GPT SERIES (2008 Release)

GPT SERIES (2008 Release)
M-08-04
REV. A
AUGUST 2010
MAINTENANCE MANUAL
GPT-25, GPT-3, GPT-4 & GPT-5
© MAXON Lift Corp. 2010
11921 Slauson Ave.
Santa Fe Springs, CA. 90670
LIFT CORP.
CUSTOMER SERVICE:
TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116
FAX: (888) 771-7713
NOTE: For latest version of all Manuals (and replacements), download the
Manuals from Maxon’s website at www.maxonlift.com.
WARRANTY/ RMA POLICY & PROCEDURE
LIFTGATE WARRANTY
Type of Warranty: Full Parts and Labor
Term of Warranty: Standard Liftgates - 2 years from ship date or 6,000 cycles
Premium Liftgates - 2 years from ship date or 10,000 cycles
This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s specifications as set forth in
MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments, damage or
malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this warranty does not
cover equipment that has had unauthorized modifications or alterations made to the product.
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 Schedule. (Copy of the Flat Rate is available at www.maxonlift.com.)
All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and labor,
MAXON’s Technical Service Department must be notified and an “Authorization Number” obtained. All claims for warranty must be received within 30 Days of the repair date, and include the following information:
1. Liftgate Model Number and Serial Number
2. The End User must be referenced on the claim
3. Detailed Description of Problem
4. Corrective Action Taken, and Date of Repair
5. Parts used for Repair, Including MAXON Part Number(s)
6. MAXON R.M.A. # and/or Authorization # if applicable (see below)
7. Person contacted at MAXON if applicable
8. Claim must show detailed information i.e. Labor rate and hours of work performed
Warranty claims can also be placed online at www.maxonlift.com. Online claims will be given priority processing. All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s Warranty
Department within 30 days of repair date.
All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior written
approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with original
invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized returns will be
refused and will become the responsibility of the returnee.
Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in plain
view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned parts
are subject to no credit and returned back to the customer. Defective parts requested for return must be returned within 30 days of the claim date for
consideration to:
MAXON Lift Corp.
10321 Greenleaf Ave., Santa Fe Springs, CA 90670
Attn: RMA#__
MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income due to
downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.
MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.
All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not returned
in new condition will be subject to an additional reworking charge, which will be based upon the labor and material cost required to return the Liftgate or
component to new condition.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase.
Type of Warranty: Part replacement only. MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts
and original invoice.
All warranty replacements parts will be sent out via ground freight. If a rush shipment is requested, all freight charges will be billed to the requesting
party.
TABLE OF CONTENTS
WARNINGS............................................................................................................................ 6
SAFETY INSTRUCTIONS..................................................................................................... 6
LIFTGATE TERMINOLOGY................................................................................................... 9
PERIODIC MAINTENANCE................................................................................................. 10
PERIODIC MAINTENANCE CHECKS................................................................................. 10
PERIODIC MAINTENANCE CHECKLIST.............................................................................11
CHECKING HYDRAULIC FLUID......................................................................................... 12
CHANGING HYDRAULIC FLUID......................................................................................... 14
REPLACING PLATFORM TORSION SPRING.................................................................... 16
PLATFORM ADJUSTMENT................................................................................................. 17
PARTS BREAKDOWN........................................................................................................ 19
MAIN ASSEMBLY (ALUMINUM PLATFORM)...................................................................... 19
MAIN FRAME ASSEMBLY: GPT-25 & GPT-3...................................................................... 20
MAIN FRAME ASSEMBLY: GPT-4 & GPT-5........................................................................ 24
PLATFORM & FLIPOVER ASSEMBLY (ALUMINUM)......................................................... 28
PLATFORM & FLIPOVER ASSEMBLY WITH CART STOPS (ALUMINUM)........................ 29
PLATFORM ASSEMBLY (ALUMINUM)................................................................................ 30
FLIPOVER WITH SINGLE CART STOP (ALUMINUM)....................................................... 32
FLIPOVER WITH DUAL CART STOPS (ALUMINUM)......................................................... 34
DOCK BUMPER................................................................................................................... 36
PUMP ASSEMBLY............................................................................................................... 37
HYDRAULIC COMPONENTS - POWER DOWN................................................................. 38
12 VDC POWER UNIT......................................................................................................... 40
CONTROL SWITCH AND POWER CABLE......................................................................... 43
DECALS............................................................................................................................... 44
SYSTEM DIAGRAMS.......................................................................................................... 47
PUMP & MOTOR SOLENOID OPERATION........................................................................ 47
HYDRAULIC SCHEMATIC (POWER DOWN)..................................................................... 48
ELECTRICAL SCHEMATIC (POWER DOWN).................................................................... 49
TROUBLESHOOTING......................................................................................................... 50
PLATFORM WILL NOT RAISE & MOTOR WILL NOT RUN................................................ 50
PLATFORM WILL NOT RAISE, BUT MOTOR RUNS.......................................................... 51
PLATFORM RAISES BUT LEAKS DOWN........................................................................... 52
PLATFORM RAISES PARTIALLY AND STOPS................................................................... 54
LIFTGATE WILL NOT LIFT RATED CAPACITY................................................................... 55
PLATFORM RAISES SLOWLY............................................................................................ 56
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY................. 58
PLATFORM WILL NOT TILT DOWN TO THE GROUND..................................................... 60
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.
WARNINGS
!
WARNING
• Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your
feet are clear of the Liftgate.
• Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
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• Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.
• If it is necessary to stand on the platform while maintaining the Liftgate, keep your feet and any
objects clear of the inboard edge of the platform. Your feet or objects on the platform can become
trapped between the platform and the Liftgate extension plate.
• Recommended practices for welding on steel parts are contained in the current AWS (American
Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and
personal injury could result from welds that are done incorrectly.
• Recommended practices for welding on aluminum parts are contained in the current AWS
(American Welding Society) D2.1 Structural Welding Code - Aluminum. Damage to Liftgate
and/or vehicle, and personal injury could result from welds that are done incorrectly.
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
• Read and understand the instructions in this Maintenance Manual before performing maintenance on the Liftgate.
• Before operating the Liftgate, read and understand the operating instructions in Operation
Manual.
• Comply with all WARNING and instruction decals attached to the Liftgate.
• Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement
decals are available from Maxon Customer Service.
• Consider the safety and location of bystanders and location of nearby objects when operating the
Liftgate. Stand to one side of the platform while operating the Liftgate
• Do not allow untrained persons to operate the Liftgate.
• Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while
performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.
• Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no flames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek first aid. If acid gets on your
skin, immediately wash it off with soap and water.
6
• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the power unit while the platform is raised. Listen for scraping, grating and binding noises and correct the problem before continuing to operate Liftgate.
• Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial number information with your parts order. Order replacement parts from:
MAXON LIFT CORP. Customer Service
11921 Slauson Ave., Santa Fe Springs, CA 90670
Online: www.maxonlift.com
Express Parts Ordering: Phone (800) 227-4116 ext. 4345
Email: Ask your Customer Service representative
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the control switch to stop the Liftgate.
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THIS PAGE INTENTIONALLY LEFT BLANK
8
CONTROL
SWITCH
MAIN
FRAME
EXTENSION
PLATE
SADDLE
DOCK
BUMPER
LIFT
CYLINDER
PARALLEL
ARM
PLATFORM
PLATFORM
OPENER
TORSION
SPRING
PUMP ASSEMBLY
(COVER IS
SHOWN)
LIFT
ARM
WEDGE FLIPOVER
9
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LIFTGATE TERMINOLOGY
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHECKS
!
WARNING
Never operate the Liftgate if parts are loose or missing.
NOTE: Make sure vehicle is parked on level ground while performing the
maintenance checks.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Quarterly or 1250 Cycles (whichever occurs first)
Check the hydraulic fluid level in the pump reservoir. Refer to the CHECKING HYDRAULIC
FLUID procedure in the PERIODIC MAINTENANCE section.
If hydraulic fluid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure in the PERIODIC MAINTENANCE section.
Keep track of the grade of hydraulic fluid in the pump reservoir and never mix two different
grades of fluid.
Check all hoses and fittings for chafing and fluid leaks. Tighten loose fittings or replace
parts as required.
Check electrical wiring for chafing and make sure wiring connections are tight and free of
corrosion. Use dielectric grease to protect electrical connections.
Check that all WARNING and instruction decals are in place. Also, make sure decals are
legible, clean and undamaged.
Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.
CAUTION
Damaged cylinder seals and contaminated hydraulic fluid can result from painting the polished portion of the cylinder rod. To prevent damage, protect the
exposed polished portion of the cylinder rod while painting.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it off.
Touch up the paint where bare metal is showing. MAXON recommends using the aluminum
primer touchup paint kit, P/N 908119-01.
Semi-annually or 2500 Cycles (whichever occurs first)
Visually check the platform hinge pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly or 1250 Cycles
maintenance checks.
10
NOTE: Make sure vehicle is parked on level ground while performing maintenance
checks.
Quarterly or 1250 Cycles (whichever occurs first)
Check the level and condition of the hydraulic fluid.
Visually check all hoses and fittings for chafing and fluid leaks. Tighten loose fittings or
replace parts as required.
Check electrical wiring for chafing and make sure wiring connections are tight and free
of corrosion. Use dielectric grease to protect electrical connections.
Check that all WARNING and instruction decals are in place. Also, make sure decals
are legible, clean, and undamaged.
Check that all bolts, nuts, and roll pins are in place. Make sure roll pins protrude evenly
from both sides of hinge pin collar. Replace fasteners and roll pins if necessary.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate or if the
Liftgate is dirty, clean it off. Touch up the paint where bare metal is showing. Refer to
the paint system CAUTION and recommended touchup kit on the preceding page.
Semi-annually or 2500 Cycles (whichever occurs first)
Visually check the platform hinge pins for excessive wear and broken welds.
Do the Quarterly or 1250 Cycles Checks on this checklist.
11
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PERIODIC MAINTENANCE CHECKLIST
PERIODIC MAINTENANCE
CHECKING HYDRAULIC FLUID
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.
NOTE: Use correct grade of hydraulic fluid for your location.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 13-1 & 13-2 for recommended brands.
1. Unbolt and remove pump cover
(FIG. 12-1).
LONG SIDE OF
HOLDER FLATS
BUTT AGAINST
COVER
POWER
UNIT
(REF)
2. Check the hydraulic fluid level in
reservoir as follows. With Liftgate
stowed, or platform at vehicle bed
height, level should be as shown in
FIG. 12-2.
NOTE: If the hydraulic fluid in the
reservoir is contaminated, do
the CHANGING HYDRAULIC
HEX NUTS
FLUID procedure in this section. (2 PLACES)
3. If needed, add fluid to the reservoir as follows. Pull out (no threads) filler cap (FIG.
12-2). Fill the reservoir with hydraulic fluid
until reservoir looks about half full (FIG. 122). Reinstall filler cap (FIG. 12-2).
FLAT
WASHERS
(2 PLACES)
PUMP
COVER CAP SCREWS
(2 PLACES)
UNBOLTING / BOLTING PUMP COVER
FIG. 12-1
FILLER
CAP
CAUTION
RESERVOIR
Pump cover must be correctly secured to prevent it from becoming
a hazard. To secure pump cover,
the long side of the holder flats
must butt against pump cover as
shown in the illustration.
HALF
FULL
4. Bolt on the pump cover as shown in
FIG. 12-1. Torque the 5/16”-18 cover
bolts from 10 to 14 lbs.-ft.
POWER UNIT FLUID LEVEL
FIG. 12-2
12
RECOMMENDED
BRANDS
PART NUMBER
AMSOIL
AWH-05
CHEVRON
HIPERSYN 32
KENDALL
GOLDEN MV
SHELL
TELLUS S2 V32
EXXON
UNIVIS N-32
MOBIL
DTE-13M, DTE-24,
HYDRAULIC OIL-13
TABLE 13-1
ISO 15 OR MIL-H-5606 HYDRAULIC OIL
RECOMMENDED
BRANDS
PART NUMBER
AMSOIL
AWF-05
CHEVRON
FLUID A, AW-MV-15
KENDALL
GLACIAL BLU
SHELL
TELLUS S2 V15
EXXON
UNIVIS HVI-13
MOBIL
DTE-11M
ROSEMEAD
THS FLUID 17111
TABLE 13-2
13
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ISO 32 HYDRAULIC OIL
PERIODIC MAINTENANCE
CHANGING HYDRAULIC FLUID
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.
NOTE: Use correct grade of hydraulic fluid for your location.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 13-1 & 13-2 for recommended brands.
1. Unbolt and remove pump cover
LONG SIDE OF
HOLDER FLATS
BUTT AGAINST
COVER
POWER
UNIT
(REF)
(FIG. 14-1). Place empty 5
gallon bucket under drain plug
(FIG. 14-2).
HEX NUTS
(2 PLACES)
FLAT
WASHERS
(2 PLACES)
PUMP
COVER CAP SCREWS
(2 PLACES)
UNBOLTING PUMP COVER
FIG. 14-1
2. Open and raise platform to vehicle bed
height. Pull out (no threads) drain plug
(FIG. 14-2). Drain hydraulic fluid.
DRAIN PLUG
POWER UNIT
FIG. 14-2
14
3. Disconnect the white wire (FIG. 15-1) from
starter solenoid. Lower the platform while
draining the remaining hydraulic fluid from
system. Reinstall drain plug. Reconnect the
white wire to starter solenoid.
STARTER
SOLENOID
WHITE
WIRE
HEX
NUT
DISCONNECTING WHITE WIRE
FIG. 15-1
FILLER
CAP
4. Pull out (no threads) filler cap (FIG.
15-2). Add 1 gallon of hydraulic fluid
to reservoir. The reservoir should look
about half full (FIG. 15-2). Reinstall
filler cap (FIG. 15-2).
HALF
FULL
5. Stow the Lift and do the CHECKING
HYDRAULIC FLUID procedure in this
section of the manual.
CAUTION
Pump cover must be correctly secured to prevent it from becoming
a hazard. To secure pump cover,
the long side of the holder flats
must butt against pump cover as
shown in the illustration.
6. Bolt on the pump cover as shown in
FIG. 15-3. Torque the 5/16”-18 cover
bolts from 10 to 14 lbs.-ft.
RESERVOIR
DRAIN PLUG
POWER UNIT
FIG. 15-2
LONG SIDE OF
HOLDER FLATS
BUTT AGAINST
COVER
POWER
UNIT
(REF)
HEX NUTS
(2 PLACES)
FLAT
WASHERS
(2 PLACES)
PUMP
COVER CAP SCREWS
(2 PLACES)
BOLTING ON PUMP COVER
FIG. 15-3
15
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NOTE: MAXON recommends using
dielectric grease on all electrical
connections.
PERIODIC MAINTENANCE
REPLACING PLATFORM TORSION SPRING
NOTE: The following procedure shows how to replace torsion spring on RH side of platform. Use this procedure for replacing torsion spring on the LH side.
1. Manually fold flipover onto platform.
PLATFORM
(REFERENCE)
2. Raise platform to a convenient work height
to gain access and release tension on the
torsion spring.
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!
HINGE PIN
CAUTION
LOCK
NUT
BOLT
To prevent injury and equipment
damage, make sure there is no
tension on torsion spring before
removing hinge pin.
3. Unbolt hinge pin from hinge bracket
(FIG. 16-1). Remove bolt and lock nut.
Drive the hinge pin inboard toward the
shackle with a hammer and pin punch,
just enough to free the torsion spring
(FIG. 16-1). Remove spring from
shackle.
4. Install the torsion spring as shown in
FIG. 16-2. Make sure the long leg
of the spring is inserted in the bracket
located on shackle (FIG. 16-2). Make
sure the short end of the spring is visible and resting against the edge of the
hinge bracket (FIG. 16-2).
5. Drive the hinge pin into correct position (FIG. 16-2) through the hinge
bracket with a hammer and pin
punch. Line up the bolt hole in the
hinge pin with the hole in the hinge
bracket. Bolt the hinge pin to hinge
bracket with bolt and lock nut (FIG.
16-2).
HINGE
BRACKET
TORSION
SPRING
SHACKLE
FIG. 16-1
HINGE PIN
HINGE
BRACKET
PLATFORM
(REFERENCE)
BOLT &
LOCK NUT
BRACKET
LONG
LEG
SHORT
LEG
6. Operate the Liftgate to make
sure it operates correctly.
SHACKLE
FIG. 16-2
16
NOTE: Before doing the following procedure, make sure vehicle is parked
on level ground.
1. With the platform and flipover unfolded,
raise platform to bed level (FIG. 17-1).
Measure how much the outboard edge
of platform rises above bed level (FIG.
17-1). The outboard edge must be level
or a maximum of 1” above bed level (FIG.
17-1). If indication is correct, Liftgate is
installed correctly and no adjustment is
needed. If the outboard edge is below
bed level, do instructions 2, 3, and 6. If
outboard edge is higher than 1”, do instructions 4 through 6.
EXTENSION
PLATE (REF)
VEHICLE
OUTBOARD EDGE
FLOOR (REF)
0” (LEVEL) - 1” MAX.
LEVEL LINE
PLATFORM EDGE AT OR
ABOVE BED LEVEL
FIG. 17-1
EXTENSION
PLATE (REF)
2. Compare measurement “A” (FIG.
17-2) with the distances and shims
in TABLE 17-1. For example: If
measurement “A” (FIG. 17-2) is
1” below level and you want to raise
outboard edge of platform 1” above
level, use 1/8” shim to raise 2”
(TABLE 17-1).
VEHICLE
FLOOR (REF)
“A”
LEVEL LINE
PLATFORM EDGE BELOW BED LEVEL
FIG. 17-2
RAISE PLATFORM
REQUIRED SHIM
WELD SIZE
THICKNESS
“W”
1”
1/16”
1/16”
2”
1/8”
1/8”
3”
3/16”
3/16”
4”
1/4”
1/4”
EDGE (OUTBOARD)
THIS DISTANCE (“A”)
SHACKLE
(REF)
TABLE 17-1
3. Weld shims (parts bag item) on both
platform stops (FIG. 17-3) to raise
outboard edge of platform to correct
position.
NEW SHIM
(TABLE 17-1)
2 PLACES
“W”
(TABLE 17-1)
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 17-3
17
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PLATFORM ADJUSTMENT
PLATFORM ADJUSTMENT - Continued
EXTENSION
PLATE (REF)
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4. Compare measurement “B” (FIG.
18-1) with the distances and grinding
depths in TABLE 18-1. For example:
If measurement “B” (FIG. 18-1) is 3”
above bed level and you want to lower
the outboard edge of platform to 1”
above bed level, grind 1/8” from each
platform stop (TABLE 18-1).
LOWER PLATFORM
EDGE (OUTBOARD)
THIS DISTANCE (“B”)
GRIND METAL
FROM PLATFORM
STOP
1”
1/16”
2”
1/8”
3”
3/16”
4”
1/4”
“B”
VEHICLE
FLOOR (REF)
LEVEL LINE
PLATFORM EDGE ABOVE BED LEVEL
FIG. 18-1
TABLE 18-1
5. Grind metal from platform stops (FIG.
18-2) to lower outboard edge of platform to correct position.
SHACKLE
(REF)
GRIND THIS FACE
(SEE TABLE 18-1)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 18-2
6. Lower the platform, then raise it to bed
level. The outboard edge of platform should
be level or up to 1” maximum above bed
level (FIG. 18-3).
EXTENSION
PLATE (REF)
OUTBOARD EDGE
0” (LEVEL) - 1” MAX.
VEHICLE
FLOOR (REF)
LEVEL LINE
PLATFORM EDGE ABOVE BED LEVEL
FIG. 18-3
18
PARTS BREAKDOWN
MAIN ASSEMBLY (ALUMINUM PLATFORM)
4B
4A
4C
REFER TO HYDRAULIC
COMPONENTS & PUMP
COVER & MOUNTING
PLATE ASSEMBLY
2
4
REFER TO MAIN
FRAME ASSEMBLY
1
REFER TO PLATFORM &
FLIPOVER ASSEMBLY
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
226938
PAD EYE, 3/4” X 1-1/2”
2
1
227700
HOOK ASSEMBLY
3
1
226355
EXTENSION PLATE
4
1
265994-01
OPENER ASSEMBLY
4A
1
030805
COTTER PIN, 1/8” X 1” LG.
4B
1
280082-01
ROLLER
4C
1
905202-03
PIN
19
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3
MAIN FRAME ASSEMBLY: GPT-25 & GPT-3
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
10B
3
5
4
6
10
2
4
4
3
12
10A
6
6
9
6
2
9B
1
15
2
9C
6
9A
1
9C
9A
1
14A
2
9B
6
9
5
6
1
14
13
6
11
1
14A
6
1
7
10
1
6
1
11
8
(6 PLACES)
20
10A
10B
QTY.
PART NO.
DESCRIPTION
1
8
030034
BOLT, 3/8”-24 X 1” LG, GRADE 8
2
4
030035
BOLT, 3/8”-24 X 1-1/4” LG, GRADE 8
3
2
040103-5
SPLIT LOOM, 1/2” X 5” LG.
4
14
205780
PLASTIC TIE, 7” LG.
5
2
221416
ROLL PIN, 3/8” X 2” LG.
6
10
226941
LOCK NUT, 3/8”-24
7
1
050175
MAXON PLATE, 3-1/4” X 15” LG.
8
6
207644-01
RIVET, 3/16” X .40” GRIP
9
2
253085-01
ROLLER PIN, ASSEMBLY
9A
1
221416
ROLL PIN, 3/8” X 2” LG.
9B
1
261793-01
ROLLER
9C
1
264272
FLAT WASHER, 1-1/4” I.D. X 2-1/4” O.D.
10
2
261788-01
PARALLEL ARM
10A
2
905112-04
BEARING, SELF LUBE 1-3/8” X 1-5/8” LG.
10B
2
905114-04
BEARING, SELF LUBE 1-1/4” X 1-1/2” LG.
11
2
282390-01
PIN WELDMENT
12
1
262322-01
LIFT ARM WELDMENT, LH
13
1
262322-02
LIFT ARM WELDMENT, RH
14
1
262396
LIFT FRAME WELDMENT
14A
2
263473
ROLLER, KNUCKLE DOWN
15
1
282462-01
MAIN FRAME
21
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
MAIN FRAME ASSEMBLY: GPT-25 & GPT-3 - Continued
31
32
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
32
34
22
33
33
30
23
34
20
29
24
30
16
28
20
25
23
25
18A
28
16
23
22
21
18
27
29
17
19A
17
26
22
19
23
21
24
QTY.
PART NO.
DESCRIPTION
16
2
262440
PIN WELDMENT
17
2
265807-01
PIN WELDMENT, 1-3/8” X 13-1/8” LG.
18
1
265815-01
SHACKLE ASSEMBLY, LH
18A
2
905112-06
BEARING, SELF LUBE, 1-3/8” X 3/8” LG.
19
1
265815-02
SHACKLE ASSEMBLY, RH
19A
2
905112-06
BEARING, SELF LUBE, 1-3/8” X 3/8” LG.
20
2
282446-01
PIN WELDMENT
21
2
902011-4
LOCK WASHER, 3/8”
22
2
902013-20
FLAT WASHER, 1-1/4”
23
4
905114-04
BEARING, SELF LUBE 1-1/4” X 1-1/2” LG.
24
2
905115-02
BEARING, SELF LUBE 1-1/2” X 1-1/2” LG.
25
2
907026
ROLL PIN, 3/16” X 2-1/4” LG.
26
1
226363-01
TORSION SPRING, RH, 1/2” X 5-3/4”
27
1
226363-02
TORSION SPRING, LH, 1/2” X 5-3/4”
28
2
262437
BUSHING WELDMENT, HOSE CLAMP
29
2
229657
PIN WELDMENT
30
2
250310
PIN WELDMENT
31
2
281539-01
SADDLE, LOW PROFILE
32
4
901024-3
HEX BOLT, 1/2”-13 X 2-1/4” LG, GRADE 8
33
4
901023
FLANGE LOCK NUT, 1/2”-13
34
2
090300-12
FLAT, 3/4” X 1” X 6” LG.
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
MAIN FRAME ASSEMBLY: GPT-4 & GPT-5
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
18A
9
7
17
18
10
5
7
3
5
7
19
18A
14
16 15
10
17
4
17
2
17
2
3
21
2
2
1
2
12
13
16
17
15
4
17
16
1
9
20
17
9
14
17
18
17
17
11
2
6
18A
1
18A
9
8
(6 PLACES)
16
13
24
1
QTY.
PART NO.
DESCRIPTION
1
4
030034
BOLT, 3/8”-24 X 1” LG, GRADE 8
2
6
030035
BOLT, 3/8”-24 X 1-1/4” LG, GRADE 8
3
2
030038
BOLT, 3/8”-24 X 1-1/2” LG, GRADE 8
4
2
262435
PIN WELDMENT
5
2
040103-5
SPLIT LOOM, 1/2 X 5” LG.
6
1
050175
MAXON PLATE, 3-1/4” X 15” LG.
7
14
205780
PLASTIC TIE, 7” LG.
8
6
207644-01
RIVET, 3/16” X .40” GRIP
9
4
221416
ROLL PIN, 3/8” X 2” LG.
10
2
226358
PIN WELDMENT
11
1
226363-01
TORSION SPRING, RH, 1/2” X 5-3/4”
12
1
226363-02
TORSION SPRING, LH, 1/2” X 5-3/4”
13
2
226365
PIN WELDMENT
14
2
226368
PIN WELDMENT
15
2
226372
ROUND TUBE X 1/4” (2” X 5/16” W)
16
4
226375
ROLLER (1” WIDE, 3-1/8” O.D.)
17
10
226941
NYLON LOCK NUT, 3/8”-24
18
2
261785-01
PARALLEL ARM
18A
4
905112-07
BEARING, SELF LUBE 1-3/8” X 1-3/4” LG.
19
1
262332-01
LIFT ARM WELDMENT, RH
20
1
262332-02
LIFT ARM WELDMENT, LH
21
1
282472-01
MAIN FRAME
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
MAIN FRAME ASSEMBLY: GPT-4 & GPT-5 - Continued
34
35
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
35
30
31
28
36
33
36
28
32
23
22
25A 31
22
23
24
29
31
30
25
27
26A
31
24
26
26
29
32
QTY.
PART NO.
DESCRIPTION
22
2
262437
BUSHING WELDMENT, HOSE CLAMP
23
2
262462
PIN WELDMENT
24
2
265807-01
PIN WELDMENT, 1-3/8” X 13-1/8” LG.
25
1
265813-01
SHACKLE ASSEMBLY, LH
25A
2
905112-06
BEARING, SELF LUBE 1-3/8” X 3/8” LG.
26
1
265813-02
SHACKLE ASSEMBLY, RH
26A
2
905112-06
BEARING, SELF LUBE 1-3/8” X 3/8” LG.
27
1
262397
LIFT FRAME WELDMENT
28
2
266033-01
PIN WELDMENT (UNDERRIDE)
29
2
902011-4
LOCK WASHER, 3/8”
30
2
902013-21
FLAT WASHER, 1-3/8”
31
4
905112-07
BEARING, SELF LUBE 1-3/8” X 1-3/4” LG.
32
2
905113-03
BEARING, SELF LUBE 1-3/4” X 1-3/4” LG.
33
2
090300-12
FLAT, 3/4” X 1” X 6” LG.
34
2
281539-01
SADDLE, LOW PROFILE
35
4
901024-3
HEX BOLT, 1/2”-13 X 2-1/4” LG, GRADE 8
36
4
901023
FLANGE LOCK NUT, 1/2”-13
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
PLATFORM & FLIPOVER ASSEMBLY (ALUMINUM)
2
REFER TO PLATFORM
ASSEMBLY
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3
4
4
3
2
1
1A
ITEM
QTY.
1
1
281512-01
FLIPOVER WELDMENT, 30”
1
265819-01
HANDLE WELDMENT
2
2
263602
HINGE PIN WELDMENT
3
4
902020-1
FLAT WASHER, NYLON, 3/4” I.D., 1-5/16” O.D.
4
2
905033-2
ROLL PIN, 1/4” X 1-1/4” LG.
1A
PART NO.
DESCRIPTION
28
1
REFER TO PLATFORM
ASSEMBLY
2
3
3
2
1
REFER TO FLIPOVER WITH SINGLE
CART STOP OR FLIPOVER WITH DUAL
CART STOPS (SINGLE IS SHOWN)
ITEM
QTY.
PART NO.
DESCRIPTION
1
2
263602
HINGE PIN WELDMENT
2
4
902020-1
FLAT WASHER, NYLON, 3/4” I.D., 1-5/16” O.D.
3
2
905033-2
ROLL PIN, 1/4” X 1-1/4” LG.
29
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM & FLIPOVER ASSEMBLY WITH CART STOPS (ALUMINUM)
PLATFORM ASSEMBLY (ALUMINUM)
6
(2 PLACES)
5
9
4
1, 1A
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3
9
2
7
(2 PLACES)
8
3
4 5
2
8
7
(2 PLACES)
6
(2 PLACES)
ITEM
QTY.
1
1
281510-01
PLATFORM ASSEMBLY, 30”
1
281508-01
PLATFORM WELDMENT, 30”
2
2
263608
HINGE BRACKET, INSIDE
3
2
263609
HINGE BRACKET, OUTSIDE
4
2
902011-6
LOCK WASHER, 1/2”
5
2
900035-5
CAP SCREW, 1/2”-20 X 2” LG.
6
4
900035-10
CAP SCREW, 1/2”-13 X 3-1/2” LG.
7
4
902013-13
FLAT WASHER, 1/2”
8
4
040066
LOCK NUT, 1/2”-13
9
4
260917-04
SELF LUBE BEARING, 1/2” LG.
1A
PART NO.
DESCRIPTION
30
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
FLIPOVER WITH SINGLE CART STOP (ALUMINUM)
16 (4 PLACES)
7
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
13
2
16 (4 PLACES)
14
8
13
9
5
7
(4 PLACES)
6 3
14
7
1, 1A
11
8
10
4
1B
4
32
11
12
6
15
QTY.
PART NO.
DESCRIPTION
1
1
281533-01
FLIPOVER ASSEMBLY, SINGLE CART STOP 30”
1A
1
281513-01
FLIPOVER WELDMENT, SINGLE CART STOP
1B
1
265819-01
HANDLE WELDMENT
2
1
262508-02
SINGLE CART STOP RAMP WELDMENT
3
1
262481-02
OPENING AND CLOSING ARM, RH
4
2
262515
METAL EYELET END FITING
5
1
262513-01
PIN, 80-5/8” LG.
6
2
905122-02
SELF LUBE BEARING, 1/2” X 5/16” LG.
7
6
253542
SELF LUBE BEARING, 1/2” X 1/2” LG.
8
2
905135
CLEVIS PIN, 5/16” X 7/8” LG.
9
1
030406
ROLL PIN, 1/8” X 1” LG.
10
1
262536
TORSION SPRING
11
2
030805
COTTER PIN, 1/8” X 1” LG.
12
1
262514
GAS SPRING, 90 LBS.
13
2
281536-01
STOP BLOCK
14
2
902022
WASHER, 1/2”
15
1
900047
SHOULDER SCREW, 1/2” X 3/4” LG.
16
8
903705-02
RIVET, BLIND, 1/4” X 5/8” LG.
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
FLIPOVER WITH DUAL CART STOPS (ALUMINUM)
14
9
13
6
14
12
7
4
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
13
17 (4 PLACES)
16
5
12
4
2
11
17 (4 PLACES)
12
10
16
15
8
11
(4 PLACES)
3
14
10
11
12
1, 1A
1B
4
13
34
14
13
4
7
9
QTY.
PART NO.
DESCRIPTION
1
1
281532-01
FLIPOVER ASSEMBLY, DUAL CART STOP 30”
1A
1
281513-02
FLIPOVER WELDMENT, DUAL CART STOP
1B
1
265819-01
HANDLE WELDMENT
2
1
262509-06
DUAL CART STOP RAMP WELDMENT, RH
3
1
262481-02
OPENING AND CLOSING ARM, RH
4
4
262515
METAL EYELET END FITING
5
1
262509-05
DUAL CART STOP RAMP WELDMENT, LH
6
1
262481-01
OPENING AND CLOSING ARM, LH
7
2
262514
GAS SPRING, 90 LBS.
8
1
262513-01
PIN, 80-5/8” LG.
9
2
900047
SHOULDER SCREW, 1/2” X 3/4” LG.
10
2
902022
WASHER, 1/2”
11
6
253542
SELF LUBE BEARING, 1/2” X 1/2” LG.
12
4
905135
CLEVIS PIN, 5/16” X 7/8” LG.
13
4
030805
COTTER PIN, 1/8” X 1” LG.
14
4
905122-02
SELF LUBE BEARING, 1/2” X 5/16” LG.
15
1
030406
ROLL PIN, 1/8” X 1” LG.
16
2
281536-01
STOP BLOCK
17
8
903705-02
RIVET, BLIND, 1/4” X 5/8” LG.
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
DOCK BUMPER
MAIN FRAME
(REFERENCE)
EXTENSION PLATE
(REFERENCE)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
5 (2 places)
4
1
7
(2 places)
2
4
6
(2 places)
8
(2 places)
3
1
6
(2 places)
5
(2 places)
7
(2 places)
PART NO.
8
(2 places)
ITEM
QTY.
DESCRIPTION
1
2
226856
DOCK BUMPER ANGLE, 23-1/2” LG.
2
1
266019-01
BRACE ANGLE, LH
3
1
266019-02
BRACE ANGLE, RH
4
2
222988
BUMPER
5
4
900033-5
CAP SCREW, 1/2”-20 X 2” LG.
6
4
901011-10
NUT, 1/2”-20
7
4
902000-14
FLAT WASHER, 1/2”
8
4
902011-6
LOCK WASHER, 1/2”
36
12
(2 PLACES)
14
6
5
9
13
1
11
(2 PLACES)
REFER TO 12 VDC
POWER UNIT
8
(2 PLACES)
2
10
(2 PLACES)
6
7
(2 PLACES)
5
4
(2 PLACES)
3
(2 PLACES)
15
(5 PLACES)
ITEM
QTY.
PART NO.
DESCRIPTION
REF
1
267990-01
PUMP ASSY, HEAVY DUTY, POWER DOWN
1
1
267992-01
PLATE, PUMP MOUNT
2
1
281038-02
PUMP COVER
3
2
900009-8
CAP SCREW, 5/16”-18 X 2” LG, GRADE 8
4
2
281062-02
FLAT, HOLDER
5
2
901001
NYLON LOCK NUT, 5/16”-18
6
2
902013-10
FLAT WASHER, 5/16”
7
2
902011-4
LOCK WASHER, 3/8”
8
2
900064-03
BUTTON SCREW, 3/8”-16 X 3/4” LG.
9
4
903400-02
EXTERNAL TOOTH WASHER, 3/8”
10
2
901002
NYLON LOCK NUT, 3/8”-16
11
2
902001-2
FLAT WASHER, 3/8”
12
2
900014-5
HEX CAP SCREW, 3/8”-16 X 1-1/4” LG, GRADE 8
13
1
093203-10
NEOPRENE SEAL, 60” LG.
14
2
266428-01
GROMMET, 1” O.D. X 3/16” I.D.
15
5
208153
PLASTIC TIE, 4” LG. (CONTROL CABLE & PUMP WIRING)
37
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP ASSEMBLY
HYDRAULIC COMPONENTS - POWER DOWN
CAUTION
If the Liftgate is equipped with a bumper (ICC-type), replacement hydraulic
hoses must be routed with sufficient clearance from the bumper. The clearance
prevents the hoses from rubbing or getting caught on the bumper.
NOTE: Replacement face seal fittings
come with required O-rings.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
2
(6 PLACES)
15
NOTE: Hoses routed to each cylinder
are secured with a spacer & ties.
RH cylinder is shown below.
5
4
15
3
REFER TO 12 VDC
POWER UNIT
17
REFER TO PUMP
COVER &
MOUNTING PLATE
18
6
15
1
1
13
13
15
15
4
12
7
15
16
14
RH
CYLINDER
16
11
10
14
8
LH
CYLINDER
9
15
38
1
QTY.
2
PART NO.
DESCRIPTION
266037-01
CYLINDER, 2-3/4” DIA. x 10” STROKE (GPT-25 & GPT-3)
266038-01
CYLINDER, 3” DIA. x 10” STROKE (GPT-4)
266039-01
CYLINDER, 3-1/2” DIA. x 10” STROKE (GPT-5)
2
6
902028-12
FLAT WASHER, 1-1/4” O.D. X 3/4” I.D.
3
1
905162
ELBOW, BULKHEAD UNION, SAE #6, FACE SEAL O-RING
4
2
906707-01
ELBOW, SAE #6, FACE SEAL O-RING, M-M
5
1
268023-01
HOSE ASSY, 3/8” HP, SAE #6, 16” LG.
6
1
267988-01
HOSE ASSY, 3/8” HP, SAE #6, 11” LG.
7
1
267987-01
HOSE ASSY, 3/8” HP, SAE #6, 100” LG.
8
1
267986-01
HOSE ASSY, 3/8” HP, SAE #6-#8, 110” LG.
9
1
906810-01
BRANCH TEE, BULKHEAD, SAE #6, FACE SEAL O-RING
10
1
906802-01
BRANCH TEE, SWIVEL NUT, SAE #6, FACE SEAL O-RING
11
1
267994-01
HOSE ASSY, 3/8” HP, SAE #6-#8, 43” LG.
12
1
267995-01
HOSE ASSY, 3/8” HP, SAE #6, 34” LG.
13
2
906707-01
ELBOW, SAE #6, FACE SEAL O-RING, M-M
14
2
906704-01
ELBOW, SAE #8, FACE SEAL O-RING, M-M
15
13
906712-02
O-RING #6 (3/8” FACE SEAL TUBE-END)
16
2
906712-03
O-RING #8 (1/2” FACE SEAL TUBE-END)
17
2
906545-01
DUAL SWIVEL SPACER (HYDRAULIC HOSES)
18
4
905322-01
PLASTIC TIE, 8”
39
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
12 VDC POWER UNIT
CAUTION
Do not over-tighten the terminal nuts on starter solenoid. For the load
terminals, torque nuts to 40 lbs.-in. max. Torque the nuts on #10-32 control
terminals 15-20 lbs.-in.
CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
To prevent damage when installing 2-way valves, torque valve cartridge
nut to 30 lbs.-in. max.
8
6B
6
6A
MANIFOLD BLOCK
(REF. ONLY)
12
9
13
18
19
21
4
20
2,16
22
11
1
10
7B
5
7A
20
7
3,17
15
14
40
QTY.
REF
1
267991-01
12 VDC POWER UNIT
1
1
268011-01
MOTOR, 12 VDC, HEAVY DUTY
2
1
268021-01
PUMP ASSEMBLY
3
1
268013-01
FILTER, PUMP INLET
4
1
268020-01
RESERVOIR, SQUARE CUT, 1 GALLON
5
1
268030-01
SWITCH, SOLENOID (12 VDC)
6
1
290043
VALVE ASSEMBLY, 2-WAY (2-POLE)
6A
1
290044
VALVE CARTRIDGE (2-WAY VALVE)
6B
1
290045
COIL, DOUBLE SPADE (2-WAY VALVE)
1
290046
VALVE ASSEMBLY, 4-WAY (2-POLE)
7A
1
290047
VALVE CARTRIDGE (4-WAY VALVE)
7B
1
290048
COIL, DOUBLE SPADE (4-WAY VALVE)
8
1
268017-01
FLOW CONTROL VALVE, 4 GPM
9
1
906738-02
RELIEF VALVE, ADJUSTABLE, 3200 PSI
10
1
268174-01
RELIEF VALVE, ADJUSTABLE, 1100 PSI
11
1
290061
SEAL, SQUARE CUT (FOR RESERVOIR)
12
1
280806-01
FILLER, BREATHER CAP
13
1
908016-01
GROMMET (FILLER CAP)
14
1
908017-01
PLUG, DRAIN PORT
15
1
908018-01
RUBBER GROMMET, 5/16” I.D. (DRAIN PLUG)
16
1
260261
OIL SEAL, PUMP
17
1
290020
O-RING (NOT SHOWN)
18
1
261067
PLUG, O-RING, SAE #6
19
1
268027-01
WIRE ASSY, 18 GA (#10 RING & 5/16” RING TERMINALS)
20
2
268016-01
WIRE ASSY (#10 RING & QUICK DISCONN. TERMINALS)
21
1
280404
CABLE ASSEMBLY
22
1
268019-01
CLAMP, STARTER SOLENOID
7
PART NO.
DESCRIPTION
41
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
42
NOTE: Use switch to raise and lower Liftgate to make sure switch
operates as shown on the decal.
NOTE: MAXON recommends using dielectric grease on all electrical connections.
BLACK
WHITE
BLACK
WHITE
6
(FOR REFERENCESEE DECALS)
GREEN
3
GREEN
2
RED
1
FIG. 43-1
ITEM
QTY.
PART NO.
DESCRIPTION
1
1
264951-04
MOLD SWITCH ASSEMBLY
2
2
900057-5
SCREW, SELF-TAPPING #10-24 X 1” LG.
3
1
905206
SWITCH BOOT SEAL
4
1
264422
CABLE ASSEMBLY, 175 AMPS, 38’ LG.
5
1
264687
KIT, MEGAFUSE (175 AMP FUSE & HEATSHRINK TUBING)
6
1
268170-01
CABLE ASSEMBLY
TABLE 43-1
Short End to
Vehicle Battery
5
4
!
Long End to Pump
Motor Solenoid
WARNING
Do not attach cable to battery until
Liftgate repairs are completed.
FIG. 43-2
43
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL SWITCH AND POWER CABLE
DECALS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
DECAL “H” (2 PLACES)
P/N 268308-01
DECAL “F”
DECAL “D”
DECAL “E”
DECAL “B”
DECAL “I”
DECAL “C”
DECAL “G”
DECAL “A”
PAINT DECAL
P/N 267338-01
SERIAL PLATE
(REF)
PLATFORM WARNING DECAL
(2 PLACES)
P/N 281189-01
PLATFORM LOADING DECAL
(2 PLACES)
P/N 281326-01
FIG. 44-1
44
DECAL SHEET
FIG. 45-1
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 45-1
45
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
(See TABLE 45-1)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
THIS PAGE INTENTIONALLY LEFT BLANK
46
SYSTEM DIAGRAMS
MOTOR
“A” Valve
“E” Valve
STARTER
SOLENOID
POWER UNIT
FIG. 47-1
POWER UNIT MOTOR & SOLENOID OPERATION
LIFTGATE
FUNCTION
SOLENOID OPERATION
( MEANS ENERGIZED)
PORT
MOTOR
RAISE
A
LOWER
B
VALVE
“A”
VALVE
“E”
-
-
REFER TO VALVES SHOWN ON
HYDRAULIC SCHEMATIC
TABLE 47-1
47
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP & MOTOR SOLENOID OPERATION
SYSTEM DIAGRAMS - Continued
HYDRAULIC SCHEMATIC (POWER DOWN)
HYDRAULIC
CYLINDERS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PORT B - LOWER
(POWER DOWN)
PORT A - RAISE
VALVE A
4 GPM FLOW
CONTROL
VALVE
RELIEF VALVE 2
(SET AT 1100 PSI)
VALVE E
RELIEF VALVE 1
(SET AT 3200 PSI)
MOTOR
(REF)
PUMP
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 48-1
48
AUX. HAND
PUMP PORT
(PLUGGED)
RED
BLACK
(DOWN)
(UP)
WHITE
CONTROL SWITCH
WHITE
GREEN
BLACK
RED
SOLENOID,
VALVE A
SOLENOID,
VALVE E
GREEN
CABLE
ASSEMBLY
THERMAL
SWITCH
(IN MOTOR
CASING)
STARTER
SOLENOID
WHITE
GREEN
CABLE WITH
175 AMP FUSE
BATTERY
FIG. 49-1
49
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SCHEMATIC (POWER DOWN)
TROUBLESHOOTING
PLATFORM WILL NOT RAISE & MOTOR WILL NOT RUN
1. Connect voltmeter between motor solenoid terminal “B” and ground wires connection
on pump (FIG. 50-1). Verify that full battery voltage is at “B”. Recharge the battery if
voltmeter indicates less than 12.6 volts dc.
2. Touch a jumper wire to terminals “B” & “D” (FIG. 50-1). If motor runs, check control
switch, the switch connections, and white wire. Check and correct wiring connections
or replace the control switch.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3. Touch heavy jumper cables to terminals “A” & “B” (FIG. 50-1).
a. If motor runs, replace the motor solenoid.
b. If motor does not run, repair or replace the pump motor.
GROUND (-) WIRE
CONNECTION
(voltmeter lead)
Terminal “a”
LOAD
motor
Solenoid
Terminal “C”
Ground (-)
Terminal “d”
SWITCHED
BATTERY
(+)
Terminal “B”
BATTERY (+)
FIG. 50-1
50
1. Do the CHECKING HYDRAULIC FLUID
procedure in this manual. If necessary,
add hydraulic fluid.
2. Check for structural damage and replace
worn parts.
CAUTION
Keep dirt, water and other contaminants from
entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain
plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.
NOTE: In most cases, you can avoid having to
manually bleed hydraulic system by
correctly positioning Liftgate platform
before disconnecting any lifting cylinder high pressure hydraulic lines.
3. Check pump oil filter in the reservoir (FIG.
51-1). Clean or replace filter, if necessary.
ADJUSTMENT
COVER
RESERVOIR
Relief
Valve
4. Check for dirty raising relief valve (FIG.
51-1). Clean or replace relief valve if
necessary.
CHECKING THE RAISING
RELIEF VALVE
FIG. 51-1
51
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PLATFORM WILL NOT RAISE, BUT MOTOR RUNS
PLATFORM RAISES BUT LEAKS DOWN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Check if the “A” (lowering) solenoid valve is constantly energized.
Connect voltmeter negative (-)
lead to ground (-) wires connection on pump and positive (+) lead
to (+) terminal on the “A” (lowering) solenoid valve (FIG. 52-1). If
voltmeter reads battery voltage,
check for faulty wiring or toggle
switch.
GROUND (-)
WIRE CONNECTION
BLACK WIRE
(+) CONNECTION
motor
“A”
(Lowering)
Solenoid
valve
Terminal “d”
SWITCHED
BATTERY (+)
CAUTION
FIG. 52-1
Keep dirt, water and other contaminants from
entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain
plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.
NOTE: In most cases, you can avoid having
to manually bleed hydraulic system by
correctly positioning Liftgate platform
before disconnecting any lifting cylinder high pressure hydraulic lines.
2. Make sure platform is on the ground. Remove
lowering solenoid valve (FIG. 52-2). Push on the
plunger in the valve by inserting small screwdriver in the open end (FIG. 52-3). If the plunger
does not move with a smooth, spring-loaded
action (approximately 1/8”), replace the valve
cartridge. Reinstall lowering solenoid valve.
Torque valve cartridge to 30 lbs.-ft. and hex
nut to 30 lbs.-in.
VALVE
CARTRIDGE
COIL
NUT
REMOVING SOLENOID VALVE
FIG. 52-2
VALVE CARTRIDGE
1/8”
CHECKING SOLENOID VALVE
FIG. 52-3
52
raise Port
lower Port
FIG. 53-1
53
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
3. Check the hydraulic cylinder. With the platform at vehicle floor level, remove the hydraulic line from the LOWER port on the cylinder (FIG. 53-1). Hold the control switch
in the UP position for two seconds while you
watch for hydraulic fluid at the LOWER port.
A few drops of hydraulic fluid escaping the
port is normal. However, if fluid streams out,
piston seals are worn. Replace seals.
PLATFORM RAISES PARTIALLY AND STOPS
1. Lower the opened platform to the ground. Do the
CHECKING HYDRAULIC FLUID procedure in
this manual. If necessary, add hydraulic fluid.
2. Use voltmeter to verify the battery voltage is 12.6
volts or more under load from pump motor.
3. Check for structural damage and poor lubrication.
Replace worn parts.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
Keep dirt, water and other contaminants from
entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain
plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.
NOTE: In most cases, you can avoid having to
manually bleed hydraulic system by correctly positioning Liftgate platform before
disconnecting any lifting cylinder high
pressure hydraulic lines.
4. Check for dirty raising relief valve (FIG.
54-1). Clean or replace relief valve, if
necessary.
5. Check the hydraulic cylinder. With the platform at vehicle floor level, remove the hydraulic line from the LOWER port on the cylinder (FIG. 54-2). Hold the control switch
in the UP position for two seconds while you
watch for hydraulic fluid at the LOWER port.
A few drops of hydraulic fluid escaping the
port is normal. However, if fluid streams out,
piston seals are worn. Replace seals.
ADJUSTMENT
COVER
Relief
Valve
FIG. 54-1
raise Port
lower Port
6. Check pump oil filter in the reservoir
(FIG. 54-1). Clean or replace filter, if
necessary.
FIG. 54-2
54
RESERVOIR
LIFTGATE WILL NOT LIFT RATED CAPACITY
2. Check for structural damage or lack of lubrication. Replace worn parts.
CAUTION
Keep dirt, water and other contaminants from
entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain
plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.
NOTE: In most cases, you can avoid having to
manually bleed hydraulic system by
correctly positioning Liftgate platform
before disconnecting any lifting cylinder
high pressure hydraulic lines.
ADJUSTMENT
COVER
Pressure
Gauge
Relief Valve
Adjust Screw
3. Check the 3200 PSI relief valve as follows. With
platform on the ground, remove plug from hand
pump port (FIG. 55-1). Install 0-4000 PSI pressure gauge in the hand pump port (FIG. 55-1).
Remove cover for access to relief valve. Hold the
control switch in the UP position. Adjust the relief
valve until the gauge reads 3200 PSI (FIG. 551). Remove guage and reinstall plug in the port.
HAND PUMP
Then, reinstall relief valve cover.
PORT
4. Check if pump relief valve is dirty. Clean or
replace relief valve, if necessary.
5. Check the hydraulic cylinder. With the platform
at vehicle floor level, remove the hydraulic line
from the LOWER port on the cylinder (FIG. 55-2).
Hold the control switch in the UP position for two
seconds while you watch for hydraulic fluid at the
LOWER port. A few drops of hydraulic fluid escaping the port is normal. However, if fluid streams
out, piston seals are worn. Replace seals.
6. If pump cannot produce 3200 PSI or
lift the load capacity with a minimum of
12.6 volts available, the pump is worn
and needs to be replaced.
FIG. 55-1
raise Port
lower Port
FIG. 55-2
55
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Use voltmeter to verify the battery voltage is 12.6
volts or more under load from pump motor.
PLATFORM RAISES SLOWLY
1. Connect voltmeter between motor solenoid terminal
“B” and ground (-) wires connection on pump (FIG.
56-1). Verify that full battery voltage is at “B”.
Recharge the battery if voltmeter indicates less than
12.6 volts dc.
GROUND (-) WIRES
CONNECTION
CAUTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Keep dirt, water and other contaminants from
entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain
plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.
NOTE: In most cases, you can avoid having to
manually bleed hydraulic system by
correctly positioning Liftgate platform before
disconnecting any lifting cylinder high pressure hydraulic lines.
2. Check the hydraulic cylinder. With the platform at vehicle floor level, remove the hydraulic line from the
LOWER port on the cylinder (FIG. 56-2). Hold the
control switch in the UP position for two seconds while
you watch for hydraulic fluid at the LOWER port. A few
drops of hydraulic fluid escaping the port is normal.
However, if fluid streams out, piston seals are worn.
Replace seals.
Terminal “B”
BATTERY (+)
FIG. 56-1
raise Port
lower Port
FIG. 56-2
FLOW CONTROL
VALVE
CAUTION
To prevent damage to flow control valve, do not
disassemble the valve.
3. Check the flow control valve as follows. Remove lowering solenoid valve and flow control
valve (FIG. 56-3). Ensure the flow control
valve operates with a smooth spring-loaded
action. Check for debris inside the valve. Clean
or replace the flow control valve, if necessary.
Reinstall flow control valve (if good) or a replacement. Then, reinstall the lowering solenoid valve. Reinstall lowering solenoid valve.
Torque valve cartridge to 30 lbs.-ft. and hex
nut to 30 lbs.-in.
56
coil
valve
cartridge
FIG. 56-3
nut
5. Check for leaking hoses and fittings. Tighten or replace as required.
6. Check for structural damage and poor lubrication.
Replace worn parts.
7. Check pump oil filter in the reservoir (FIG. 57-1).
Clean or replace filter, if necessary.
8. Check the 3200 PSI relief valve as follows. With
platform on the ground, remove plug from hand
pump port (FIG. 57-1). Install 0-4000 PSI pressure gauge in the hand pump port (FIG. 57-1).
Remove cover for access to relief valve. Hold the
control switch in the UP position. Adjust the relief
valve until the gauge reads 3200 PSI (FIG. 571). Remove guage and reinstall plug in the port.
Then, reinstall relief valve cover.
ADJUSTMENT
COVER
3200 PSI
Relief
Valve
Pressure
Adjust
Screw
Gauge
HAND PUMP
PORT
FIG. 57-1
57
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
4. Verify the pump motor is grounded to vehicle frame.
PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY OR TOO QUICKLY
1. Connect voltmeter (+) lead to motor solenoid terminal “B” and the (-) lead to the
ground wires connection on pump (FIG.
58-1). Verify that full battery voltage is at
“B”. Recharge the battery if voltmeter indicates less than 12.6 volts dc.
GROUND (-)
WIRE CONNECTION
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
“A”
(Lowering)
Solenoid
valve
2. Check for structural damage or poor
lubrication. Replace worn parts.
motor
Terminal “d”
SWITCHED
BATTERY (+)
Terminal “B”
BATTERY (+)
3. Check if the “D” terminal and “A” (lowering) solenoid valve are getting battery voltage (FIG. 58-1). Connect voltmeter negative
(-) lead to ground (-) wires connection on
pump and positive (+) lead to the “D” terminal (FIG. 58-1). Hold control switch in the
DOWN position. Then, connect voltmeter (+)
lead to (+) terminal on the “A” (lowering) solenoid valve (FIG. 58-1). If voltmeter shows
a much lower reading than +12.6 volts dc or
a reading of 0 volts, check for faulty control
switch and wiring, battery cable, ground wire
connections in pump assembly, and pump
motor.
58
FIG. 58-1
Keep dirt, water and other contaminants from
entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain
plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.
NOTE: In most cases, you can avoid having to
manually bleed hydraulic system by
correctly positioning Liftgate platform before
disconnecting any lifting cylinder high pressure hydraulic lines.
4. Make sure platform is on the ground. Check the
flow control valve as follows. Remove lowering
solenoid valve and flow control valve (FIG. 591). Ensure the flow control valve operates with
a smooth spring-loaded action. Check for debris
inside the valve. Clean or replace the flow control
valve, if necessary. Reinstall flow control valve (if
good) or a replacement.
FLOW CONTROL
VALVE
coil
valve
cartridge
nut
FIG. 59-1
CAUTION
To prevent damage to flow control valve, do not
disassemble the valve.
5. Check the lowering solenoid valve as follows.
Check if filtering screen is plugged. Clean
carefully if required. Push on the plunger in
the valve by inserting small screwdriver in the
open end (FIG. 59-1). If the plunger does not
move with a smooth, spring-loaded action (approximately 1/8”), replace the valve cartridge.
Reinstall lowering solenoid valve (if good) or
a replacement. Torque valve cartridge to 30
lbs.-ft. and hex nut to 30 lbs.-in.
59
VALVE CARTRIDGE
1/8”
CHECKING SOLENOID VALVE
FIG. 59-2
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
PLATFORM WILL NOT TILT DOWN TO THE GROUND
NOTE: If the Liftgate is not damaged, the 1100 psi (lowering) pressure relief valve in
the pump may need to be adjusted as follows.
1. Unhook safety chain. Lower the platform until
shackles touch the ground (FIG. 60-1).
SAFETY
CHAIN
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
SHACKLE
PLATFORM LOWERED WITH SHACKLES
TOUCHING THE GROUND
FIG. 60-1
LONG SIDE OF
HOLDER FLATS
BUTT AGAINST
COVER
POWER
UNIT
(REF)
2. Unbolt and remove pump cover
(FIG. 60-2).
HEX NUTS
(2 PLACES)
FLAT
WASHERS PUMP
(2 PLACES) COVER
CAP SCREWS
(2 PLACES)
UNBOLTING PUMP COVER
FIG. 60-2
60
1100 psi
Relief Valve
Adjust SCREW
CAUTION
ADJUSTMENT
COVER
ADJUSTING RELIEF VALVE
FIG. 61-1
Pump cover must be correctly secured to prevent it from becoming
a hazard. To secure pump cover,
the long side of the holder flats
must butt against pump cover as
shown in the illustration.
4. Bolt on the pump cover as shown in
FIG. 61-2. Torque the 5/16”-18 cover
bolts from 10 to 14 lbs.-ft.
LONG SIDE OF
HOLDER FLATS
BUTT AGAINST
COVER
POWER
UNIT
(REF)
NUTS
(2 PLACES)
FLAT
PUMP
WASHERS
COVER
(2 PLACES)
CAP SCREWS
(2 PLACES)
BOLTING ON PUMP COVER
FIG. 61-2
61
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
Pressure Gauge
(HAND PUMP PORT)
3. Adjust the 1100 PSI relief valve as follows. With platform on the ground, remove plug from hand pump port (FIG.
61-1). Install 3000 PSI pressure gauge
in the hand pump port (FIG. 61-1).
Remove cover for access to relief valve.
Hold the control switch in the DOWN position. Adjust the relief valve until the gauge
reads 1100 PSI (FIG. 61-1). Remove
guage and reinstall plug in the port. Then,
reinstall relief valve cover.
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