Maxon GPT SERIES (2006 Release) Operating instructions

Maxon GPT SERIES (2006 Release) Operating instructions
M-06-09
REV. B
APRIL 2008
O P E R AT I O N M A N U A L
GPT-25, GPT-3, GPT-4 & GPT-5
© MAXON Lift Corp. 2008
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
! 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 GPT44, and 5000 lbs. for the GPT-5.
3.
4.
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 floor
of truck body (or between platform and the ground) when Liftgate is
operated.
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 defaced 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 this
Liftgate.
12. Never use a cell phone while operating the Liftgate.
4
LIFTGATE TERMINOLOGY
EXTENSION
PLATE
SADDLE
DOCK
BUMPER
CONTROL
SWITCH
MAIN
FRAME
LIFT
CYLINDER
PARALLEL
ARM
PUMP BOX
PLATFORM
TORSION
SPRING
PLATFORM
OPENER
WEDGE FLIPOVER
5
LIFT
ARM
RECOMMENDED DAILY OPERATION CHECKS
NOTE: Before you check the Liftgate, park vehicle on flat 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 qualified
mechanic services or repairs the Liftgate.
Before operating the Liftgate, the operator should do the following:
† Make sure vehicle battery is fully charged and battery terminal connections are clean and tight.
† Visually check that pump cover is latched closed securely and undamaged. Look for hydraulic fluid 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 DECAL pages). Also
make sure decals are clean, readable, and undamaged.
Use the operation instructions in this manual to lower the Liftgate to
the ground and open the platform and flipover.
† 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, nuts, 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, chafing, and fluid leaks.
6
† With the platform unfolded
and raised to bed level,
check if the outboard
edge of platform is level
or rises up to 2” above
bed level (YES illustration). 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 illustration, do not operate the
Liftgate. (See NOTE at
beginning of the DAILY
OPERATION CHECKS.)
YES
EXTENSION
PLATE (REF)
OUTBOARD EDGE
0” (LEVEL) - 2” MAX.
VEHICLE
FLOOR (REF)
LEVEL LINE
NO
EXTENSION
PLATE (REF)
VEHICLE
FLOOR (REF)
LEVEL LINE
† Check the platform and flipover 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 flipover 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 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 “F”
DECAL “H” (2 PLACES)
DECAL “E”
P/N 268308-01
DECAL “D”
DECAL “I”
DECAL “B”
DECAL “C”
DECAL “G”
PAINT DECAL
P/N 267338-01
DECAL “A”
PLATFORM WARNING DECAL
(2 PLACES)
P/N 281189-01
PLATFORM LOADING DECAL
(2 PLACES)
P/N 281326-01
8
(See TABLE 9-1)
DECAL SHEET
FIG. 9-1
MODEL
DECAL SHEET P/N
DECAL “B”
GPT-25
268308-01
2500 POUNDS
GPT-3
268308-02
3000 POUNDS
GPT-4
268308-03
4000 POUNDS
GPT-5
268308-04
5000 POUNDS
DECAL SHEET
TABLE 9-1
9
THIS PAGE INTENTIONALLY LEFT BLANK
10
FORKLIFT ADVISORY
! WARNING
Keep Forklift OFF of Platform.
NO
NO
FIG. 11-1
11
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 DOWN 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
UNFOLDING PLATFORM
FIG. 12-3
12
4. Unfold the flipover (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 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
INBOARD
EDGE
9. Lower the platform to ground
level (FIG. 15-2). Move load
off the platform (FIG. 15-2)
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 flatform 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
flipover.
NOTE: Before folding flipover, make sure cart stops are stowed (if
equipped).
12. Fold the flipover (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.
FOLDING PLATFORM
FIG. 17-2
17
OPERATION - Continued
CAUTION
Stow Liftgate under hydraulic pressure.
14. Raise the Liftgate by pushing the toggle switch to the
UP position (FIG. 181B). 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; however, a single cart stop operates the same way.
1. Load a 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
CLOSING CART STOPS
(RH VIEW OF FLIP OVER)
FIG. 19-2
19
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. 201 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.
INBOARD
6. When loading the platEDGE
form at bed level, make
TRUCK
sure cart stops are open
BODY
(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 plat- CART STOPS
form with heaviest part
PLATFORM
toward the truck body as
LOADING PLATFORM AT BED LEVEL
shown in FIG. 21-1.
(DUAL CART STOPS OPEN)
If standing on platform
FIG. 21-1
with the load, stand in the
footprint area shown and
PUSH HERE
comply with the WARNOPENER
ING on page 15.
CART STOP
7. Unload a platform with cart
Stops at ground level as
shown in FIG. 21-3. Make
sure cart stops are closed
when unloading the platform
(FIGS. 21-2). Move cart
enough to close cart stop.
BLOCK
CLOSING CART STOPS
(RH VIEW OF FLIP OVER)
FIG. 21-2
8. Move load off the platform
as shown in FIG. 21-3.
CART STOPS
CART STOPS CLOSED
FIG. 21-3
21
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