Maxon BMR-35 Maintenance Manual Download Page 25 | Manualshive

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11921

Slauson

A

ve.

Santa

Fe

Springs,

CA.

90670

(800)

227-41

16

FA

X

(888)

771-7713

PAGE 25

SWITCH AND HARNESS REPLACEMENT

Remove the existing Harness/Switch Assembly and replace it with the

3-Piece Cable Assembly as shown.

The first piece of cable runs from

inside the Runner Switch to the bottom of
the Runner. The second piece of cable
runs from the bottom of the Runner,
through the Spring Guard and out through
the bottom of the Column. The third piece
of cable runs through the channel inside
the Column, over the top, and out the
bottom of the Column to the Pump Box.

1

2

3

4,6

5,7

8

3

1

8

2

4,6

5,7

TO PUMP BOX

SPRING GUARD

* NOT SHOWN

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Summary of Contents for BMR-35

Page 1: ...LIFT CORP 11921 Slauson Avenue Santa Fe Springs CA 90670 800 227 4116 BMR 35 BMR 44 BMR 55 BMR 66 MAINTENANCE MANUAL C MAXON Lift Corp 1997 M 94 21 REV B NOV 1997...

Page 2: ...ust be notified and an Authorization Number obtained Major repairs would generally be considered repairs made to the structural assembly of the liftgate and or repairs not outlined in the MAXON Liftga...

Page 3: ...PLATFORM WILL NOT RAISE MOTOR WON T RUN PAGE 31 PLATFORM WILL NOT PICK UP RATED CAPACITY PAGE 32 PLATFORM RAISES HALFWAY STOPS PAGE 33 PLATFORM LOWERS UNEVEN PAGE 34 PLATFORM WILL NOT CLOSE PAGE 35 P...

Page 4: ...ep your feet and any foreign objects clear of the rear edge of the platform Otherwise your feet or the foreign objects could become trapped between the edge of the platform and the vehicle bed 8 Inspe...

Page 5: ...I T C E S G N I D L O F M R O F T A L P E G N A H C N O I T C E S G N I D L O F M R O F T A L P E G N A H C N O I T C E S G N I D L O F M R O F T A L P E G N A H C N O I T C E S G N I D L O F M R O F...

Page 6: ...er Roll Pin from the Inside Coupling and then remove the Lower Cylinder Pin 4 Remove the Upper Roll Pin from the Runner Weldment and then remove the Upper Cylinder Pin 5 Replace the Cylinder and rever...

Page 7: ...isconnect the Cylinder Fitting from the Pressure Compensated Flow Control Valve located at the top of both Lift Cylinders 3 Activate the RAISE switch for approximately one second and then release the...

Page 8: ...ver from the top of the Column COLUMN COVERS NOTE If your unit was one of the first in production it came equipped with an Extension Tube Assembly shown below Left If so skip Step 3 and go to Step 9 I...

Page 9: ...Cylinder from the top of the Column CHAIN HOIST LIFTING CYLINDER COLUMN RUNNER ASSEMBLY PIN PIN 6 Remove the Plug from the compression fitting on the New Lift Cylinder Fasten a Drain Hose with a 1 4...

Page 10: ...connect the Nut to the Elbow on top of the Cylinder Re install the Valve Cartridge Coil and Coil Nut to the Hyd Lock Valve Re attach the Hyd Lock Valve to the Column if needed Re connect the Cylinder...

Page 11: ...Using a device such as a Chain Hoist hold the Lift Cylinder while removing the upper Roll Pin Pin Remove the Lift Cylinder from the top of the Column VALVE BLOCK PRESSURE COMP VALVE ELBOW 11 Remove t...

Page 12: ...nd Coil Nut to the Hyd Lock Valve Re attach the Hyd Lock Valve to the Column if needed Re connect the Cylinder Nut to the Hyd Lock Valve COIL NUT 12 Remove the Plug from the compression fitting on the...

Page 13: ...ain Arms and Covers from the Runners and Platform 3 Use a Forklift to slide the Platform forward towards the cab of the vehicle approximately 6 or enough to clear the Platform away from the Runner Bra...

Page 14: ...R PINS 6 R H COLUMN ONLY remove the Switch Mounting Bracket Remove the terminals from the Switch and release the electric cable from the clamp inside the hole SWITCH MOUNTING BRACKET CABLE CLAMP COVER...

Page 15: ...any that secure the Valve Block to the Column Remove the Nut from the Elbow on the top of the Cylinder Loosen but do not remove the Nut on the Elbow of the Valve Block Using a device such as a Chain H...

Page 16: ...tie a 10 ft piece of wire to the electrical cable that was removed from the Switch Insert the opposite end of the wire through the bottom of the Runner and bring it out through the Switch opening in t...

Page 17: ...h the fixed end of the Closing Cylinder to the Runner with the Pin and Roll Pin Re attach the Spring Guard and Harness to the Runner 16 Pull the electrical cables through the Switch Mounting Bracket h...

Page 18: ...h of the Hydraulic Override Locks There is one located at the top of each Column To disengage you must pull down on the Coil Nut and twist until it locks into place To re engage you must twist the Coi...

Page 19: ...the setting to approximately 300 psi below the desired pressure and slowly raise the pressure until you reach the recommended pressure shown in the table below SCREWS TEE FITTING HOSE 0 3000 PSI GUAGE...

Page 20: ...the desired pressure and slowly raise the pressure until you reach the recommended pressure shown in the table below RELIEF VALVE ADJUSTMENT SCREW 3000 PSI GAUGE WARNING Setting the pressure higher t...

Page 21: ...i l e R u r h t t r o P B m o r f s w o l f l i O s n u r r o t o M s r e d n i l y C t f i L o t s e v l a V D u r h t r e z i l a u q E e d i R u r h t R E W O L R E W O L R E W O L R E W O L R E W...

Page 22: ...f s w o l f l i O s n u r r o t o M e d i R u r h t t r o P B m o r f s w o l f l i O s n u r r o t o M s r e d n i l y C t f i L o t s e v l a V D u r h t r e z i l a u q E R E W O L R E W O L R E W...

Page 23: ...in 1 from the top 4 Replace the Filler Breather Cap POWER DOWN UNITS DRAIN PLUG 1 Place an empty 3 Gallon Container under the Drain Plug WHITE WIRE 2 Raise the Platform and remove the Drain Plug 3 Rem...

Page 24: ...e valve itself remove the Valve Coil from the Valve Cartridge Using a paper clip push on the Plunger inside the Valve Cartridge It should move freely approximately 1 8 Inspect O Ring and wash the Cart...

Page 25: ...L B M E S S A E L B A C N M U L O C Y L B M E S S A E L B A C N M U L O C Y L B M E S S A E L B A C N M U L O C Y L B M E S S A E L B A C N M U L O C Y L B M E S S A E L B A C N M U L O C 4 4 4 4 4 5...

Page 26: ...embly and remove the wires from the Switch Attach a rope or cable at least 20 ft in length to the end of the wires from the Switch This will become the Fishing Rope and will be used to pull the new ca...

Page 27: ...the cable from the fishing rope and attach the Switch and Cable Assembly P N 260529 less the Switch to the fishing rope Pull the rope back up through the Runner and out the Switch Mounting hole until...

Page 28: ...ssembly P N 260533 and the Closing Cylinder Hose through the Spring Guard NOTE Be sure the Flexing Cable is located on the Platform side of the Spring Guard and is parallel not twisted with the hydrau...

Page 29: ...out with a sharp tug The Locking Wedge can now be easily removed Push the Socket Contacts through the Rear Seal of the Connector Plug until it snaps into a locked position Place the Locking Wedge bac...

Page 30: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 PAGE 30 TROUBLESHOOTING...

Page 31: ...Pump Motor Solenoid should be energized If any other Solenoid is energized while in the UP mode there is damaged or improper wiring in the Solenoids Control Box or Switches Disconnect the Runner Swit...

Page 32: ...aulic Cylinders as follows GRAVITY DOWN UNITS Lower the Platform to the ground Remove the hose from the Top Port of each Cylinder Raise the Platform and see if any oil sprays out of the fitting If so...

Page 33: ...charge Replace or recharge as needed The use of a Voltage Load Tester is recommended Check the Circuit Breaker Reset or replace as needed 3 Check for structural damage to the liftgate Visually inspect...

Page 34: ...sassemble and clean each valve Reinstall or replace as necessary using the thread Sealant Instructions on the inside back cover of this manual PRESSURE COMPENSATION VALVE 2 Drain all the Hydraulic Oil...

Page 35: ...est Lamp on terminal A If nothing registers on the Test Lamp the Battery or Battery Cables are faulty Check the Motor Solenoid M itself by placing the 12 Volt Test Lamp on terminal B If nothing regist...

Page 36: ...alve Cartridge It should move freely approximately 1 8 Inspect O Ring and wash the Cartridge in solvent to remove any foreign substances inside the Cartridge If Plunger still does not move freely appr...

Page 37: ...s the closing speed The Valve that points toward the Pump controls the opening speed 2 Turn the Valves clockwise to decrease the speed Turn the Valves counter clockwise to increase the speed CLOSING S...

Page 38: ...Solenoid Valve Coil for power Place a screwdriver about 1 4 from the A Solenoid and energize the unit If the screwdriver is not drawn to the energized solenoid the solenoid must be repaired or replac...

Page 39: ...itch check the electrical connections OLD STYLE PUMPS ONLY M Valve Motor Solenoid E Valve 4 Way Valve 1 Check the Pump Motor Solenoid for 12 Volts of power from the battery If there is no power to the...

Page 40: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 PAGE 40 TROUBLESHOOTING GRAVITY DOWN...

Page 41: ...Lower the Platform to the ground OLD STYLE PUMP Check the C Valve to see if it is stuck in the open position Place a screwdriver about 1 4 from end of solenoid It should be magnetically drawn to the...

Page 42: ...VALVE CARTRIDGE Place a screwdriver about 1 4 from the Solenoid and energize the unit If the screwdriver is not drawn to the energized solenoid the solenoid must be repaired or replaced SOLENOID B SO...

Page 43: ...aced 1 4 VALVE COIL VALVE CARTRIDGE SOLENOID B SOLENOID B SOLENOID C SOLENOID C 2 To clean the Valve remove the Valve Coil from the Valve Cartridge Using a paper clip push on the Plunger inside the Va...

Page 44: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 PAGE 44 TROUBLESHOOTING POWER DOWN...

Page 45: ...at the F Solenoid Valve is not energized during the RAISE function Remove the F Solenoid Valve Body and clean To clean the Valve remove the Valve Coil from the Valve Cartridge Using a paper clip push...

Page 46: ...the M Motor Solenoid Valves and the 4 Way Solenoid Valves located in the Pump Box VALVE COIL VALVE CARTRIDGE SOLENOID D 3 To clean the Valve remove the Valve Coil from the Valve Cartridge Using a pap...

Page 47: ...substances inside the Cartridge If Plunger still does not move freely approx 1 8 then replace the Valve Cartridge OLD STYLE PUMP 4 Check the Pressure Compensation Valves Ref Platform Lowers Uneven 1 C...

Page 48: ......

Page 49: ...ting and return to Step 1 If fitting is loosened or removed return to Step 1 1 2 3 4 5 6 P N 260798 02 CAUTION Due to the 80 lead content in PLS 2 follow these safety and first aid precautions Eye Con...

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