Maxon COLUMNLIFT BMR-35 Maintenance Manual
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Maxon COLUMNLIFT BMR-35 Maintenance Manual

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

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Summary of Contents for Maxon COLUMNLIFT BMR-35

  • Page 1 M-94-21 REV. B NOV. 1997 MAINTENANCE MANUAL BMR-35 BMR-44 BMR-55 BMR-66 11921 Slauson Avenue. Santa Fe Springs, CA. 90670 LIFT CORP. (800) 227-4116 MAXON Lift Corp. 1997...
  • Page 2 Term of Warranty: 2 Years from Date of In-Service Type of Warranty: Full Parts and Labor MAXON agrees to replace any components which are found to be defective during the first 2 years of service, and will reimburse for labor based on MAXON’s Liftgate Warranty Flat Rate Labor Schedule.

  • Page 3: Table Of Contents

    Table of Contents WARNING ..................... PAGE 4 SERVICE TIME CHART ................ PAGE 5 FOLDING CYLINDER REPLACEMENT ..........PAGE 6 LIFT CYLINDER BLEEDING..............PAGE 7 LIFT CYLINDER REPLACEMENT ............PAGE 8 RUNNER REPLACEMENT ..............PAGE 13 HYDRAULIC OVERRIDE LOCK ............PAGE 18 RELIEF VALVE PRESSURE SETTING ..........

  • Page 4: Warning

    The cause will need resolving before any further deterioration of performance occurs. Use only Maxon Authorized Parts for replacement. Replacement parts should be ordered from: MAXON LIFT CORP. Parts Department 11921 Slauson Ave., Santa Fe Springs, Ca.

  • Page 5: Service Time Chart

    SERVICE TIME CHART PAGE 5...

  • Page 6: Folding Cylinder Replacement

    FOLDING CYLINDER REPLACEMENT 1. Lower the Platform to the ground. 2. Disconnect and plug the Hydraulic Hose from the lower part of the Cylinder (for cleanliness). 3. Remove the Lower Roll Pin from the Inside Coupling and then remove the Lower Cylinder Pin.

  • Page 7: Lift Cylinder Bleeding

    LIFT CYLINDER BLEEDING NOTE: This operation must be performed in a location where the maximum distance of 60” between the ground and the vehicle bed may be obtained. Lower the opened platform to the ground. Loosen, but do not disconnect the Cylinder Fitting from the Pressure Compensated Flow Control Valve, located at the top of...

  • Page 8: Lift Cylinder Replacement

    LIFT CYLINDER REPLACEMENT COLUMN COVERS Raise the open Platform about 20” above the ground. Place a jack under the Platform and raise an additional 3” or 4”. Measure the distance between the Cylinder Pins and record this distance for later use. Remove the Column Cover from the top of the Column.
  • Page 9 LIFT CYLINDER REPLACEMENT VALVE BLOCK 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. CHAIN LIFTING HOIST CYLINDER COLUMN . Remove the Roll Pin & Pin that fastens the RUNNER Rod End of the Lift Cylinder to the Runner ASSEMBLY...
  • Page 10 LIFT CYLINDER REPLACEMENT Lower the New Lift Cylinder CHAIN LIFTING HOIST CYLINDER through the top of the Column. Fasten at the top with the Pin & Roll Pin. Then fasten at the Rod End of the Cylinder with the Pin & COLUMN Roll Pin.
  • Page 11 LIFT CYLINDER REPLACEMENT CHAIN LIFTING HOIST CYLINDER . Remove the Roll Pin & Pin that fastens the Rod End of the Lift COLUMN Cylinder to the Runner Assembly. Using a device such as a Chain Hoist, hold the Lift Cylinder while RUNNER removing the upper Roll Pin &...
  • Page 12 LIFT CYLINDER REPLACEMENT HYD. LOCK, Remove the Plug from the PRESS. COMP. LIFT VALVE compression fitting on the New Lift CYLINDER Cylinder. Fasten a Drain Hose with a 1/4” NPT Female end to the compression fitting. Place the other end of the Hose in a 1 gallon container for bleeding.

  • Page 13: Runner Replacement

    RUNNER REPLACEMENT REMOVE OLD RUNNERS Lower the opened Platform and let it rest on a PINS stand approximately 25” off of the ground. Be sure to allow access to a forklift to position the Runner. Remove the Bolts, Pins, Chain Arms, and Covers from the Runners and Platform.
  • Page 14 RUNNER REPLACEMENT Remove the Pins from the old Runner, (two Pins on the R.H. Runner, and one Pin PINS on the L.H. Runner). Do not remove the Upper Cylinder Pin at this time. Activate the Control Switch to the “UP” position to fully retract the Lift Cylinders.
  • Page 15 RUNNER REPLACEMENT VALVE Remove the Column Cover from the top BLOCK LOCK VALVE of the Column. Remove the Coil Nut from & COIL the Lock Valve & Coil. Slide off the Coil and unscrew the Valve Cartridge (screwed into the Valve Block). Remove the bolts (if any), that secure the Valve Block to the Column.
  • Page 16 RUNNER REPLACEMENT INSTALL NEW RUNNERS ROLLER BRACKET WELDMENT . Remove the remaining parts of the two Tandem Roller Assemblies from the Old Runners and place them on the New Runners. The remaining parts for each Tandem Assembly consist of: (1) Roller Bracket Weldment, (3) Roller Axles, ROLLER and (2) Mounting Brackets.
  • Page 17 RUNNER REPLACEMENT . Activate the “DOWN” switch on the PINS Control Panel to extend the Cylinders. Attach the Lifting Cylinder to the Runner with the Pin and Roll Pin. On the R.H. Runner only, attach the fixed end of the Closing Cylinder to the Runner with the Pin RUNNER and Roll Pin.

  • Page 18: Hydraulic Override Lock

    HYDRAULIC OVERRIDE LOCK In the event that the BMR Column Lift will not lower, you will need to disengage both 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.

  • Page 19: Relief Valve Pressure Setting

    RELIEF VALVE PRESSURE SETTING OLD STYLE RELIEF VALVE The Relief Valve pressure is set at the factory. If adjustment is needed, use the following instructions to set the pressure per the table below. WARNING! Setting the pressure higher than recommended could result in damage to your unit.
  • Page 20 RELIEF VALVE PRESSURE SETTING NEW STYLE RELIEF VALVE The Relief Valve pressure is set at the factory. If adjustment is needed, use the following instructions to set the pressure per the table below. Attach a 0-3000 PSI gauge to the Pressure Port. Actuate the Control Switch to the “Raise”...

  • Page 21: Pump Valve Operation

    PUMP VALVE OPERATION OLD STYLE PUMP VALVES A,B,C, or D, Energized “D” Valves Located inside the top of each Column FREE FLOW IN “C” Valve VALVES A,B,C, or D, Not Energized Located in Pump Box FREE FLOW OUT “B” Valve Lifting Port “A”...
  • Page 22 PUMP VALVE OPERATION NEW STYLE PUMP VALVES A,B,C, or D, Energized VALVES A,B,C, or D, Not Energized FREE FLOW IN FREE FLOW OUT “D” Valves Located inside the top of each Column “B” Valve Lifting Port “A” Valve Folding Port “E”...

  • Page 23: Oil Change Instructions

    OIL CHANGE INSTRUCTIONS NOTE: Determine if your unit is Gravity Down or Power Down before choosing the method of oil change. GRAVITY DOWN UNITS Place an empty 3 Gallon Container under the Drain Plug. Remove the Drain Plug and activate the DRAIN switch to “Lower”...

  • Page 24: Solenoid Check

    SOLENOID CHECK ” 1 / 4 To check the Solenoids for power, hold a screwdriver approximately 1/4” from the top nut of the Solenoid and energize the unit. If the Solenoid is good, it will draw the screwdriver to the nut through a magnetic force.

  • Page 25: Switch And Harness Replacement

    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.
  • Page 26 SWITCH AND HARNESS REPLACEMENT Lower the Platform to the ground. TEAR DROP & Remove the Tear Drop Assembly and the CHAIN ASSEMBLY Cover from the curb side Column. COVER PLATE Remove the Switch Plate from the Runner Assembly, and remove the wires from the Switch.
  • Page 27 SWITCH AND HARNESS REPLACEMENT Remove the fitting from the lower port of the Closing Cylinder. Remove the opposite end of the hose from the bottom REMOVE 2 BOLTS of the Column. Remove the two bolts that secure the Spring Guard to the unit. One is located at the bottom of the Column, the other is located between the bottom FISHING...
  • Page 28 SWITCH AND HARNESS REPLACEMENT Remove the middle light from a 3 light Column, or the top light on a 2 light Column. Inside the light mounting hole near the top, loosen but do not remove the nut that fastens the clamp to the Column, so that the cable will slide freely through the clamp.
  • Page 29 SWITCH AND HARNESS REPLACEMENT INSTALLATION OF CONTACTS SOCKET Use the DT Removal Tool (P/N 260875), CONTACTS to pry between the lip of the Locking Wedge LOCKING and the Connector Plug. Then twist, popping WEDGE PLUG the Wedge free. The Locking Wedge can now be easily removed.

  • Page 30: Troubleshooting

    TROUBLESHOOTING PAGE 30...

  • Page 31: Platform Will Not Raise, Motor Won't Run

    PLATFORM WILL NOT RAISE, MOTOR WON’T RUN BATTERY CABLE Check the Pump Motor TERMINAL Solenoid for 12 Volts of power from the battery. If there is no power to the Solenoid, check the Battery Cables for damage, and the Battery for a charge.

  • Page 32: Platform Will Not Pick Up Rated Capacity

    PLATFORM WILL NOT PICK UP RATED CAPACITY Check the Battery Cables for damage, and the Battery for a charge. Replace or recharge as needed. The use of a Voltage Load Tester is recommended. Check for structural damage to the liftgate. Visually inspect for improper bending of structures that could prevent normal operation.

  • Page 33: Platform Raises Halfway & Stops

    PLATFORM RAISES HALFWAY & STOPS Check the hydraulic fluid level in the Reservoir. GRAVITY DOWN UNITS: Lower the Platform to the ground. Fill the Reservoir to about 1” from the top. Do not overfill as this causes spillage. POWER DOWN UNITS: Raise the Platform to bed height. Fill the Reservoir to about the middle.

  • Page 34: Platform Lowers Uneven

    PLATFORM LOWERS UNEVEN Lower the Platform to the ground and remove the Pressure Compensation Valves located at the top of each Column. Disassemble 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...

  • Page 35: Platform Will Not Close

    PLATFORM WILL NOT CLOSE Check the hydraulic fluid level in the Reservoir. GRAVITY DOWN UNITS: Lower the Platform to the ground. Fill the Reservoir to about 1” from the top. Do not overfill as this causes spillage. POWER DOWN UNITS: Raise the Platform to bed height. Fill the Reservoir to about the middle.
  • Page 36 PLATFORM WILL NOT CLOSE Check the “E” Valve, remove VALVE COIL the Valve Coil from the Valve Cartridge. Using a paper clip, VALVE CARTRIDGE push on the Plunger inside the Valve 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.

  • Page 37: Platform Folding Speed Adjustment

    PLATFORM FOLDING SPEED ADJUSTMENT CLOSING SPEED OPENING SPEED ADJUSTMENT ADJUSTMENT OLD STYLE PUMP The speed settings for the Closing Cylinder are regulated by the Flow Control Valves located on the “A” Port. Each Valve has an arrow on it indicating the direction of flow it regulates.

  • Page 38: Platform Will Not Unfold

    PLATFORM WILL NOT UNFOLD The flow of hydraulic oil may be restricted. Check the following: a. OLD STYLE PUMP, turn the “A” Port Flow Control Valve nearest the Reservoir in a counter-clockwise direction to open the valve. b. NEW STYLE PUMP, adjust the “O” Pressure Relief Valve to open the valve. “A”...

  • Page 39: Platform Raises Instead Of Folding

    PLATFORM RAISES INSTEAD OF FOLDING OLD STYLE PUMPS ONLY Check the Pump Motor Solenoid for 12 Volts of power from the battery. If there is no power to the Solenoid, check the Battery Cables for damage, and the Battery for a charge.

  • Page 40: Troubleshooting Gravity Down

    TROUBLESHOOTING GRAVITY DOWN PAGE 40...

  • Page 41: Platform Will Not Raise, Motor Runs

    PLATFORM WILL NOT RAISE, MOTOR RUNS Check the hydraulic fluid level in the Reservoir. Lower the opened Platform to the ground. Fill the Reservoir to about 1” from the top. Do not overfill as this causes spillage. Check the Relief Valve for contamination or defective operation. Lower the Platform to the ground.

  • Page 42: Platform Will Not Lower

    PLATFORM WILL NOT LOWER Check the Battery Cables for damage, and the Battery for a charge. Replace or recharge as needed. The use of a Voltage Load Tester is recommended. Check the two “D” Solenoid Valve Coils (located at the top of each Column), and the “B”...

  • Page 43: Platform Lowers Slowly

    PLATFORM LOWERS SLOWLY Check the “B” and “C” Valve Coils (located in the Pump Box), for power. 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.

  • Page 44: Troubleshooting Power Down

    TROUBLESHOOTING POWER DOWN PAGE 44...

  • Page 45: Platform Will Not Raise, Motor Runs

    PLATFORM WILL NOT RAISE, MOTOR RUNS Raise the Platform to bed height. Fill the Reservoir to about the middle. Do not overfill as this causes spillage. The Motor Solenoid (“M”) Valve should be the only solenoid energized during the “RAISE” function. Verify that no other Solenoid is energized. The 4-Way Solenoid Valve may be stuck in the “open”...

  • Page 46: Platform Will Not Lower

    PLATFORM WILL NOT LOWER Check the Battery Cables for damage, and the Battery for a charge. Replace or recharge as needed. The use of a Voltage Load Tester is recommended. Check the following Solenoids for power: the two “D” Solenoid Valve Coils (located at the top of each Column), the “M”...

  • Page 47: Platform Lowers Slowly

    PLATFORM LOWERS SLOWLY Check the “M” Motor Solenoid Valves, and the “4-Way” Solenoid Valves (located in the Pump Box), for power. 4-WAY SOLENOID SOLENOID “F” “M” 4-WAY SOLENOID “C” NEW STYLE PUMP SOLENOID “M” ” 1 / 4 OLD STYLE PUMP Check the Solenoid Valve Coil for power.
  • Page 49 LIQUID SEALANT APPLICATION Clean all threads with a soft brush and a suitable cleaning solvent. Dry threads thoroughly with compressed air or shop towel. Apply the Liquid Sealant (Compound PLS 2), to the external threads of the Male Connector. Assemble the fitting and torque it to the prescribed value. Check for leakage.

This manual is also suitable for:

Columnlift bmr-44Columnlift bmr-55Columnlift bmr-66

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