INSTRUCTION, BATTERY BOX AND FRAME INSTALLATION KIT

Transcription

1 LIFT CORPORATION Sht. 1 of 1 DSG# M-1-1 Rev. A Date: 08/1/1 INSTRUCTION, BATTERY BOX AND FRAME INSTALLATION KIT BATTERY BOX ASSEMBLY P/N QTY. 1 SINGLE FRAME ASSEMBLY P/N P/N G (GALVANIZED) QTY. 1

2 LIFT CORPORATION Sht. of 1 DSG# M-1-1 Rev. A Date: 08/1/1 1. Select holes on top of battery box frame to align mounting brackets fl ush to cross members. Refer to FIGS. -1A & -1B for trailers and FIG. - for trucks. Bolt mounting brackets to battery box frame as shown in FIG. -1C. Torque each bolt and lock nut to 8-18 lb-ft. WASHER MOUNTING BRACKETS LOCK NUT BOLTING BRACKETS FIG. -1C LOCK WASHER CROSS MEMBER WASHER CAP SCREW TRAILER BODY CROSS MEMBER BATTERY BOX FRAME MOUNTING BRACKETS BATTERY BOX FRAME ALIGNING BATTERY BOX FRAME (TRAILER SHOWN) FIG. -1A FLUSH BRACKETS FOR TRAILERS FIG. -1B TRUCK BODY CROSS MEMBER MOUNTING BRACKETS BATTERY BOX FRAME FLUSH BRACKETS FOR TRUCKS FIG. -

3 LIFT CORPORATION Sht. 3 of 1 DSG# M-1-1 Rev. A Date: 08/1/1 NOTE: If welding mounting brackets to cross members, skip instruction.. Using mounting brackets as a template mark and drill holes through cross members (FIG. 3-1). Bolt mounting brackets to cross members as shown in FIGS. 3-A and 3-B. Torque bolts and lock nuts to 8-18 lb-ft. MOUNTING BRACKETS CROSS MEMBER WASHERS 1/ HOLES MARK AND DRILL FIG. 3-1 LOCK NUTS CAP SCREWS LOCK WASHERS CROSS MEMBER BOLTING BRACKETS FIG. 3-B MOUNTING BRACKETS CROSS MEMBERS BOLTING BATTERY BOX FRAME FIG. 3-A

4 LIFT CORPORATION Sht. of 1 DSG# M-1-1 Rev. A Date: 08/1/1! 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. CAUTION Cover battery box with flame-resistant covering before welding pump box frame to vehicle. 3. For galvanized frame, read warning decal shown in FIGS. -1A and FIGS. -1B before welding. Weld each bracket to cross members as shown in FIGS. -1A and -1C. Weld top of bracket if accessible. IF ACCESSIBLE 3/16 3/16 CROSS MEMBERS 3/16 BRACKET CROSS MEMBERS WELDING BRACKETS FIG. -1C WELDING GALVANIZED, WARNING DECAL FIG. -1B BOLTING BATTERY BOX FRAME FIG. -1A

5 LIFT CORPORATION Sht. of 1 DSG# M-1-1 Rev. A Date: 08/1/1! 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.. Connect battery cables, fused cables, and ground cables as shown in FIG. -1. ELECTRICAL COMPONENTS - BATTERY BOX 3 (GROUND CABLE TO PUMP BOX OR COMMON CHASSIS GROUND) 1 VOLT BATTERY CONNECTIONS (-) BATTERY CABLE TO COMMON GROUND FUSED CABLE (SEE NOTE) (FUSED CABLE TO PUMP BOX) (IN PARTS BOX) 1 FIG. -1 ITEM QTY PART NO. DESCRIPTION CIRCUIT BREAKER 10 AMP CABLE ASSEMBLY, GA,18 LG CABLE ASSEMBLY, GA, 7 LG CABLE ASSEMBLY, GA, 10 LG CABLE ASSEMBLY, GA, 00 AMP, LG.

6 LIFT CORPORATION Sht. 6 of 1 DSG# M-1-1 Rev. A Date: 08/1/1! 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. 6-1

7 LIFT CORPORATION Sht. 7 of 1 DSG# M-1-1 Rev. A Date: 08/1/1 BATTERY BOX ASSEMBLY REFER TO BATTERY BOX 9 (3 PLACES) 6 11, 1, (3 PLACES) 8 (3 PLACES)

8 LIFT CORPORATION Sht. 8 of 1 DSG# M-1-1 Rev. A Date: 08/1/1 BATTERY BOX ASSEMBLY ITEM QTY PART NO. DESCRIPTION G BATTERY MOUNT PLATE WELDMENT, GALVANIZED ROD, BATTERY HOLD DOWN LOCK NUT, /16-18, STAINLESS STEEL FLAT WASHER, M8, STAINLESS STEEL HEX NUT, / ROD, L-SHAPE BATTERY HOLD DOWN BRACKET (BATTERY HOLD DOWN) FLAT WASHER, / HEX NUT, /16-18, GR LOCK WASHER, # FLAT WASHER, 1/ PAN HEAD SCREW, 1/ -0 X 1 LG LOCK NUT, 1/ FLAT WASHER, 9/ LOCK WASHER, 9/ CAP SCREW, 1/ -0 X -1/ LG., GR HEX NUT, 1/ -0

9 LIFT CORPORATION Sht. 9 of 1 DSG# M-1-1 Rev. A Date: 08/1/1 BATTERY BOX

10 LIFT CORPORATION Sht. 10 of 1 DSG# M-1-1 Rev. A Date: 08/1/1 BATTERY BOX ITEM QTY PART NO. DESCRIPTION REF BATTERY BOX BOX PLUG, 3/ PLUG, 1-1/ PLUG, 1/ GROMMET, COVER RUBBER LATCH FASTENING KNOB BATTERY BOX HINGE STAINLESS STEEL BLIND RIVET, 1/ X 1/ -3/ WASHER, 1/ PLUG, 9/ PAN HEAD SCREW, 1/ -0 X 3/ LG.

11 LIFT CORPORATION Sht. 11 of 1 DSG# M-1-1 Rev. A Date: 08/1/1 SINGLE FRAME ASSEMBLY REFER TO SINGLE UPPER FRAME KIT 3 1 ITEM QTY PART NO. DESCRIPTION REF SINGLE FRAME ASSEMBLY G SINGLE FRAME ASSEMBLY (GALVANIZED) SINGLE FRAME WELDMENT 87-11G SINGLE FRAME WELDMENT (GALVANIZED) HEX HEAD CAP SCREW, 3/8-16 X 1-3/ LG, GR LOCK WASHER, 3/ FENDER WASHER, 13/ LOCK NUT, 3/8-16

12 LIFT CORPORATION Sht. 1 of 1 DSG# M-1-1 Rev. A Date: 08/1/1 SINGLE UPPER FRAME KIT (ONLY ON GALVANIZED FRAME) 1 ITEM QTY PART NO. DESCRIPTION REF SINGLE UPPER FRAME KIT 87-01G SINGLE UPPER FRAME KIT (GALVANIZED) SINGLE UPPER FRAME WELDMENT G SINGLE UPPER FRAME WELDMENT (GALVANIZED) FENDER WASHER, 1/ LOCK WASHER, 9/ CAP SCREW, 1/ -0 X 1-3/ LG, GR LOCK NUT, 1/ MOUNTING BRACKET WARNING DECAL, WELD ON GALVANIZED