OPERATION MANUAL

GPT-25, GPT-3, GPT-4 & GPT-5

M-08-03

REV. A

AUGUST 2010

© MAXON Lift Corp. 2010

TABLE OF CONTENTS

WARNINGS ................................................................................4

LIFTGATE TERMINOLOGY .......................................................5

RECOMMENDED DAILY OPERATION CHECKS .....................6

DECALS .....................................................................................8

FORKLIFT ADVISORY ............................................................. 11

OPERATION ............................................................................ 12

USING CART STOPS (IF EQUIPPED) .................................... 19

WARNINGS !

WARNING

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:

MAXON Lift Corp.

11921 Slauson Ave

Santa Fe Springs, CA 90670

(800) 227-4116

NOTE: For latest version manuals (and replacements), download manuals from Maxon’s website at www.maxonlift.com.

2. Do not exceed rated load capacity of the Liftgates, which is

2500 lbs. for the GPT-25, 3000 lbs. for the GPT-3, 4000 lbs. for

the GPT-4, and 5000 lbs. for the GPT-5.

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

operating.

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.

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.

8. Do not move vehicle unless Liftgate is correctly stowed.

9. Correctly stow platform when not in use. Extended platforms could create a hazard for people and vehicles passing by.

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 raised. Listen for scraping, grating and binding noises and have the problem corrected before continuing to operate the Liftgate.

11. Above all, USE GOOD COMMON SENSE when operating the

Liftgate.

12. Never use a cell phone while operating the Liftgate.

4

LIFTGATE TERMINOLOGY

DOCK

BUMPER

EXTENSION

PLATE

LIFT

CYLINDER

PARALLEL

ARM

PLATFORM

SADDLE

PLATFORM

OPENER

CONTROL

SWITCH

WEDGE FLIPOVER

MAIN

FRAME

TORSION

SPRING

LIFT

ARM

PUMP ASSY

(COVER IS

SHOWN)

5

RECOMMENDED DAILY OPERATION CHECKS

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.

Before operating the Liftgate, the operator should do the following:



Make sure battery is fully charged and battery terminal connections are clean and tight.



Make sure cab cutoff switch is ON, if equipped.



Visually check that pump cover is bolted on securely and undamaged.

Look for hydraulic fl uid leaking from the pump box.



Visually check that control switch is in place and undamaged.



Visually check for cracks and bends on the extension plate. Also, make sure fasteners are in place and undamaged and extension plate is clean (no oil, debris, or corrosion).



Visually check that all decals are in place (see DECALS page). Make sure decals are legible, clean, and undamaged.

Use the operation instructions in this manual to lower the Liftgate to the ground and open the platform and fl ipover.



Check main frame, lift arms, parallel arms and platform openers for cracks and bends. Make sure rollers, on the platform openers, roll freely. Also, make sure all bolts and pins are in place and undamaged.



Make sure main frame, lift arms, parallel arms and platform openers are clean (no oil, debris, or corrosion).



Check the hydraulic cylinders for leaking seals and hose connections.

Follow the hydraulic hoses (or return lines for gravity down Liftgates) from the cylinders to pump box. Make sure all hoses are connected at both ends and there are no cracks, chafi ng, and fl uid leaks.

6



With the platform unfolded and raised to bed level, check if the outboard edge of platform is level or rises up to 1” above bed level (YES illustra-

tion). If the outboard edge of platform looks like the YES illustration, you can operate Liftgate.

If the outboard edge of platform is below level line and platform looks like the NO illustra-

tion, do not operate the

Liftgate. (See NOTE at beginning of the DAILY

OPERATION CHECKS.)

YES

OUTBOARD EDGE

0” (LEVEL) - 1” MAX.

LEVEL LINE

NO

LEVEL LINE

EXTENSION

PLATE (REF)

VEHICLE

FLOOR (REF)

EXTENSION

PLATE (REF)

VEHICLE

FLOOR (REF)



Check the platform and fl ipover for cracks, holes, and bends on the load-carrying surface and side plates. Also, make sure torsion bars, coil springs, and fasteners are in place and undamaged.



Make sure platform and fl ipover load-carrying surfaces are clean (no oil, debris, or corrosion).

Use the operation instructions in this manual to operate the Liftgate through one cycle without a load on the platform. Raise the platform to vehicle bed height. Next, lower the platform to ground level.



When the Liftgate is moving, listen for unusual noises and look for a

“jerking” motion or uneven movement on either side of the platform.

If service or repairs are not required (or if completed), stow the Liftgate.

7

DECALS

DECAL “H” (2 PLACES)

P/N 268308-01

PAINT DECAL

P/N 267338-01

DECAL “D”

DECAL “F”

DECAL “E”

DECAL “B”

DECAL “C”

DECAL “I”

DECAL “G”

DECAL “A”

PLATFORM WARNING DECAL

(2 PLACES)

P/N 281189-01

PLATFORM LOADING DECAL

(2 PLACES)

P/N 281326-01

8

SERIAL PLATE

(REF)

(See TABLE 9-1)

DECAL SHEET

FIG. 9-1

MODEL DECAL SHEET P/N

GPT-25 268308-01

GPT-3 268308-02

GPT-4

GPT-5

268308-03

268308-04

DECAL SHEET

TABLE 9-1

9

DECAL “B”

2500 POUNDS

3000 POUNDS

4000 POUNDS

5000 POUNDS

THIS PAGE INTENTIONALLY LEFT BLANK

10

FORKLIFT ADVISORY

!

WARNING

Keep forklift OFF of platform.

NO

FIG. 11-1

11

NO

OPERATION

1. Unhook safety chain from the eye on the Liftgate (FIG. 12-1).

SAFETY

CHAIN

EYE

HOOK

UNHOOKING SAFETY CHAIN

FIG. 12-1

2. Standing to the side of platform (FIG. 12-2A), push the toggle switch to the UP position as shown in FIG. 12-2B. FIG. 12-2B

FIG. 12-2A

!

WARNING

Never operate control switch while unfolding platform.

3. Lower the platform until it touches the ground. Unfold platform (FIG. 12-3).

PLATFORM

12

UNFOLDING PLATFORM

FIG. 12-3

4. Unfold the fl ipover (FIG. 13-1).

FLIPOVER

UNFOLDING FLIPOVER

FIG.13-1

NOTE: While operating the Liftgate, release the toggle switch

to stop the platform.

5. Raise the platform (FIG. 13-2A) by pushing the toggle switch to the UP position (FIG. 13-2B). Wait a second before releasing the toggle switch, after platform reaches bed height. To lower the platform, push the toggle switch to the DOWN position (FIG. 13-2C).

FIG. 13-2B

FIG. 13-2C

RAISING & LOWERING PLATFORM

FIG. 13-2A

13

OPERATION - Continued

!

WARNING

A load should never extend past the edges of the platform. Do not place unstable loads on platform and do not allow load to exceed the lifting capacity of the Liftgate. If standing on platform, do not allow your feet to extend beyond the inboard edge of the platform.

6. Load the platform at ground level as shown in FIG. 14-1.

INBOARD

EDGE

LOAD

PLATFORM

LOADING PLATFORM AT GROUND LEVEL

FIG. 14-1

7. Raise the platform to bed level (FIG. 14-2). Move load from platform to inside the vehicle body.

LOAD

VEHICLE

BODY

PLATFORM

UNLOADING PLATFORM AT BED LEVEL

FIG. 14-2

14

!

WARNING

Pulling the load from vehicle to platform can result in a fall from platform and cause serious injury. When unloading vehicle, always push the load out on the platform.

8. Load the platform at bed level as follows. Push load out of the vehicle to correct position on the platform (FIG. 15-1).

Place all loads as close as possible to the inboard edge of the platform with heaviest part toward the truck body as shown in FIG. 15-1. If standing on platform with the load, stand in the footprint area shown and comply with the WARNING on the previous page.

LOAD INBOARD

EDGE

TRUCK

BODY

PLATFORM

LOADING PLATFORM AT BED LEVEL

FIG. 15-1

9. Lower the platform to ground level (FIG. 15-2). Move load off the platform (FIG. 15-2).

INBOARD

EDGE

LOAD

PLATFORM

PLATFORM AT GROUND LEVEL

FIG. 15-2

15

OPERATION - Continued

!

WARNING

Never move the vehicle unless the Liftgate is properly stowed.

10. Before moving the vehicle,

prepare the Liftgate as

follows. Make sure load is

removed from platform. If

the platform is at bed height,

push the toggle switch to the

DOWN position as shown in

FIG. 16-1B. Release toggle

switch when platform touches

the ground (FIG. 16-1A).

FIG. 16-1B

LOWERING LIFT

FIG. 16-1A

11. Stow the Liftgate by doing the following. Raise the platform a little above the ground

(FIG. 16-2A) by pushing the toggle switch to the UP position (FIG. 16-2B).

FIG. 16-2B

RAISING LIFT

FIG. 16-2A

16

!

WARNING

Keep hands clear of the platform support when folding the fl ipover.

NOTE: Before folding fl ipover, make sure cart stops are stowed (if equipped).

12. Fold the fl ipover (FIG. 17-1).

FOLDING FLIPOVER

FIG. 17-1

!

WARNING

Keep hands clear of the extension plate when folding the platform under the extension plate.

13. Fold the platform as shown in FIG. 17-2.

17

FOLDING PLATFORM

FIG. 17-2

OPERATION - Continued

CAUTION

Stow Liftgate under hydraulic pressure.

14. Raise the Liftgate by pushing the toggle switch to the UP position (FIG. 18-1B). Wait a second before releasing toggle switch after Liftgate is raised all the way (FIG.

18-1A).

FIG. 18-1B

CORRECTLY STOWED LIFTGATE

FIG. 18-1A

15. Hook the safety chain to the eye on Liftgate (FIG. 18-2).

Liftgate is ready for transport.

SAFETY

CHAIN

EYE

HOOK

HOOKING SAFETY CHAIN

FIG. 18-2

18

USING CART STOPS (IF EQUIPPED)

!

CAUTION

To prevent injuries caused by tripping and falling, make sure cart stops are closed before walking on and off outboard end of platform.

NOTE: Some Liftgates are equipped with single or dual cart stops.

Cart stops prevent loaded carts from rolling off outboard end of platform. Single cart stops are 1 section, about the same as overall width of platform, and operate with one set of controls.

Dual cart stops are 2 identical sections, with a combined width about the same as overall width of platform, and each is independently operated with separate controls (1 set of controls per cart stop). The following procedure shows how to operate dual cart stops. A single cart stop operates the same way.

1. Load the platform with cart stops at ground level as shown in FIG. 19-1. Make sure cart stops are closed when loading the platform (FIGS. 19-1 and

19-2).

CART STOPS

LOADING PLATFORM AT GROUND LEVEL

(CART STOPS CLOSED)

FIG. 19-1

2. To close cart stops, push on the opener block as shown in FIG.

19-2.

CART STOP

PUSH HERE

OPENER

BLOCK

19

CLOSING CART STOPS

(RH VIEW OF FLIPOVER)

FIG. 19-2

USING CART STOPS (IF EQUIPPED) - Continued

3. To open cart stops, push on the opener block as shown in FIG. 20-1. CART STOP

OPENER

BLOCK

PUSH HERE

OPENING CART STOPS

(RH VIEW OF FLIP OVER)

FIG. 20-1

4. Open cart stops (FIGS. 20-

1 and 20-2). Next, position cart and stand in the footprint area as shown in FIG.

20-2.

CART STOPS

CART STOPS OPEN

FIG. 20-2

5. Raise the platform to bed level (FIG. 20-3). Move the load off the platform into the vehicle body (FIG. 20-3).

VEHICLE

BODY

PLATFORM

UNLOADING PLATFORM AT BED LEVEL

(DUAL CART STOPS OPEN)

FIG. 20-3

20

!

WARNING

Pulling the load from vehicle to platform can result in a fall from platform and serious injury. When unloading vehicle, always push the load out on the platform.

6. When loading the platform at bed level, make sure cart stops are open (FIG.

21-1). Push load out of the vehicle to correct position on the platform. Place all loads as close as possible to the inboard edge of the platform with heaviest part toward the truck body as shown in FIG. 21-1.

If standing on platform with the load, stand in the footprint area shown and comply with the WARNING on page 15.

CART

STOPS

CART STOP

INBOARD

EDGE

TRUCK

BODY

PLATFORM

LOADING PLATFORM AT BED LEVEL

(DUAL CART STOPS OPEN)

FIG. 21-1

PUSH HERE

OPENER

BLOCK

CLOSING CART STOPS

(RH VIEW OF FLIP OVER)

FIG. 21-2

7. Unload the platform with cart stops at ground level as shown in FIG. 21-3. Make sure cart stops are closed when unloading the platform

(FIG. 21-2). Move cart and close cart stop.

8. Move load off the platform as shown in FIG. 21-3.

CART STOPS

CART STOPS CLOSED

FIG. 21-3

21