
280275-03
SINGLE POLE
280275-04
DUAL POLE
280275-05
SINGLE & DUAL
POLE
COMPONENTS - Continued
TABLE 17-2
BMR
MODEL
DIRECT TRAIL CHARGER OPTIONS
DIRECT WITH
DUAL POLE CON-
NECTIONS
DIRECT, DUAL
COMBINATION CON-
NECTIONS
DIRECT,
7-WAY
CONNEC-
TIONS
DIRECT, REFRIGERATED
OR STRAIGHT TRUCK
CONNECTIONS
BMR-35
BMR-44
BMR-55
BMR-66
295219-01
(DIRECT-01) 295220-01 (DIRECT-02) 295211-01 (DIRECT-03) 295972-01 (DIRECT-04)
BMR
MODEL
SELECT TRAIL CHARGER OPTIONS
SELECT WITH
REFRIGERATED
& DUAL POLE
CONNECTIONS
SELECT WITH
DUAL POLE &
7-WAY
CONNEC-
TIONS
SELECT WITH
DUAL
COMBINATION &
7-WAY
CONNECTIONS
SELECT WITH DUAL
COMBINATION, REFRIGERATED
& 7-WAY
CONNECTIONS
BMR-35
BMR-44
BMR-55
BMR-66
295210-01
(SELECT-21) 295217-01 (SELECT-24) 295218-01 (SELECT-25) 296170-01 (SELECT-32)
TABLE 17-3

18
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
COMPONENTS - Continued
BMR
MODEL
MISCELLANEOUS OPTIONS
DIRECT / SELECT BYPASS MANUAL HOLDER BATTERY STATE OF CHARGE
INDICATOR
BMR-35
BMR-44
BMR-55
BMR-66
295221-01
(BYPASSES TRAIL CHARGER OR
DISCONNECTS
BATTERIES FROM CHARGING
SYSTEM)
286328-01
(INSTALLS IN BAT-
TERY BOX)
908171-01-100
(INSTALLS ON BATTERY BOX)
BMR
MODEL
MISCELLANEOUS OPTIONS
200 AMP CIRCUIT
BREAKER
KIT
150 AMP CIRCUIT
BREAKER
KIT
BATTERY BOX LOCK
KIT
(SINGLE FRAME)
BATTERY BOX
LOCK KIT
(DUAL FRAME)
BMR-35
BMR-44
BMR-55
BMR-66
296504-200
(WITHOUT BATTERY
BOX)
296504-150
(FOR TRUCK AP-
PLICATION & AUXIL-
IARY BATTERY)
295245-02G
(BATTERY BOX IN-
STALLED IN SINGLE
FRAME)
295245-01G
(BATTERY BOX IN-
STALLED IN DUAL
FRAME WITH
PUMP BOX)
TABLE 18-1
TABLE 18-2

19
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
STEP 1 - PREPARE VEHICLE IF REQUIRED
1. Fabricate framework, as shown
in FIGS. 19-1A, -1B & -1C, to
support Liftgate on a flatbed ve-
hicle. Then, go to the next page
for welding instructions.
NOTE: Materials for support framework are not provided with Liftgate.
RECTANGULAR TUBING, 1/8” WALL
ASTM-A36 GENERAL PURPOSE
STEEL, 2” x 4” x 70” LG.
(QTY. 2)
RECTANGULAR TUBING, 1/8” WALL
ASTM-A36 GENERAL PURPOSE
STEEL, 2” x 4” x 85” LG.
(QTY. 2)
RECTANGULAR TUBING,
1/8” WALL, ASTM-A36
GENERAL PURPOSE STEEL
2” x 4” x 88” LG. (96”WIDE BODY)
2” x 4” x 94” LG. (102”WIDE BODY)
(QTY. 1)
60”
36”
Approx.
RIGHT HAND (RH)
SUPPORT
LEFT HAND (LH)
SUPPORT
2”
VEHICLE BODY
SIDE RAIL
FLOOR PLATE,
1/4” THICK, ASTM-A36
GENERAL PURPOSE STEEL
4” x 10” LG.
(QTY. 2)
POSITIONING FLOOR PLATE
FIG. 19-1B
LOWER SUPPORT GUSSET,
1/4” THICK, ASTM-A36
GENERAL PURPOSE STEEL
8” x 8” LG. SIDES
(QTY. 2)
LOWER SUPPORT GUSSET,
1/4” THICK, ASTM-A36
GENERAL PURPOSE STEEL
8” x 16” LG. SIDES
(QTY. 2)
LIFTGATE SUPPORT
FRAMEWORK FOR FLATBED
FIG. 19-1A
POSITIONING GUSSETS
FIG. 19-1C
12”(MAX. BELOW
BED HEIGHT)
32”
NOTE: LH and RH supports must be perpendicular to level ground. See VEHICLE
REQUIREMENTS, INSTALLED LIFTGATE.
NOTE: Perform the following step for flatbed vehicle body only. If vehicle body is
not a flatbed, skip this step.
Recommended practices for welding on steel parts are contained in the current
AWS (American Welding Society) D1.1 Structural Welding Code - Steel. Dam-
age to Liftgate and/or vehicle, and personal injury can result from welds that
are done incorrectly.
WARNING
!

20
11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
TYP. LH &
RH TUBING
1/8”
STEP 1 - PREPARE VEHICLE IF REQUIRED - Continued
2. Weld Liftgate supports, as shown in
FIGS. 20-1A, -1B, -1C & -1D.
TYP. AT LH &
RH SUPPORTS
TYP. AT LH & RH
SUPPORT GUSSETS.
MOUNT EACH GUSSET
FLUSH WITH OUTER
EDGES OF BODY
FRAME.
60”
RIGHT HAND
(RH) SUPPORT
LEFT HAND (LH)
SUPPORT
36”
Approx.
1/8”
1/8” 2-8
2”
WELDING THE
FLOOR PLATES
FIG. 20-1A
1/8”
WELDING LIFTGATE SUPPORTS
FIG. 20-1B
WELDING THE GUSSETS
FIG. 20-1C
TYP. AT LH & RH
SUPPORTS 1/8”
WELDING THE SUPPORTS
FIG. 20-1D
32”
12”
(MAX. BELOW
BED HEIGHT)
VEHICLE BODY
SIDE RAIL
TYP. LH & RH
FLOOR PLATES
1/8”
1/8”
TYP. AT LH & RH SUPPORT GUS-
SETS. MOUNT EACH GUSSET
FLUSH WITH OUTER EDGES OF
BODY FRAME.
TYP. AT LH & RH
VERTICAL SUPPORTS.
WELD HERE BEFORE
WELDING HORIZONTAL
TUBE & SUPPORT
GUSSETS.
1/8”
1/8”
TYP. AT LH & RH VERTICAL SUP-
PORTS. WELD HERE BEFORE
WELDING HORIZONTAL TUBE &
SUPPORT GUSSETS.
1/8”
1/8”
1/8” 2-8