When the taillift becomes an integral part of the commercial vehicle
A tail lift is only as good as its integration into the vehicle. Anyone who thinks that installation is simply a matter of bolting a taillift to the rear of the vehicle underestimates the complexity of modern commercial vehicle systems. In fact, mechanical, electrical and digital interfaces determine whether the tail lift and vehicle function as a harmonious integrated system – and whether friction losses, malfunctions and unplanned downtime result in everyday use. For operators and drivers, utilising all available possibilites combined with the suitable lift equipment means, above all, reliability and simplicity in daily use. For bodybuilders, certain components and options enable shorter installation times, less adaptation work and seamless compatibility with other vehicle components.
Precisely because commercial vehicles today are increasingly networked and electronically controlled, the demands on well-thought-out vehicle integration are rising at every level. Whether it’s the frame design, power supply or data communication with the vehicle’s CAN bus: every interface needs to be carefully considered – ideally right from the vehicle and lift ordering stage. Taking this into account speeds up the fitment process, saves on costly retrofitting later on and lays the foundation for maximum uptime of the Cargolift during daily use.
Select an interface type by clicking on the image or heading – or simply scroll down.
Mechanical interfaces: Secure vehicle connection combined with quick installation
The focus: The secure connection between lift and vehicle chassis
The fitment of a tail lift requires specialist knowledge. Installation must only be carried out by trained specialists who are familiar with the requirements. BÄR supports the bodybuilder in this process by providing the highest possible level of pre-assembly for the lift and a well-designed fitment procedure. At the heart of the lift installation is the secure connection between the Cargolift and the carrier vehicle:
When fitting to lorries or trucks, the lifting mechanism is positioned at the rear of the vehicle using a specific mounting device. It is then bolted to the vehicle frame using mounting plates. The mounting plates are available in various designs with drill holes to match the vehicle frame. For medium-duty, leaf-sprung lorries (up to approx. 18 tonnes gross vehicle weight (GVW)), there is a specific vehicle suspension under the spring mount.
Transporter or Van chassis, i.e. light lorries up to approximately 7.5 tonnes GVW, have a variety of vehicle frames. In this case, fitment is carried out using vehicle-specific mounting adapters or fitment kits, which are also bolted to the vehicle frame. Further information can be found on the BC 750 product page.
Semi-trailers require a different approach: here, the lifts are bracketed to the vehicle frame. You can find more detailed information on installation in the downloadable fitment instructions.
But there is more related to the optimum mechanical integration of the lift!
As an integral part of the overall commercial vehicle system, the tail lift must match the vehicle visually, technically and functionally. The lifting mechanism out of steel can be ordered with either a cathodic dip coating (KTL) or KTL+PEP (+powder) coating, or in some cases galvanised with a MicroZinq coating. The aluminum platforms are available in natural (untreated), anodised, wet-painted or powder-coated finishes – and, on request, in a specific colour to match the vehicle and corporate identity.
If the rear of the vehicle body is to be closed with the platform, all Standard platforms come with load securing certificates (downloadable from this website). If a load securing rail is used, the SoftLock operating sequence makes day-to-day work easier. A flat bolt lock – also available as customs lock – is also available.
The CargoSeal sealing system completes this configuration. In its basic version, this tight-sealing body seal consists of aluminium profiles with sealing lips for all four outer edges, as well as two arm stops for the loading edge. CargoSeal is available either as a side body seal only or as a seal on the lower rail including the support arm stops.
Do you use a rolling gate? Ask BÄR about integrating your roller door with the lift, the rolling gate control system or the "Food Package".
If the lift is fitted behind body doors, external twist-lock fasteners often pose an obstacle to the lift. BÄR therefore offers an alternative to the body-side ramp: aluminum bridge plate.
- In the case of Standard S4 Cargolifts, the CargoBridge can simply be fitted with cut-outs for the external door locks.
- Retractable RetFalt Cargolifts come as standard with a fixed bridge plate to create a level surface between the load floor and the platform.
- Alternatively, some slider lifts can be fitted with flapping bridge plates.
- On Bär VanLifts, a two-part ramp, known as the VanBridge, bridges the gap between the platform and the load floor as standard. A special version of the VanBridge is available for panel vans with refrigerated bodies.
For refrigerated and insulated bodies, slip resistance on the platform is a key consideration. Here, BÄR offers the TracGrip platform surface (class R11) as standard; the noise-reducing SilentGrip (R11) and the specially treated TracGrip Plus surface (R13) are available as options.
If a roller door is used, it can be linked to the lift – please contact BÄR regarding the rolling gate control system.
Overall, refrigerated vehicles benefit from the aluminum platform, as it not only provides a rust-free appearance (who wants rust on their freezer?) but also, thanks to its lower weight, offers valuable payload capacity compared to a steel platform.
The vehicle-specific equipment is complemented by steps at the rear of the vehicle, various rear light brackets and different fitment possibilities for control elements (see relevant blog post) – all components that complete the professional vehicle integration of the lift.
Specific vehicle configurations require special solutions
In most cases, the taillift serves as underrun protection. The relevant certificates are available for download on this website. Generally, the underrun protection on Standard S4 Cargolifts is bolted on, allowing it to adapt to various fitment situations. When ordered with vehicle specifications, the underrun bar is delivered pre-assembled in the correct position.
BÄR also offers specific underrun protection solutions: For trucks with a low-mounted coupling – also known as deep coupling or under-coupling – BC S4U with hydraulic underrun bar or BC R4U with hydraulic underrun bar or BC S4V and for truck and trailer combinations (TTC), BC S4T with hydraulic underrun bar.
On BDF swap bodies, lifting arm stops and flapping bridge plates play a key role in safe operation: Ret/HydFalt Cargolifts, as well as the BC R4U, can handle different swap body lengths (see blog post on operating functions). In this installation, two bolted support arm stops are required combined with the flapping bridge. Whilst the arm stops ensure stability, the flapping bridge creates a level connection to the swap body floor.
If a trailer is to be used, BÄR offers a towing bracket for ball coupling as well as the coupling ball. More detailed information is available on the Standard, taillifts with 750 kg load capacity and VanLift pages. The certificate for ball-head coupling can be found in the document downloads section of this website.
If a Standard Cargolift should be fitted to a flatbed vehicle, the platform can be equipped with a folding joint. The division between the fixed and folding parts is 50/50. The folding section is 100 mm narrower than the fixed section and must be unfolded manually after opening and folded back in again before closing. Please contact BÄR to discuss the options for Standard platforms with a folding joint.
For emergency vehicles – such as those used by the fire service or fire brigades – BÄR offers a sturdy Standard platform that can be folded when required. BÄR calls this folding joint the FoldLock: the horizontal locking mechanism on the platform joint allows the unfolded platform to be used as a rear panel instead of vehicle body doors. Thanks to the sturdy, locked folding joint, the platform can also be driven over the ramp whilst carrying its nominal load. Locking is achieved via a lever with two positions:
- Open – platform can be folded
- Closed – platform is locked and ready for use
Electrical interfaces for a reliable power supply and the connection of additional components
A reliable power supply is essential for the tail lift to function properly. In most cases, the lift is powered by the vehicle battery or an additional battery – in 12V or 24V.
Trucks can often be ordered with a tail-lift preparation. In this case, the lorry already has main power connections (Code B/C) and a control power connection (Code A). The main power connection – also known as the power wiring or main feed cable – comprises a ground cable with a blue plug and a positive cable with a red plug. The control feed connection enables, via the control power wiring, the ON/OFF switch with indicator light – also known as the cabin control switch (FHE) – and other components to switch the lift on and off from the cab, display the operating position (cab feedback or feedback signal) and, if desired, engage the starter lock (starter cut-off). If the truck has a lift preparation, these components are already installed and the cables can be easily connected to the Cargolift’s electrical interface – in-house often referred to as the ‘Christmas tree’ – via plug-and-play connectors. In addition to the simpler and faster electrical connection, the lift preparation includes a push-button in the design of the driver’s cab (FHE)..
If the truck is not prepared, or if it is a trailer or semi-trailer, you can order the cables and electrical components described from the installation company or from BÄR.
The fourth socket on the electrical interface is intended by BÄR for the body interior lighting (also known as box lighting). You can order the appropriate plug for box lighting from BÄR, as well as various types of fuses and, in some cases, rear lights together with rear light bracket.
To ensure that trailers and semi-trailers are reliably supplied with power, BÄR recommends the standardised, electronically controlled SmartCharge charging cable combined with a side-mounted BatteryBox or a battery case on underrun protection (for Standard S4). Further information is available on the SmartCharge website and from your contact person.
Control elements in the sense of electrical interfaces are covered in a separate blog post – as are control functions. Consider, for example, the Bär SmartControl Plus radio remote control, which offers significant advantages in day-to-day operation for trucks with trailers, i.e. lorry-trailer combinations.
The “eBC Controller” electronic control system is covered in the next section.
Digital interfaces of Bär Cargolifts and the Bär ecosystem
Modern taillifts have become more than purely mechanical systems – the lifts are digitally networked, diagnosable and embedded in a growing ecosystem of tools and services.
On the lift: connected, documented, operable
Every Bär Cargolift has digital intelligence as standard. At its heart is the eBC Controller – the electronic control unit that automatically detects and documents electrical faults. These faults can then be read out using the Bär CargoCheck diagnostic software. This enables targeted fault diagnosis and significantly reduces maintenance and repair times.
In addition, every Cargolift is equipped with the standardised data interface called CargoConnect. When this is active and connected to the vehicle’s existing telematics system, it opens up a range of practical possibilities: from geofencing and time fencing to usage-based maintenance intervals and seamless integration into existing fleet management systems. Anyone who manages their fleet digitally will find CargoConnect to be the ideal interface.
There is also a digital solution for drivers and users: a QR code on the lift leads directly to the lift-specific operating instructions – BÄR calls the web application HowToCargoLift. No searching, no scrolling – the correct instructions for exactly this lift, available at any time, with images and videos, in eleven languages.
BÄR’s digital ecosystem: from vehicle configuration to spare parts
Beyond the lift, BÄR offers a comprehensive digital ecosystem that supports operators and installation companies throughout the entire lifecycle. With the MyCargolift product finder, the right lift can be configured quickly and precisely. The fitment calculation programme gives the bodybuilder certainty regarding technical feasibility already in the planning phase and it saves time.
In the Bär WebShop, workshops can easily find the suitable spare part thanks to a wide range of search options, access to original parts lists and exploded views. The shop features a platform configurator as well as maintenance recommendations and retrofit options for the specific lift. And anyone who needs a quick answer can now turn to BC.AI – the AI-powered telephone assistant on the Bär service hotline – which provides information on all aspects of the Cargolift service.
Conclusion: The right integration makes all the difference
Mechanical connection, electrical supply and digital networking – only when all three interfaces have been carefully considered and coordinated, the vehicle and tail lift do become a true integrated system. The wide range of possibilities demonstrates just how customisable a lift integration can be: depending on the vehicle type, bodywork and intended use, different requirements and solutions arise that can go far beyond a standard installation.
This guide cannot cover all configuration options and special solutions – the practical applications are simply too varied. If you are unsure about choosing the suitable equipment or have a specific application, you are in good hands with BÄR: your contacts are always on hand to help you find the optimal lift configuration for your vehicle and your application.
The next post will focus on equipment and services designed to ensure maximum uptime of your Cargolift and, consequently, your vehicle during ongoing operations.