Maxon GPT SERIES (2006 Release) Installation guide

Maxon GPT SERIES (2006 Release) Installation guide
M-06-08
REV. B
APRIL 2008
INSTALLATION MANUAL
GPT-25, GPT-3, GPT-4 & GPT-5
© MAXON Lift Corp. 2008
TABLE OF CONTENTS
WARNINGS ........................................................................................................................... 3
STANDARD LIFTGATE COMPONENTS .............................................................................. 4
GPT-SERIES INSTALLATION PARTS BAGS ....................................................................... 5
VEHICLE REQUIREMENTS ................................................................................................. 6
STEP 1 - WELD EXTENSION PLATE TO VEHICLE ............................................................ 9
STEP 2 - WELD LIFTGATE TO VEHICLE ...........................................................................11
STEP 3 - RUN POWER CABLE .......................................................................................... 14
STEP 4 - CONNECT POWER CABLE ................................................................................ 15
STEP 5 - INSTALL CONTROL SWITCH ............................................................................. 16
STEP 6 - CONNECT POWER CABLE TO BATTERY ......................................................... 19
STEP 7 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS ........................................... 20
STEP 8 - WELD PLATFORM OPENER TO LIFTGATE ...................................................... 21
STEP 9 - FINISH WELDING LIFTGATE TO VEHICLE ....................................................... 24
STEP 10 - INSTALL & ADJUST SADDLES ......................................................................... 25
STEP 11 - WELD ON SADDLE SUPPORTS ...................................................................... 26
STEP 12 - ADJUST PLATFORM (IF REQUIRED) .............................................................. 28
STEP 13 - CHECK HYDRAULIC FLUID ............................................................................. 30
STEP 14 - WELD HOOK AND EYE TO LIFTGATE............................................................. 31
STEP 15 - WELD DOCK BUMPERS TO LIFTGATE........................................................... 32
STEP 16 - BOLT RUBBER BUMPERS TO LIFTGATE ....................................................... 33
STEP 17 - VEHICLE TAILLIGHT POSITIONING ................................................................ 34
ATTACH DECALS ............................................................................................................... 35
TOUCHUP PAINT ............................................................................................................... 37
HYDRAULIC SYSTEM DIAGRAM ..................................................................................... 38
ELECTRICAL SYSTEM DIAGRAM .................................................................................... 39
OPTIONS ............................................................................................................................ 40
OPTIONAL LIFTGATE COMPONENTS .............................................................................. 40
RECOMMENDED LIFTGATE POWER CONFIGURATION ................................................ 41
Comply with the following WARNINGS while installing Liftgates. See Operation Manual
for operating safety requirements.
!
WARNING
• Read and understand the instructions in this Installation Manual before installing 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.
• 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.
• Make sure vehicle battery power is disconnected while installing Liftgate. Connect vehicle
battery power to the Liftgate only when installation is complete or as required in the installation
instructions.
• 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.
• If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the control switch to stop the Liftgate.
• 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 and lowered. Listen for
scraping, grating and binding noises and correct the problem before continuing to operate Liftgate.
• If it is necessary to stand on the platform while operating 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.
• Never perform unauthorized modifications on the Liftgate. Modifications may result in early failure
of the Liftgate and may create hazards for Liftgate operators and maintainers.
• 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.
3
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WARNINGS
STANDARD LIFTGATE COMPONENTS
CAUTION
Prevent injuries and equipment damage. Before cutting the shipping straps from
the Liftgate, put Liftgate on level ground that will support at least 1500 pounds. Be
careful lifting and moving components (such as extension plate) after shipping
straps are removed.
NOTE: Make sure you have all components and parts before you start installing Liftgate.
Compare parts in the part box and each kit box with packing list enclosed in each
box. If parts and components are missing or incorrect, call:
Maxon Customer Service
Call (800) 227-4116 or
Send e-mail to [email protected]
OPENER ASSEMBLY
PUMP BOX
(SEE TABLE 5-1)
PARTS BAGS
(SEE TABLE 5-1)
BOXED COMPONENTS
(INCLUDES STEEL DOCK
BUMPER PARTS)
EXTENSION
PLATE
MAIN
ASSEMBLY
TYPICAL LIFTGATE PACKAGED FOR SHIPMENT
FIG. 4-1
4
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!
GPT-SERIES INSTALLATION PARTS BAGS
QTY.
PART NUMBER
1 PUMP ASSY, POWER DOWN
1
267490-01
2 HEAT SHRINK TUBING, 3/4” X 1-1/2" LG.
1
253316-04
3 MOLDED SWITCH ASSEMBLY
1
264951-01
4 SHIM, 3-1/2” X 1-3/4” X 1/4”
2
264731
5 SHIM, 2-1/5” X 1” X 1/16”
2
264732
6 FLAT, 2-1/2" 1” X 1/8”
2
201999
7 FLAT, 5" X 4” X 3/8”
2
229295
8 COPPER LUG (2GA)
1
906497-02
9 SELF-TAPPING SCREW, 10-24 X 1” LG.
4
900057-5
10 CLAMP, #10 RUBBER LOOM
2
801681
11 FRAME CLIP 1/2” X 1-3/8”
7
050079
266004-01 (GPT-25)
DECAL & MANUAL KIT
1
266005-01 (GPT-3)
266006-01 (GPT-4)
266007-01 (GPT-5)
A. OPERATION MANUAL
1
M-06-09
1
M-06-08
C. MAINTENANCE MANUAL
1
M-06-10
D. WARRANTY CARD
1
M-78-78
E. CUSTOMER SURVEY CARD
1
M-94-04
F. DECALS
-
REFER TO DECAL PAGES IN
THIS MANUAL
13 EYE, DROP FORGED PAD, 3/4” X 1-1/2”
1
226938
14 HOOK ASSEMBLY
1
227700
15 FUSED POWER CABLE, 200 AMP, 38’ LG.
1
264422
16 RUBBER DOCK BUMPER KIT
1
203410
17 SADDLE, LOW PROFILE
2
281539-01
18 HEX BOLT, FRAME, 1/2” -13 X 2-1/4” LG., GRADE 8
4
901024-3
19 LOCK NUT, FLANGE, 1/2”- 13
4
901023
20 FLAT, 3/4” X 1” X 6” (SADDLE SUPPORT)
2
090300-12
12 B. INSTALLATION MANUAL
TABLE 5-1
5
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NOMENCLATURE OR DESCRIPTION
NOTE: BODY maximum and minimum operating bed height:
For GPT-25, GPT-3, GPT-4, & GPT-5 with standard platform:
Maximum height is 55” (Unloaded). Minimum height is 46” (Loaded).
On vehicle bodies equipped with swing open doors, the extension plate
and vehicle body must be modified to install this Liftgate.
NOTE: Make sure vehicle is parked on level ground while preparing vehicle and
installing Liftgate.
NOTE: Dimensions are provided as reference for fitting Liftgate to vehicle body.
1. Check for correct clearances (FIGS. 6-1 and 6-2) on vehicle to prevent interference between vehicle and Liftgate.
32”
30-5/16”
14”
22-3/8”
23-7/8”
55” MAX. BED HEIGHT
46” MIN. BED HEIGHT
12-3/8” - 21-3/8”
GPT-25 & GPT-3 CLEARANCES
FIG. 6-1
33-5/16”
32-5/16”
14”
24-1/2”
22-3/8”
55” MAX. BED HEIGHT
46” MIN. BED HEIGHT
13”- 22”
GPT-4 & GPT-5 CLEARANCES
FIG. 6-2
6
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VEHICLE REQUIREMENTS
VEHICLE REQUIREMENTS - Continued
• To prevent aluminum platform from being damaged, make sure vehicle frame
is cut correctly and rear sills are modified if over 4” in height. If the cutouts are
incorrect, platform may hit vehicle frame or underbody when stowing the Liftgate. If the rear sill is over 4” in height, bottom of the platform may hit the sill.
• Installer is responsible for ensuring that vehicle body and frame modifications
do not adversely affect the integrity of the body and frame.
NOTE: The dimensions, shown in the illustration below, are maximums except as
indicated.
NOTE: The platform cutout area shown below applies to trucks and trailers.
NOTE: See the next page for interference areas that can result from rear sills over 4”
in height.
2. Fit the Liftgate to vehicle body by cutting
vehicle frame as shown in FIG. 7-1.
TRUCK BODY
BODY FLOOR
REAR SILL
6”
4” (SEE CAUTION)
BODY CROSSMEMBERS
10-1/4”
LONG SILL
WOODEN SPACER
PLATFORM CLEARANCE CUTOUT AREA
(WITHIN DASHED LINES)
2-3/4”
23” (MIN.)
VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE
(GPT-25, GPT-3, GPT-4 & GPT-5)
(TRUCK FRAME IS SHOWN)
FIG. 7-1
7
TRUCK
FRAME
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CAUTION
VEHICLE REQUIREMENTS - Continued
6-3/4”
(2 PLACES)
CENTER
LINE
40-1/2”
40-1/2”
REAR SILL
4”
BODY
FRAME
VEHICLE
FRAME
2-1/2”
(4 PLACES)
AREA TO
MODIFY
(4 PLACES)
FRONT VIEW - REAR SILL MORE THAN 4” IN HEIGHT
(LIFTGATE & EXTENSION PLATE NOT SHOWN)
FIG. 8-1
REAR
SILL
MARK
4”
MEASURE “H”
NOTE: L= 3.75 x H
“L”
SIDE VIEW - REAR SILL MORE THAN 4” IN HEIGHT
FIG. 8-2
8
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3. If the rear sill is over 4” in height, measure and mark the areas to be modified on the sill
as shown in FIG. 8-1. A side view of the interference areas is shown in FIG. 8-2.
1. Center the extension plate on vehicle body. Before welding extension plate to vehicle
body, make sure top surface of extension plate is flush with floor of vehicle body. Weld
the extension plate to vehicle body sill as shown in FIG. 9-1 and FIG. 9-2.
4” LG. LOCATED ABOVE EACH OF
3 RECTANGULAR TUBES (TUBES
SHOWN SHADED IN FIG. 3)
1/4”
SILL
(PART OF VEHICLE BODY)
4” LG.
1/4”
2” LG. CENTERED 1/4”
BETWEEN
4” WELDS SHOWN
4” LG.
1/4”
EXTENSION PLATE WELDS - VIEWED FROM ABOVE
FIG. 9-1
1/4”
2 PLACES, MAKE 1”
GAP WHERE SHOWN
2” LG, 12 PLACES
EQUAL SPACING 1/4”
(TYP.)
1” GAP
SILL
(PART OF
VEHICLE BODY)
1/4”
5 PLACES, MAKE 1”
GAP WHERE SHOWN
1” GAP
1” GAP
EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH
FIG. 9-2
9
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STEP 1 - WELD EXTENSION PLATE TO VEHICLE
2. Place 2 temporary support straps (5” x 4” x 3/8”
flats from parts bag) on the extension plate as
shown in FIG. 10-1A. Also, put 2 temporary
spacers (2” x 1” x 1/8” flats from parts bag) between platform and extension plate as shown in
FIG. 10-1B. (Spacers keep 1/8” between platform and extension plate while welding Liftgate
to vehicle frame.) Weld the straps and spacers
to extension plate (FIG. 10-1B).
1/4”
4”
1” (APPROX. - TYP.
STRAP OVERHANG)
1/4” LG. TACK, SUPPORT
STRAP TO EXTENSION
PLATE (1 WELD ONLY),
SPACER & SUPPORT
STRAP TO EXTENSION
PLATE (1 WELD ONLY)
1/2” (APPROX.TYP. SPACER
OVERHANG)
1/8” SPACER
17-1/2”
STRAP & SPACER WELDS
(TYPICAL - BOTH ENDS OF
EXTENSION PLATE)
FIG. 10-1B
EXTENSION
PLATE
SUPPORT
STRAPS
FIG. 10-1A
10
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STEP 1 - WELD EXTENSION PLATE TO VEHICLE Continued
1. Remove split looms from mounting
plates (FIGS. 11-1A & 11-1B).
(Split looms will be reinstalled later
after final welding.)
MOUNTING
PLATE
SPLIT LOOMS
MOUNTING PLATES
FIG. 11-1B
RH SIDE VIEW OF LIFTGATE
FIG. 11-1A
2. Unfold the platform and flipover (FIG. 11-2).
PLATFORM
(UNFOLDED)
LOCKING ANGLES
(REF)
FLIPOVER
(UNFOLDED)
PLATFORM & FLIPOVER UNFOLDED
FIG. 11-2
11
MOUNTING
PLATES
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STEP 2 - WELD LIFTGATE TO VEHICLE
STEP 2 - WELD LIFTGATE TO VEHICLE - Continued
CAUTION
To prevent damage to aluminum flipover, NEVER hoist the Liftgate by the
flipover as shown in the NO illustration. Hoist the Liftgate by the platform only
as shown in the YES illustration.
3. Make sure hoist is
not being set up the
VEHICLE FLOOR
incorrect way (FIG.
(HORIZONTAL)
12-2). Place
HOIST CHAIN
FLIPOVER
MOUNTING
a “C”-clamp on
PLATE
each side of platform as shown
in FIG. 12-1.
(Clamps prevent
C-CLAMP
hoist chain from slipping
PLATFORM
(2 PLACES)
off platform.) Place chain
PINS
all around platform (FIG.
(LINED UP12-1).
VERTICAL)
MAIN FRAME
FLOOR JACK
(CENTERED ON
MAIN FRAME TUBE)
CCORRECT WAY TO HOIST LIFTGATE
FIG. 12-1
4. Hoist the Liftgate.
Then place floor jack
under main frame
(FIG. 12-1). Jack
the Liftgate into position. Make sure vehicle floor is horizontal and pins are lined
up (FIG. 12-1).
FLIPOVER
HOIST CHAIN
INCORRECT WAY TO HOIST LIFTGATE
FIG. 12-2
12
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!
STEP 2 - WELD LIFTGATE TO VEHICLE - Continued
WARNING
Liftgate is shipped from factory with mounting plates that are only tack welded to main frame. Weld as shown in illustration before operating Liftgate.
CAUTION
Prevent damaged hydraulic hoses. If welding next to hydraulic hoses, use a
protective cover such as a welding blanket to cover the hoses.
5. Check if both mounting
VEHICLE FRAME CUTOUT
(TYPICAL TRUCK FRAME SHOWN)
plates line up with the vehicle frame. If the mounting
plates do not line up,
remove the tack welds
from one mounting plate ORIGINAL TACK WELDS
(REMOVE TO REPOSITION
(FIG. 13-1). Make sure
MOUNTING PLATE)
Liftgate stays centered
TACK
on vehicle. Reposi(TYPICAL - RH & LH
5/16”
tion the mounting plate
MOUNTING PLATES)
MOUNTING
against vehicle frame.
MAIN FRAME
PLATE
Tack weld as shown in
(CUT-AWAY VIEW)
FIG. 13-1. Repeat for
second mounting plate
REPOSITIONING MOUNTING PLATE
(reposition and tack weld).
(RH SIDE SHOWN)
FIG. 13-1
NOTE: Weld both mounting plates to
vehicle frame before welding
mounting plates to main frame.
VEHICLE FRAME CUTOUT
(TYPICAL TRUCK FRAME SHOWN)
6. Clamp both mounting
plates to vehicle frame.
Before welding, make
sure cutout in vehicle
MOUNTING
2” LG. 4 PLACES
PLATE
frame does not block 2
(TYPICAL - RH & LH 5/16”
slotted holes in mounting MOUNTING PLATES)
plate (FIG. 13-2). Weld
the mounting plates to
vehicle frame as shown
MAIN FRAME
in FIG. 13-2. Next, weld
(CUT-AWAY VIEW)
5/16”
both mounting plates to
main frame (FIG. 13-2).
WELD TO VEHICLE FRAME AND MAIN FRAME
Remove clamps.
(RH SIDE SHOWN)
FIG. 13-2
13
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!
STEP 3 - RUN POWER CABLE
CAUTION
Never route an energized wire. Make sure the vehicle battery is disconnected.
Always route electrical wires clear of moving parts, brake lines, sharp edges and
exhaust systems. Avoid making sharp bends in wiring. Attach securely. If drilling
is necessary, first check behind the drilling surface so you do not damage any fuel
lines, vent lines, brake lines or wires.
Clip fused power cable to vehicle chassis, with fuse nearest the vehicle battery, as shown in
FIG. 14-1. Keep enough cable near the battery to reach the positive terminal without putting tension on cable (after connection). Run bare wire end of cable to Liftgate.
VEHICLE FRAME
(TRUCK FRAME SHOWN)
BARE WIRE END
(TO PUMP BOX)
18” - 24”
SPACING
CABLE
CLIPS
FUSE
FRONT OF VEHICLE
REAR OF VEHICLE
SHORTEST
CABLE END
TERMINAL LUG
(VEHICLE BATTERY
END)
FIG. 14-1
14
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!
1. On the bare wire end of fused power cable, keep enough length to attach copper terminal lug and reach motor solenoid without putting tension on cable (after connection)
(FIG. 15-1A). Measure (if needed), and then cut excess cable from bare wire end of
cable. Put heatshrink tubing (parts bag item) (FIG. 15-1B) on the end of the cable
(leave room for terminal lug). Crimp copper terminal lug (parts bag item) on the fused
power cable and shrink the heatshrink tubing (FIG. 15-1C).
COPPER TERMINAL LUG
FUSED
POWER CABLE
HEATSHRINK TUBING
FIG. 15-1B
FIG. 15-1C
TYPICAL FUSED POWER CABLE ROUTING
(POWER DOWN PUMP BOX SHOWN)
FIG. 15-1A
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.
FUSED
POWER CABLE
NOTE: MAXON recommends using
dielectric grease on all electrical connections.
STARTER
SOLENOID
NOTE: Do not remove flat washer from
the battery power terminal.
2. Remove hex nut and lock washer
from battery power terminal on
the starter solenoid. Connect the
fused power cable to the starter
solenoid as shown in FIG. 152. Reinstall and tighten lock
washer and hex nut.
LOCK
WASHER
HEX NUT
BATTERY
POWER TERMINAL
TYPICAL FUSED POWER CABLE ELECTRICAL
CONNECTION (POWER DOWN PUMP BOX SHOWN)
FIG. 15-2
15
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STEP 4 - CONNECT POWER CABLE
1. Drill one 3/4“ hole and two #21–size holes in the vertical post
on curb side of vehicle body as shown in FIG. 16-1A. Use
template shown in FIG. 16-1B.
VEHICLE BODY
VERTICAL POST
(CURB SIDE)
18”
FIG. 16-1A
7/8”
1-3/4”
HOLE DRILLING TEMPLATE
FIG. 16-1B
16
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STEP 5 - INSTALL CONTROL SWITCH
2. Route the control switch cable through the
¾” hole in the vertical post (FIG. 17-1B)
and down the vertical post as shown in
(see dashed line in FIG. 17-1A). When
the control switch is close to the post, attach control switch to vertical post with 2
self-tapping screws (FIG. 17-1B).
CONTROL SWITCH
3/4” HOLE
DECAL
(SEE DECALS PAGE)
SELF-TAPPING
SCREW
ATTACHING CONTROL SWITCH
3. Run control switch cable under vehicle body
FIG. 17-1B
(see dashed line in FIG. 17-1A) and
through the grommet on the pump box. Use 2
loom clamps and 2 self-tapping screws (parts
bag item) to secure the control switch cable
CONTROL SWITCH
to vehicle frame.
CABLE
PLATFORM
(OPEN AND RAISED)
3/4” HOLE
VEHICLE BODY
VERTICAL POST
PUMP BOX
GROMMET
ROUTING CONTROL SWITCH WIRING
FIG. 17-1A
17
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STEP 5 - INSTALL CONTROL SWITCH - Continued
STEP 5 - INSTALL CONTROL SWITCH - Continued
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.
NOTE: An extra crimp-on connector is supplied with the RED wire and BLACK
wire on the control switch cable. Crimp each of the extra connectors to
the correct wires shown in the illustration.
NOTE: MAXON recommends using dielectric grease on all electrical connections.
4. Open the pump box cover. Connect the
RED, BLACK, GREEN, and WHITE
wires from the control switch cable to
BLACK
pump wiring as shown in FIG. 18-1.
CRIMP
TERMINALS
“A” VALVE
WIRE
“A” VALVE
WIRE
RED
WIRE
CONTROL
SWITCH CABLE
“E” VALVE
WIRE
“E” VALVE
TERMINAL “D”
SWITCH CABLE PUMP WIRING
WIRE COLOR
CONNECTION
BLACK
“A“ VALVE WIRE
RED
“E” VALVE WIRE
GREEN
TERMINAL “B”
WHITE
TERMINAL “D”
WIRING CONNECTIONS
TABLE 18-1
WHITE
WIRE
GREEN
WIRE
TERMINAL “B”
CONNECTING CONTROL SWITCH
CABLE TO PUMP WIRING
FIG. 18-1
18
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CAUTION
STEP 6 - CONNECT POWER CABLE TO BATTERY
Remove nut from positive (+) battery terminal
connector. Connect power cable to the positive
(+) battery terminal connector (FIG. 19-1). Reinstall and tighten nut.
POSITIVE (+)
BATTERY TERMINAL
NUT
FIG. 19-1
19
FUSED
POWER CABLE
BOLT
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
NOTE: MAXON recommends using dielectric grease on all electrical connections.
STEP 7 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS
Check for leaking hydraulic fluid as the system is being pressurized. If there is
leakage, stop & correct the problem before fully pressurizing the system.
1. Push control switch to UP position to pressurize hydraulic system. Listen for hydraulic
fluid flowing through the system. Check for fluid leaks. When the sound of flowing fluid
stops, release control switch. Hydraulic system is ready.
NOTE: To operate Liftgate, locking angles must be removed from the hydraulic
cylinders and shipping bolt must be removed from both knuckles.
2. Remove locking angles from hydraulic cylinders (FIG. 20-1A).
3. With platform open (FIG. 20-1A), unbolt each knuckle as shown in FIGS. 20-1B.
PLATFORM
(UNFOLDED)
LOCKING
ANGLE
FLAT WASHER
(GPT 4/5 ONLY)
FLIPOVER
(UNFOLDED)
FIG. 20-1A
BOLT
LOCK WASHER
(GPT 25/3 ONLY)
LOCK NUT
(GPT 4/5 ONLY)
FLAT WASHER
UNBOLTING KNUCKLE
(GPT 4/5 SHOWN)
FIG. 20-1B
20
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CAUTION
STEP 8 - WELD PLATFORM OPENER TO LIFTGATE
FLOOR JACK
FIG. 21-1
SUPPORT STRAPS
& SPACERS
(BOTH SIDES)
2. Lower the platform to the ground.
Remove both support straps and
both spacers from extension plate
(FIG. 21-2).
PLATFORM
FIG. 21-2
3. Fold flipover (FIG. 21-3).
FLIPOVER
FOLDING FLIPOVER
FIG. 21-3
21
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1. Remove floor jack and hoist
supporting Liftgate (FIG. 21-1).
NOTE: Platform opener may only be installed on right hand side of main frame
(see the illustrations on this page).
4. Position the opener on main frame as
shown in FIG. 22-1.
13”
OPENER
MAIN
FRAME
POSITIONING OPENER
FIG. 22-1
5. Fold the platform against opener (FIG. 22-2A). Make sure opener
is entered on protective plate as shown in FIG. 22-2B. Reposition
the opener if necessary. Clamp opener to main frame.
PROTECTIVE
PLATE
OPENER
PLATFORM
OPENER
MAIN
FRAME
CENTERING OPENER
ON PLATE
FIG. 22-2B
FIG. 22-2A
22
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 8 - WELD PLATFORM OPENER TO LIFTGATE
- Continued
!
CAUTION
If there is any interference with the platform while stowing Liftgate, check for
damage on bottom of platform, flipover, and the hinge in between. A damaged
platform or flipover may result in personal injury and more damage to Liftgate.
1” (MIN, EACH SIDE)
1/4”
(MIN.)
REAR SILL
PLATFORM
SIDE PLATE
PLATFORM
SUPPORT GUSSET
CHECKING FOR MINIMUM CLEARANCES BETWEEN PLATFORM &
MODIFIED AREAS ON REAR SILL
(EXTENSION PLATE NOT SHOWN)
FIG. 23-1
NOTE: If the rear sill was over 4” in
height and had to be modified,
check those modified areas
for the minimum clearances
shown in FIG. 23-1.
6. Stow and unfold Liftgate several
times to verify there is no interference. If there is no interference, weld opener to main frame
(FIG. 23-2).
7. If the platform lowered with a “jerking” motion, bleed air from the
hydraulic system by doing the following. Push the control switch to
the DOWN position until you hear
air escaping into the hydraulic fluid
reservoir. Raise the platform and
then repeat this step until there is
no air left in the system and platform
lowers smoothly.
OPENER
3/16”
1” LG.
4 PLACES
MAIN
FRAME
WELDING OPENER TO MAIN FRAME
FIG. 23-2
23
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 8 - WELD PLATFORM OPENER TO LIFTGATE
- Continued
STEP 9 - FINISH WELDING LIFTGATE TO VEHICLE
Prevent damaged hydraulic hoses. Before welding next to hydraulic hoses,
protect the hoses with a heat-resistant cover such as a welding blanket.
1. Weld each of the two
mounting plates to vehicle
frame (FIG. 24-1A).
VEHICLE FRAME CUTOUT
(DASHED LINES)
MOUNTING PLATE
VEHICLE FRAME
(TYPICAL TRUCK FRAME
SHOWN)
5/16”
TYPICAL
- BOTH
MOUNTING
PLATES
WELDING MOUNTING PLATE
FIG. 24-1A
FIBERGLASS
SLEEVES
SPLIT LOOMS
2. After welding is done and mounting plates are cool, remove the 4
fiberglass sleeves shown in FIG.
24-1B. Next, reinstall the split
looms removed in STEP 3 (FIG.
24-1B).
FIBERGLASS
SLEEVES
MOUNTING
PLATES (REF)
REINSTALLING SPLIT LOOMS
FIG. 24-1B
24
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
STEP 10 - INSTALL & ADJUST SADDLES
CAUTION
Make sure mounting plates are cooled before installing saddles. Hot surface
could result in personal injury and damaged saddles.
1. Stow the platform as shown in
FIG. 25-1A. Use floor jack
positioned at center of platform
(near hinge) to raise platform 1/8”
above roller (FIG. 25-1B). Install saddle, bolts and lock nuts
on RH side mounting plate (FIG.
25-1A). Repeat for saddle on
LH side. Butt each saddle against
platform, and tighten lock nuts.
MOUNTING
PLATE
HINGE
SADDLE
2. Install saddle, bolts and lock nuts
on RH side mounting plate (FIG.
25-1A). Repeat for saddle on
LH side. Butt each saddle against
platform, and tighten lock nuts.
BOLTS &
LOCK NUTS
STOWED LIFTGATE - SIDE VIEW
(RH SIDE SHOWN)
FIG. 25-1A
LIFTING FRAME
BRACKET
ROLLER
PLATFORM
1/8”
GAP
GAP BETWEEN PLATFORM & ROLLER
FIG. 25-1B
25
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
!
STEP 11 - WELD ON SADDLE SUPPORTS
Prevent damaged hydraulic hoses. Before welding next to hydraulic hoses,
protect the hoses with a heat-resistant cover such as a welding blanket.
1. Position a support flat (Parts Bag item)
against the bottom of the first saddle and
weld as shown in FIG. 26-1. Repeat this
step for the second saddle on LH side of
Liftgate.
SADDLE
1/2”
SUPPORT
FLAT
1/4”
TACK WELD
TACK WELDING SUPPORT FLAT
TO MOUNTING PLATE
(RH SIDE SHOWN)
FIG. 26-1
2. Lower the floor jack. Move floor jack to
a place where it will not interfere with
Liftgate or vehicle.
3. Lower platform to the ground.
Unfold platform and flipover
(FIG. 26-2).
PLATFORM & FLIPOVER UNFOLDED
AT GROUND LEVEL
FIG. 26-2
26
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
4. Loosen upper bolt on the RH
saddle. Then, remove the lower
bolt (FIG. 27-1). Rotate saddle
up and away from support flat
(FIG. 27-1).
MOUNTING
PLATE
SADDLE
BOLT & LOCK
NUT REMOVED
SUPPORT
PLATE
ROTATING SADDLE AWAY FROM
SUPPORT FLAT (RH SIDE SHOWN)
FIG. 27-1
5. Weld support flat to mounting
plate as shown in FIG. 27-2.
MOUNTING
PLATE
SADDLE
SUPPORT
PLATE
2 PLACES
1/4”
1/4”
2 PLACES
WELDING SUPPORT FLAT TO MOUNTING
PLATE (RH SIDE SHOWN)
FIG. 27-2
6. When mounting plate is cool
to the touch, rotate saddle into
place against the support flat
(FIG. 27-3). Bolt the saddle
to mounting plate (FIG. 27-3).
Tighten lock nuts and bolts.
SADDLE
MOUNTING
PLATE
BOLT & FLANGE
LOCK NUT
(2 PLACES)
BOLTING SADDLE TO MOUNTING
PLATE (RH SIDE SHOWN)
FIG. 27-3
7. Repeat steps 4 through 6 for
the LH saddle.
27
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 11 - WELD ON SADDLE SUPPORTS
- Continued
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. 28-1).
Measure how much the outboard edge
of platform rises above bed level (FIG.
28-1). The outboard edge must be level
or a maximum of 2” above bed level (FIG.
28-1). 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 2”, do instructions 4 through 6.
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”
THIS DISTANCE (“A”)
LEVEL LINE
PLATFORM EDGE AT OR
ABOVE BED LEVEL
FIG. 28-1
EXTENSION
PLATE (REF)
2. Compare measurement “A” (FIG.
28-2) with the distances and shims
in TABLE 28-1. For example: If
measurement “A” (FIG. 28-2) is
1” below level and you want to raise
outboard edge of platform 1” above
level, use 1/8” shim to raise 2”
(TABLE 28-1).
EDGE (OUTBOARD)
EXTENSION
PLATE (REF)
VEHICLE
OUTBOARD EDGE
FLOOR (REF)
0” (LEVEL) - 2” MAX.
VEHICLE
FLOOR (REF)
“A”
LEVEL LINE
PLATFORM EDGE BELOW BED LEVEL
FIG. 28-2
SHACKLE
(REF)
TABLE 28-1
3. Weld shims (Parts Bag item) on both
platform stops (FIG. 28-3) to raise
outboard edge of platform to correct
position.
NEW SHIM
(TABLE 28-1)
2 PLACES
“W”
(TABLE 28-1)
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 28-3
28
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 12 - ADJUST PLATFORM (IF REQUIRED)
EXTENSION
PLATE (REF)
4. Compare measurement “B” (FIG.
29-1) with distances and grinding
depths in TABLE 29-1. For example:
If measurement “B” (FIG. 29-1) 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 29-1).
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. 29-1
TABLE 29-1
5. Grind metal from platform stops (FIG.
29-2) to lower outboard edge of platform to correct position.
SHACKLE
(REF)
GRIND THIS FACE
(SEE TABLE 29-1)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 29-2
6. Lower the platform, then raise it to bed
level. The outboard edge of platform should
be level or up to 2” maximum above bed
level (FIG. 29-3).
EXTENSION
PLATE (REF)
OUTBOARD EDGE
0” (LEVEL) - 2” MAX.
VEHICLE
FLOOR (REF)
LEVEL LINE
PLATFORM EDGE ABOVE BED LEVEL
FIG. 29-3
29
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 12 - ADJUST PLATFORM - Continued
STEP 13 - CHECK HYDRAULIC FLUID
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.
+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606
See TABLES 30-1 & 30-2 for recommended brands.
1. Remove the filler cap (FIG. 30-1).
PUMP
RESERVOIR
ISO 32 HYDRAULIC OIL
RECOMMENDED
BRANDS
FILLER
CAP
DECAL
(FLUID LEVEL)
PART NUMBER
AMSOIL
AWH-05
CHEVRON
HIPERSYN 32
KENDALL
GOLDEN MV
SHELL
TELLUS T-32
EXXON
UNIVIS N-32
MOBIL
DTE-13M, DTE-24,
HYDRAULIC OIL-13
TABLE 30-1
CHECKING HYDRAULIC FLUID LEVEL
FIG. 30-1
ISO 15 OR MIL-H-5606 HYDRAULIC OIL
RECOMMENDED
BRANDS
2. Check the hydraulic fluid level in the
pump reservoir (FIG. 30-1). If fluid
is below FILL LEVEL shown on decal on the pump reservoir (FIG. 301), add fluid to the FILL LEVEL.
3. Reinstall the filler cap (FIG. 30-1).
PART NUMBER
AMSOIL
AWF-05
CHEVRON
FLUID A, AW-MV-15
KENDALL
GLACIAL BLU
SHELL
TELLUS T-15
EXXON
UNIVIS HVI-13
MOBIL
DTE-11M
ROSEMEAD
THS FLUID 17111
TABLE 30-2
30
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
STEP 14 - WELD HOOK AND EYE TO LIFTGATE
INBOARD SIDE OF
TUBING, ONLY
EXTENSION PLATE
3/16”
HOOK
(WITH CHAIN)
KNUCKLE
BASE OF
PAD EYE, ONLY
1/4”
PAD EYE
2. Weld the pad eye (from installation
Parts Pag) to knuckle as shown in
FIG. 31-1.
RH SIDE VIEW OF STOWED LIFTGATE
FIG. 31-1
3. Insert the safety hook through the pad
eye (FIG. 31-1). Next, position the
safety hook chain on the extension
plate as shown in FIG. 31-1. Leave
enough slack in the chain to hook and
unhook the pad eye. Weld the free end
of chain to the inboard side of the tubing on extension plate.
31
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Stow the Liftgate under hydraulic pressure
(FIG. 31-1).
STEP 15 - WELD DOCK BUMPERS TO LIFTGATE
2. Clamp a dock bumper to left hand (LH) side of extension plate as shown in FIG. 321A. Weld the dock bumper to extension plate as shown in FIG. 32-1B. Make sure bolt
holes in the dock bumper are visible from the rear of the vehicle. Repeat step for dock
bumper on right hand (RH) side of extension plate.
GRIND OFF
2 PLACES
LH & RH DOCK
BUMPER
SHARP
CORNERS
3/16”
EXTENSION
PLATE
WELDING ANGLE TO EXTENSION PLATE
FIG. 32-1B
DOCK BUMPER
BRACE
2 PLACES
LH & RH BRACES
3/16”
3/16”
LINE UP BOTTOM EDGES AT
THIS POINT.
2 PLACES
LH & RH BRACES
FLAT
(PART OF BRACE)
MAIN FRAME
TYPICAL DOCK BUMPER & BRACE
POSITIONING (LH SIDE SHOWN)
FIG. 32-1A
BRACE
(CENTERED
BETWEEN 2 PINS)
PINS
3. Clamp open end of brace to dock bumper as shown in
FIG. 32-1A. Clamp closed end of brace to main frame
(FIG. 32-1A). Weld the brace to dock bumper (FIG. 32-1A)
and main frame (FIG. 32-1C). Repeat step for brace and dock
bumper on RH side of extension plate.
FIG. 32-1C
4. Raise and lower platform. Next, stow Liftgate (see Operation Manual). Make sure dock
bumper does not interfere with Liftgate.
32
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
1. Lower the platform to the ground (see Operation Manual).
NOTE: The rubber dock bumpers kit P/N 203410 contains 2 rubber bumpers
and 2 sets of fasteners.
Bolt a rubber bumper to each of the 2 dock bumpers (FIG. 33-1).
FLAT WASHER
(1/2”)
HEX NUT
(1/2”- 20)
CAP SCREW
(1/2”- 20 x 2”)
LOCK WASHER
(1/2”)
DOCK
BUMPER
RUBBER
BUMPER
BOLTING RUBBER BUMPER TO DOCK BUMPER
(RIGHT HAND SIDE DOCK BUMPER SHOWN)
FIG. 33-1
33
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 16 - BOLT RUBBER BUMPERS TO LIFTGATE
NOTE: Positions are based on using taillights of 6-3/4” height by 5-3/4” width. Larger
taillights may interfere with Liftgate. Taillights and attaching hardware are not
provided with the Liftgate. Underride is optional equipment.
OPTIONAL
UNDERRIDE
(REFERENCE)
Install vehicle taillights
(FIG. 34-1) as shown in
FIG. 34-2 and FIG. 34-3.
TAILLIGHTS
VEHICLE TAILLIGHTS INSTALLED ON LIFTGATE
FIG. 34-1
ANGLE STEEL
(NOT SUPPLIED)
MAIN
FRAME
EXTENSION
PLATE
(REFERENCE)
PLATFORM OPENER
(REFERENCE)
14”
TAILLIGHTS
TAILLIGHTS POSITION (TOP VIEW)
FIG. 34-2
ANGLE STEEL
(NOT SUPPLIED)
PLATFORM OPENER
(REFERENCE)
OPTIONAL
UNDERRIDE
(REFERENCE)
TAILLIGHT
24”
24”
30”
TAILLIGHT
GROUND LEVEL
TAILLIGHTS HORIZONTAL SPACING (FRONT VIEW)
FIG. 34-3
34
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 17 - VEHICLE TAILLIGHT POSITIONING
(IF REQUIRED)
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
PLATFORM WARNING DECAL
(2 PLACES)
P/N 281189-01
PLATFORM LOADING DECAL
(2 PLACES)
P/N 281326-01
FIG. 35-1
35
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH DECALS
(See TABLE 36-1)
DECAL SHEET
FIG. 36-1
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 36-1
36
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH DECALS - Continued
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.
If bare metal or primer is exposed on the painted portions of the Liftgate, touch up the
paint. To maintain the protection provided by the original paint system, MAXON recommends aluminum primer touchup paint kit, P/N 908119-01.
37
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
TOUCHUP PAINT
HYDRAULIC SYSTEM DIAGRAM
4 GPM FLOW
CONTROL VALVE
ADJUSTABLE
NEEDLE VALVE
FILL HOLE
(PLUGGED)
PORT ARAISE VALVE “A”
PORT BLOWER
(PWR DN)
FILTER
VALVE “E”
CHECK VALVE
MOTOR
(REFERENCE)
HAND PUMP
PORT
RELIEF
VALVE
(SET AT
2200 PSI)
M
PUMP
HAND PUMP
PORT
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 38-1
38
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC CYLINDERS
ELECTRICAL SYSTEM DIAGRAM
RED
GREEN
BLACK
CABLE
ASSEMBLY
WHITE
SOLENOID,
VALVE A
SOLENOID,
VALVE E
MOTOR
STARTER
SOLENOID
CABLE WITH
200 AMP FUSE
BATTERY
FIG. 39-1
39
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CONTROL SWITCH
OPTIONS
MISCELLANEOUS KITS
PART NUMBER
IN CAB ON-OFF SWITCH
250477
LOW VOLTAGE SWITCH (LVS), GPT
267494-01
FRAMELESS TRAILER SUBFRAME MOUNTING KIT
280010
102” WIDE TRAILER
263552
CIRCUIT BREAKER (150 AMP)
251576
HAND PUMP, GPT POWER DOWN
267491-01
GREASE-ABLE PINS (GPT-25 & GPT-3 ONLY)
281946-01
EXTRA CONTROLS & CONTROL KITS
CONTROL STATION, POWER UP & DOWN (120” LG)
229068
CONTROL STATION, POWER UP & DOWN (144” LG)
229068-01
CONTROL STATION, POWER UP & DOWN, COILED CORD (20’ LG)
229068-102
HAND HELD CONTROL, POWER DOWN
263260-04
STREET SIDE CONTROL, 4-WIRE MOLDED SWITCH
265378
DUAL SWITCH CONTROL, 4-WIRE MOLDED SWITCH
265380
BUMPER/UNDERRIDE KITS
UNDERRIDE (GPT-4 & GPT-5 ONLY)
266043-01
UNDERRIDE (GPT-25 & GPT-3 ONLY)
266042-01
LIFTGATE BUMPER (ALL GPT MODELS)
265860-01
2 STEP DOCK BUMPER
DOCK BUMPER, 2-STEP
266220-01
BATTERY BOX KITS
TRUCK BATTERY BOX WITHOUT BATTERY (FOR 6V BATTERY)
251154-03
TRUCK BATTERY BOX WITHOUT BATTERY (FOR 12V BATTERY)
251154-05
TRAILER CHARGE LINE KITS
TRAILER, SINGLE POLE CHARGE LINE
280275-01
TRAILER, DUAL POLE CHARGE LINE
280275-02
TRAILER SINGLE & DUAL POLE CHARGE LINE
280275-06
TRAIL CHARGER
267370-01
HIGH PERFORMANCE CHARGER
267850-01
TRACTOR CHARGE LINE KIT
TRACTOR SINGLE POLE CHARGE LINE
280275-03
TRACTOR DUAL POLE CHARGE LINE
280275-04
TRACTOR CHARGE LINE WITH ADAPTER
280275-05
EXTENSION KIT
30’ EXTENSION, SAE, POWER DOWN
266389-01
BATTERY
BATTERY,12V HD (SEALED, MAINTENANCE FREE, GROUP SZ 31)
267318-01
CYCLE COUNTER KIT
CYCLE COUNTER, GPT
280590-02
40
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
OPTIONAL LIFTGATE COMPONENTS
NOTE: Make sure the Liftgate power unit, and all batteries on the vehicle for the
power unit are connected correctly to a common chassis ground.
1. Liftgate and additional
battery box are typically
installed on trailers as
shown in FIG. 41-1 and
on trucks as shown in
FIG. 41-2. See the following page for battery
and cable connections.
TRAILER-MOUNTED
CIRCUIT BREAKER,
ADDITIONAL RECOMMENDED LOCATION
POWER CABLE
(200 AMP IN-LINE
FUSE SHOWN)
TRACTOR BATTERY
CIRCUIT BREAKER REQUIRED LOCATION
CIRCUIT
BREAKER
LIFTGATE
LIFTGATE
POWER UNIT
ADDITIONAL BATTERY BOX
- TYPICAL LOCATION
TRACTOR BATTERIES
- TYPICAL LOCATION
CHARGE LINE
RECOMMENDED LIFTGATE & BATTERY BOX
INSTALLATION ON TRAILER
FIG. 41-1
TRUCK BATTERY
CIRCUIT BREAKER REQUIRED LOCATION
POWER CABLE
(200 AMP IN-LINE
FUSE SHOWN)
CIRCUIT
BREAKER
LIFTGATE
LIFTGATE
POWER UNIT
ADDITIONAL BATTERY BOX
- TYPICAL LOCATION
TRUCK BATTERIES
- TYPICAL LOCATION
CHARGE LINE
RECOMMENDED LIFTGATE & BATTERY BOX
INSTALLATION ON TRUCK
FIG. 41-2
41
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RECOMMENDED LIFTGATE POWER CONFIGURATION
NOTE: Always connect fused end of power cable to battery positive (+) terminal.
2. Recommended battery box
setup for 6 volt batteries is
shown in FIG. 42-1.
(+)
BATTERY
CABLES
150 AMP CIRCUIT BREAKER
(NEAR TRUCK OR
150 AMP CIRCUIT
TRACTOR
BATTERY AND/OR
BREAKER
NOSE OF TRAILER)
200 AMP FUSED POWER CABLE
(ONLY IF REQUIRED - SEE NOTE)
CHARGE LINE TO
TRUCK OR TRACTOR
BATTERY
POWER CABLE
TO PUMP BOX
(-) BATTERY
CABLE
6 VOLT BATTERY CONNECTIONS
FIG. 42-1
NOTE: Always connect fused end of power cable to battery positive (+) terminal.
3. Recommended battery box
setup for 12 volt batteries is
shown in FIG. 42-2.
150 AMP CIRCUIT
(+)
BREAKER
BATTERY
CABLES
150 AMP CIRCUIT BREAKER
(NEAR TRUCK OR
TRACTOR BATTERY AND/OR
NOSE OF TRAILER)
200 AMP FUSED POWER CABLE
(ONLY IF REQUIRED - SEE NOTE)
CHARGE LINE TO
TRUCK OR TRACTOR
BATTERY
POWER CABLE
TO PUMP BOX
(-) BATTERY
CABLES
12 VOLT BATTERY CONNECTIONS
FIG. 42-2
42
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued
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