Maxon Railift Series Operation Manual

Register your liftgate on line at www.maxonlift.com/htm/services/reg.htm. For a free copy of other manuals that pertain to this model Liftgate, please visit our website at www.maxonlift.com or customer service at (800) 227-4116. © MAXON Lift Corp. 2021 To fi nd maintenance information for your RC Liftgate, go to www.maxonlift.com. Click the PRODUCTS, RAILIFT & RC buttons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, RAILIFT & RC buttons.

SUMMARY OF CHANGES: M-90-2, REVISION D ..................4 WARNINGS ..............................................................................5 RECOMMENDED DAILY OPERATION CHECKS ...................6 LIFTGATE TERMINOLOGY .....................................................8 DECALS AND PLATES ...........................................................9 FORKLIFT ADVISORY ............................................................11 OPERATION ............................................................................12 STANDARD CONTROLS .........................................................12 UNLOADING VEHICLE ...........................................................16 RAISING PLATFORM ..............................................................16 POSITIONING LOAD ...............................................................18 LOWERING & UNLOADING PLATFORM ................................19 LOADING VEHICLE ................................................................20 UNFOLDING RETENTION RAMP (IF EQUIPPED) .................20 POSITIONING LOAD ...............................................................21 RAISING & UNLOADING PLATFORM .....................................22 STOWING PLATFORM ............................................................24 STOW RETENTION RAMP (IF EQUIPPED) ...........................24 FOLDING & RAISING PLATFORM ..........................................25 DOCK LOADING & UNLOADING ...........................................27 LOWER PLATFORM BELOW DOCK LEVEL...........................27

All Converted to folded booklet layout suitable for storing in glovebox of vehicle. COVER Updated REV, graphics and date of release. 6,7 Inserted pages with RECOMMENDED DAILY OPERATION CHECKS. 8 Inserted page with LIFTGATE TERMINOLOGY. 12-13 Inserted descriptions of liftgate controls. 14-28 Updated instructions about the use of liftgate to unload and load a vehicle, and loading/unloading from a dock without using the liftgate. 18-21 Updated WARNINGS with consequences of placing too much of a load on the outer folding section of the platform. SUMMARY OF CHANGES: M-90-2, REVISION D

2,000 lbs. for model RC-2B, 3,000 lbs. for model RC-3B, 4,000 lbs. for model RC-4B, 5,000 lbs. for model RC-5B, and 6,000 lbs. for models RC-6B and RC-6K. 3. Do not allow any part of your body to be placed under, within, or around any portion of the moving Liftgate or its mechanisms, or in a position that would trap them between the platform and the fl oor of truck body (or between platform and the ground) when Liftgate is operated. 4. Consider the safety and location of bystanders and location of nearby objects when operating the Liftgate. Stand to one side of platform while operating the Liftgate. Be certain that the area the Liftgate will move through during operation is clear of all obstacles. 5. Comply with all attached instruction decals and warning decals. 11. Above all, USE GOOD COMMON SENSE when operating this Liftgate. 8. Do not move vehicle unless Liftgate is correctly stowed. 6. Keep decals clean and legible. If decals are illegible or missing, have them replaced. Get free replacement decals from Maxon. 7. Never drive a forklift on the Liftgate platform. 10. A correctly installed Liftgate will operate smoothly and reasonably quiet. The only noticeable noise, during Liftgate operation, is from the power unit while the platform is being opened (SD models only), lowered (power down models only), raised, or closed. Listen for scraping, grating and binding noises and have the problem corrected before continuing to operate the Liftgate. MAXON Lift Corp. Customer Service 11921 Slauson Ave Santa Fe Springs, CA 90670 (800) 227-4116 9. Correctly stow platform when not in use. Extended platforms could create a hazard for people and vehicles passing by. 1. Incorrect operation of this Liftgate can result in serious personal injury. Comply with WARNINGS and Liftgate operating instructions in this manual. Do not allow untrained persons to operate the Liftgate. If you need to replace an Operation Manual, additional copies are available from: 12. Never use a cell phone while operating the Liftgate. WARNINGS WARNING ! 5

Before operating the Liftgate, the operator should do the following: Use the operation instructions in this manual to unfold the platform and lower it to the ground.  Check for smooth operation as platform unfolds and as runners lower the platform to the ground.  Check for fl uid leaks from hydraulic cylinders.  Make sure load-carrying surfaces on platform, folding section, and retention ramp (if equipped) are clean (no oil, debris, or corrosion). NOTE: Before you check the Liftgate, park vehicle on fl at ground and set the parking brake. NOTE: If any of the following operation checks reveal a need to service or repair Liftgate, do not operate the Liftgate until a qualifi ed mechanic services or repairs the Liftgate.  Check main frame, columns, runners and platform openers for cracks and bends. Make sure platform chains are undamaged and connected securely at both ends. Also, make sure all bolts and pins are in place and undamaged.  Check platform and folding section for cracks, holes, and bends on the load-carrying surfaces and side plates. Also, make sure retention ramps (if equipped) are undamaged and operate smoothly.  Make sure batteries are fully charged, battery terminal connections are clean and tight, and battery box is undamaged.  Visually check that main frame housing cover is bolted on securely and undamaged. Look for hydraulic fl uid leaks from main frame and columns.  Visually check that standard and optional controls are in place and undamaged.  Visually check that all decals are in place (see DECALS page). Make sure decals are legible, clean, and undamaged.  Make sure cab cutoff switch is ON, if equipped.  Follow the visible routing of hydraulic hoses from cylinders to main frame housing . Make sure all hoses are connected at both ends and there are no cracks, chafi ng, and fl uid leaks. 6

through one cycle without a load on the platform. Raise the platform to vehicle bed height. Next, lower the platform to ground level.  When raising and lowering platform, listen for unusual noises and look for a “jerking” motion or uneven movement at LH and RH sides of the platform. Uneven movement should not exceed 1”. If service or repairs are not required (or if completed), stow platform for transport.  Retention ramps (if equipped) release, unfold and fold smoothly, and remain in ramp, retention, and stowed positions until intentionally moved.  With platform at bed height, make sure the LH and RH platform chains feel even in tightness. 7

(MANUAL OPENER) CAM FOLLOWER (MANUAL OPENER) FLIPOVER PLATFORM PLATFORM CHAIN NOISE ABATEMENT SLEEVE NOISE ABATEMENT BUMPER RC WITH MANUAL CLOSER FIG. 8-1 UP-DOWN SWITCH CAM

PAINT DECAL (2 PLACES) P/N 267338-01 DECAL “F” OR DECAL “G” DECAL “C” DECAL “D” DECAL “B” DECAL “A” DECAL “I” (FOR HYDRAULIC CLOSER ONLY) SERIAL PLATE (REF) RC WITH MANUAL CLOSER FIG. 9-1 DECAL “H” DECAL “E”

268385-01 RC-3 CAM OPENER 268385-02 RC-4 CAM OPENER 268385-03 RC-5 CAM OPENER 268385-04 RC-6 CAM OPENER 268385-05 DECAL SHEET FIG. 10-1 DECAL SHEET PART NUMBERS TABLE 10-1 DECAL SHEET PART NUMBERS TABLE 10-2 MODEL ORDER P/N RC-2 HYD OPENER 268386-01 RC-3 HYD OPENER 268386-02 RC-4 HYD OPENER 268386-03 RC-5 HYD OPENER 268386-04 RC-6 HYD OPENER 268386-05 (See TABLES 10-1 & 10-2) DECALS AND PLATES - Continued

lets operator raise (UP) and lower (DOWN) the platform (FIG. 12-1) while standing on the ground. Toggle switch (FIG. 12-1B) on RH column lets operator raise (UP) and lower (DOWN) the platform (FIG. 12-1) while standing on the platform. FIG. 12-1 OUTSIDE COLUMN FIG. 12-1A UP-DOWN CONTROL SWITCH UP-DOWN CONTROL SWITCH GROUND ACCESS TO UP-DOWN SWITCH INSIDE COLUMN FIG. 12-1B PLATFORM ACCESS TO UP-DOWN SWITCH OPERATION FIG. 12-2 12

The cam follower, and handle on the RH side of the platform (FIG. 13-2A) lets operator fold the platform (FIG. 13-1) while standing on the ground. CAM FOLLOWER HANDLE CAM FOLLOWER NOTE: The platform on Liftgate with cam open and close automatically unfolds as it lowers to the ground. Handle is used to fold platform while it is being raised to stowed position. FOLD-UNFOLD SWITCH (HYDRAULIC OPEN & CLOSE ONLY) The FOLD-UNFOLD switch at bottom of the RH column (FIG. 13-1A) lets operator UNFOLD and FOLD the platform (FIG. 13-1) while standing on the ground. FIG. 13-1 FIG. 13-1A FOLD-UNFOLD CONTROL SWITCH 13

1. Use UP-DOWN switch on curbside column to raise (UP) the runners off the stop block. Next, disconnect platform holding chain from platform (FIG. 14-1). Then, raise stop and move slide bar on column away from stop block on runner (FIG. 14-1). This keeps slide bar clear of stop block when lowering platform. FIG. 14-2 Ensure no people or objects are in the path of the platform when unfolding. Serious personal injury and propery damage can result from being struck by platform. WARNING ! 2. Use UP-DOWN switch (FIG. 14-1) to lower the platform to the ground (FIG. 14-2). Platform unfolds as it lowers. UP-DOWN SWITCH SLIDE BAR FIG. 14-1 STOP BLOCK PLATFORM HOLDING CHAIN STOP RUNNER CAM OPEN & CLOSE 14

(FIG. 15-2) near bottom of column to unfold platform. Then, use UP-DOWN switch (FIG. 14-1) to lower the platform to the ground (FIG. 14-2). FIG. 15-1 FOLD-UNFOLD SWITCH PLATFORM HYDRAULIC OPEN & CLOSE RCT PLATFORM 3. Use handle to unhook platform (FIG. 15-1). Continue with step 4 to unfold platform. FIG. 15-1 PLATFORM HOOK HANDLE 15

retention ramp up to retention position and fasten in place (FIGS. 16-2 and 16-2A). Then, stand in the operator area shown by footprints in FIG. 16-2. FIG. 16-2 RAISING PLATFORM A ramp in retention position can trip you when stepping over it. To prevent possible injury, get on the platform before putting the ramp in retention position. CAUTION ! PLATFORM RAMP IN RETENTION POSITION FIG. 16-2A FIG. 16-1 FIG. 16-1A 1. Release retention ramp (if equipped) from stowed position by rotating latch off plate on curbside and streetside of the ramp (FIGS. 16-1 and 16-1A). LATCH PLATE RAMP 16

to raise (UP) platform from the ground to bed height (FIG. 17-1). Release switch when platform reaches bed height. UP UP-DOWN SWITCH FIG. 17-1A 17

edge of the platform with heaviest part toward the inboard edge as shown in FIG. 18-1. Comply with the preceding WARNING. If standing on platform with the load, stand in the footprint area shown and comply with the preceding WARNING. A load should never extend past the edges of the platform, and the greatest portion of the load must rest on the main section of the platform. Do not place unstable loads on platform and do not allow load to exceed lifting capacity of Liftgate. If standing on platform, do not allow your feet to extend beyond inboard edge of platform. If most of a load is on the outer folding section of platform, it can cause platform to start folding and dumping operator and load off the platform. Serious bodily harm and property damage could result. WARNING ! POSITIONING LOAD MOVING LOAD ON PLATFORM FIG. 18-1 INBOARD EDGE 18

FIG. 19-1 1. Use UP-DOWN switch (FIG. 19-1A) to lower (DOWN) platform to the ground (FIG. 19-1). 4. If there are more loads to unload from vehicle, repeat the previous UNLOADING VEHICLE steps for each load. When unloading and loading are fi nished, use STOWING PLATFORM procedure in this manual. PLATFORM DOWN UP-DOWN SWITCH FIG. 19-1A LOWERING & UNLOADING PLATFORM 2. Unfold retention ramp to ramp position (FIG. 19-2). 3. Carefully move the load off the platform and clear of the work area (FIG. 19-2). RAMP UNLOADING PLATFORM FIG. 19-2 19

FIG. 20-1 FIG. 20-1A 1. Release retention ramp from stowed position by rotating both latches off the plate on curbside and streetside of the ramp (FIGS. 20-1 and 20-1A). 2. Unfold retention ramp to ramp position (FIG. 20-1). LATCH PLATE RAMP LOADING VEHICLE 20

edge of the platform with heaviest part toward the inboard edge as shown in FIG. 21-1. Comply with the preceding WARNINGS. Move loads across the ramp (FIG. 21-1) to the platform, but never rest or raise loads on the ramp. If standing on platform with the load, stand in the footprint area shown and comply with the preceding WARNING. A load should never extend past the edges of the platform, and the greatest portion of the load must rest on the main section of the platform. Do not place unstable loads on platform and do not allow load to exceed lifting capacity of Liftgate. If standing on platform, do not allow your feet to extend beyond inboard edge of platform. If most of a load is on the outer folding section of platform, it can cause platform to start folding and dumping operator and load off the platform. Serious bodily harm and property damage could result. WARNING ! RAMP INBOARD EDGE LOADING PLATFORM AT GROUND LEVEL FIG. 21-1 POSITIONING LOAD Liftgates equipped with manual platform close have a cam follower mechanism to fold platform. Before lifting a load to bed height, ensure the cam follower is disengaged to prevent platform from folding near bed height. Cam follower in close position can cause platform to start folding. Folding platform could dump operator and load off the platform resulting in serious bodily harm and property damage. WARNING ! CAM FOLLOWER DISENGAGED FIG. 21-1A 21

A ramp in retention position can trip you when stepping over it. To prevent possible injury, get on the platform before putting the ramp in retention position. CAUTION ! PLATFORM RAMP IN RETENTION POSITION LOADING VEHICLE - Continued FIG. 22-1A 1. Stand on the platform to rotate retention ramp up (if equipped) and fasten in retention position (FIGS. 22-1 and 22-1A). Then, stand in the operator area shown by footprints in FIG. 22-1. 22

vehicle (FIG. 23-1). MOVING LOAD INTO VEHICLE FIG. 23-1 2. Use UP-DOWN switch (FIG. 23-2A) to raise (UP) platform from ground level to bed height (FIG. 23-2). Release switch when platform reaches bed height. UP UP-DOWN SWITCH FIG. 23-1A LOWERING PLATFORM FIG. 23-2 4. Use UP-DOWN switch (FIG. 23-2A) to lower (DOWN) platform to ground level (FIG. 23-2). 5. If there are more loads to put in vehicle, repeat the previous LOADING VEHICLE steps for each load. When loading is fi nished, use STOWING PLATFORM procedure in this manual. PLATFORM DOWN UP-DOWN SWITCH FIG. 23-2A 23

STOWING PLATFORM FIG. 24-1 FIG. 24-1A LATCH PLATE RAMP 2. Secure retention ramp on platform by rotating each latch over plate on curbside and streetside of the ramp (FIGS. 24-1 and 24-1A). 1. Fold retention ramp to stowed position (FIG. 24-1). 24

1. Ensure the slide bar is clear from the path of the runner (FIG. 25-1). Then, use UP- DOWN control switch on curbside column to raise (UP) the platform. FIG. 25-2 Ensure no people or objects are in the path of the platform when folding. Serious personal injury and propery damage can result from being struck by platform. WARNING ! 2. Use UP-DOWN control switch (FIG. 25-1) to raise (UP) platform to cams on bottom of the main frame housing (FIG. 25-2). Continue to hold switch in the UP position. Next, pull up on the cam follower handle (FIG. 25-2A) to engage the cam followers with cams under the housing. As cam followers engage the cams, release handle as platform begins to fold (FIG. 25-2). Allow platform to fold against bumper on runner and runners raise to stops. Then, release the UP-DOWN switch (FIG. 25-1). UP-DOWN SWITCH SLIDE BAR FIG. 25-1 STOP HANDLE CAM FOLLOWER FIG. 25-2A CAM OPEN & CLOSE 25

(FIG. 26-1) near the bottom of column. Then, use UP-DOWN control switch (FIG. 27-1) to raise runners to the stops. FOLD-UNFOLD CONTROL SWITCH PLATFORM 4. Connect platform holding chain to folded platform (FIG. 26-2A). Next move slide bar under stop block on runner (FIG. 26-2A). Liftgate is ready for transport. PLATFORM HOLDING CHAIN UP-DOWN SWITCH STOP BLOCK FIG. 26-2A SLIDE BAR FIG. 26-2 HYDRAULIC OPEN & CLOSE FIG. 26-1 26

(FIG. 27-2A) to lower (DOWN) platform below fl oor level of vehicle body (FIG. 27-2). Then, release switch when folded platform is below fl oor level. Loads can now be moved between dock and vehicle fl oor using a dock plate. PLATFORM LOWERED TO DOCK LOADING POSITION FIG. 27-2 DOCK Use dock plate for moving loads between dock and vehicle. Dock plate must be supported by dock and vehicle fl oor. Placing dock plate on platform of the Liftgate could result in personal injury and property damage when moving loads across the plate. CAUTION ! LOWER PLATFORM BELOW DOCK LEVEL DOCK LOADING & UNLOADING VEHICLE FLOOR PLATFORM NOTE: This procedure is only for RC Liftgates. RCT Liftgates are ready for dock load- ing with platform stowed. Platform is lower than fl oor of the vehicle body. The stowed platform on RC liftgates must be lowered below fl oor of vehicle body. UP-DOWN SWITCH DOWN OUTSIDE COLUMN FIG. 27-2A 1. Use UP-DOWN switch on curbside column (FIG. 27-1) to raise (UP) the runners off the stop block. Then, lift stop and move slide bar away from stop block on runner (FIG. 27-1). This will keep slide bar clear of stop block when lowering platform. UP-DOWN SWITCH SLIDE BAR STOP BLOCK STOP RUNNER FIG. 27-1 27

and slide bar engaged before moving vehicle. Serious injury and property damage could result if platform is unfolded while vehicle is moving. WARNING ! 3. When fi nished loading and unloading from the dock, use UP-DOWN switch to raise (UP) platform to the stops (FIGS. 28-1 and 28-1A). UP-DOWN SWITCH UP OUTSIDE COLUMN FIG. 28-1A PLATFORM RAISED TO STOWED POSITION FIG. 28-1 4. Connect platform holding chain to folded platform (FIG. 28-2). Next move slide bar under stop block on runner (FIG. 28-2). Liftgate is ready for transport. FIG. 28-2 PLATFORM HOLDING CHAIN UP-DOWN SWITCH STOP BLOCK SLIDE BAR 28