INSTALLATION MANUAL

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

M-08-02

REV. A

AUGUST 2010

© MAXON Lift Corp. 2010

TABLE OF CONTENTS

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

STANDARD LIFTGATE COMPONENTS .............................................................................. 5

GPT-SERIES INSTALLATION PARTS BAGS ....................................................................... 6

VEHICLE REQUIREMENTS ................................................................................................. 7

STEP 1 - WELD EXTENSION PLATE TO VEHICLE .......................................................... 10

STEP 2 - WELD LIFTGATE TO VEHICLE .......................................................................... 12

STEP 3 - RUN POWER CABLE .......................................................................................... 16

STEP 4 - CONNECT POWER CABLE ................................................................................ 17

STEP 5 - INSTALL CONTROL SWITCH ............................................................................. 19

STEP 6 - CONNECT POWER CABLE TO BATTERY ......................................................... 22

STEP 7 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS ........................................... 23

STEP 8 - WELD PLATFORM OPENER TO LIFTGATE ...................................................... 24

STEP 9 - FINISH WELDING LIFTGATE TO VEHICLE ....................................................... 28

STEP 10 - INSTALL & ADJUST SADDLES ......................................................................... 29

STEP 11 - WELD ON SADDLE SUPPORTS ...................................................................... 30

STEP 12 - ADJUST PLATFORM (IF REQUIRED) .............................................................. 32

STEP 13 - CHECKING HYDRAULIC FLUID ....................................................................... 34

STEP 14 - WELD HOOK AND EYE TO LIFTGATE ............................................................. 36

STEP 15 - WELD DOCK BUMPERS TO LIFTGATE ........................................................... 37

STEP 16 - BOLT RUBBER BUMPERS TO LIFTGATE ....................................................... 39

STEP 17 - VEHICLE TAILLIGHT POSITIONING (IF REQUIRED) ...................................... 40

ATTACH DECALS ............................................................................................................... 41

TOUCHUP PAINT ............................................................................................................... 43

SYSTEM DIAGRAMS ......................................................................................................... 44

PUMP & MOTOR SOLENOID OPERATION ....................................................................... 44

HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 45

ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 46

OPTIONS ............................................................................................................................ 47

OPTIONAL LIFTGATE COMPONENTS .............................................................................. 47

RECOMMENDED LIFTGATE POWER CONFIGURATION ................................................ 48

Comply with the following WARNINGS while installing Liftgates. See Operation Manual for operating safety requirements.

WARNINGS

!

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.

4

STANDARD LIFTGATE COMPONENTS

!

CAUTION

Unpacking the Liftgate on unlevel surface may allow heavy components to slide off when shipping bands are cut. Injury and equipment damage could result. Before the shipping bands are cut, put Liftgate on level surface that will support 1500 lbs.

When unpacking the Liftgate, remove heavy components carefully to avoid injury and damage.

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

BOXED COMPONENTS

(INCLUDES STEEL DOCK

BUMPER PARTS)

EXTENSION

PLATE

MAIN

ASSEMBLY

PUMP ASSEMBLY

(COvER IS ShOWN)

TYPICAL LIFTGATE PACKAGED FOR ShIPMENT

FIG. 5-1

5

GPT-SERIES INSTALLATION PARTS BAGS

1

2 MOLDED SWITCH ASSEMBLY

3 SHIM, 3-1/2” X 1-3/4” X 1/4”

4

5 FLAT, 2-1/2" 1” X 1/8”

6

FLAT, 5" X 4” X 3/8”

7 COPPER LUG (2GA)

8 SELF-TAPPING SCREW, 10-24 X 1” LG.

9 CLAMP, #10 RUBBER LOOM

10

11

NOMENCLATURE OR DESCRIPTION

HEAT SHRINK TUBING, 3/4” X 1-1/2" LG.

SHIM, 2-1/5” X 1” X 1/16”

FRAME CLIP, 1/2” X 1-3/8”

DECAL & MANUAL KIT

A. OPERATION MANUAL

B. INSTALLATION MANUAL

C. MAINTENANCE MANUAL

D. WARRANTY CARD

E. CUSTOMER SURVEY CARD

F. DECALS -

12 EYE, DROP FORGED PAD, 3/4” X 1-1/2”

13 HOOK ASSEMBLY

1

1

14 FUSED POWER CABLE, 175 AMP, 38’ LG.

18 LOCK NUT, FLANGE, 1/2”- 13

1

15 RUBBER DOCK BUMPER KIT

16

SADDLE, LOW PROFILE

1

2

17 HEX BOLT, FRAME, 1/2” -13 X 2-1/4” LG, GRADE 8 4

4

19 FLAT, 3/4” X 1” X 6” (SADDLE SUPPORT)

20 PLASTIC TIE, 7” LG.

21 DOCK BUMPER ANGLE, 23-1/2” LG.

22 BRACE ANGLE, LH

23 BRACE ANGLE, RH

2

1

2

1

1

1

1

1

1

1

4

2

7

1

2

2

2

2

QTY.

PART NUMBER

1 253316-04

1

264951-04

264731

264732

201999

229295

906497-02

900057-5

801681

050079

282661-01 (GPT-25)

282662-01 (GPT-3)

282671-01 (GPT-4)

282672-01 (GPT-5)

M-08-03

M-08-02

M-08-04

M-78-78

1 M-94-04

REFER TO DECAL

PAGES IN THIS

MANUAL

226938

227700

264422

203410

281539-01

901024-3

901023

090300-12

205780

226856

266019-01

266019-02

TABLE 6-1

6

VEHICLE REQUIREMENTS

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. 7-1 and 7-2) on vehicle to prevent interference between vehicle and Liftgate.

22-3/16

11-5/8”

14”

55” MAX. BED HEIGHT

46” MIN. BED hEIGhT

10”-19”

GPT-25 & GPT-3 CLEARANCES

FIG. 7-1

24-1/2”

11-5/8”

14”

18-1/4”

55” MAX. BED HEIGHT

46” MIN. BED hEIGhT

12”-21”

GPT-4 & GPT-5 CLEARANCES

FIG. 7-2

7

19-1/4”

vEhICLE REQUIREMENTS - Continued

CAUTION

• 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. 8-1.

TRUCK BODY

REAR SILL

6”

4” (SEE CAUTION)

10-1/4”

BODY FLOOR

BODY CROSS-

MEMBERS

LONG SILL

PLATFORM CLEARANCE CUTOUT AREA

(WIThIN DAShED LINES)

2-3/4”

WOODEN SPACER

TRUCK

FRAME

23” (MIN.)

VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE

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

(TRUCK FRAME IS ShOWN)

FIG. 8-1

8

vEhICLE REQUIREMENTS - Continued

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. 9-1. A side view of the interference areas is shown in FIG. 9-2.

CENTER

LINE

6-3/4”

(2 PLACES)

40-1/2” 40-1/2”

REAR SILL 4”

BODY

FRAME

VEHICLE

FRAME

AREA TO

MODIFY

(4 PLACES)

FRONT VIEW - REAR SILL MORE THAN 4” IN HEIGHT

(LIFTGATE & EXTENSION PLATE NOT ShOWN)

FIG. 9-1

2-1/2”

(4 PLACES)

MARK

REAR

SILL

MEASURE “H”

4”

NOTE: L= 3.75 x H “L”

SIDE VIEW - REAR SILL MORE THAN 4” IN HEIGHT

FIG. 9-2

9

STEP 1 - WELD EXTENSION PLATE TO VEHICLE

CAUTION

To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.

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. 10-1 and FIG. 10-2.

1/4”

4” LG. LOCATED ABOVE EACH OF

3 RECTANGULAR TUBES (TUBES

ShOWN ShADED IN FIG. 10-2)

SILL

(PART OF vEhICLE BODY)

4” LG.

1/4”

2” LG. CENTERED

BETWEEN

4” WELDS SHOWN

1/4”

4” LG.

1/4”

EXTENSION PLATE WELDS - VIEWED FROM ABOVE

FIG. 10-1

1/4”

2 PLACES, MAKE 1”

GAP WHERE SHOWN

2” LG, 12 PLACES

EQUAL SPACING

(TYP.)

1/4”

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. 10-2

10

STEP 1 - WELD EXTENSION PLATE TO VEHICLE -

Continued

2. Place 2 temporary support straps (5” x 4” x 3/8” flats from parts bag) on the extension plate as shown in FIG. 11-1A. Also, put 2 temporary spacers (2” x 1” x 1/8” flats from parts bag) between platform and extension plate as shown in

FIG. 11-1B. (Spacers keep 1/8” between platform and extension plate while welding Liftgate to vehicle frame.) Weld the straps and spacers to extension plate

(FIG. 11-1B).

1” (APPROX. - TYP.

STRAP OvERhANG)

1/4”

4”

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”

EXTENSION

PLATE

STRAP & SPACER WELDS

(TYPICAL - BOTh ENDS OF

EXTENSION PLATE)

FIG. 11-1B

SUPPORT

STRAPS

FIG. 11-1A

11

STEP 2 - WELD LIFTGATE TO VEHICLE

1. Remove split looms from mounting plates

(FIG. 12-1). (Split looms will be reinstalled later after final welding.) MOUNTING

PLATES

FIG. 12-1

2.

Unfold the platform and flipover (FIG. 12-2).

PLATFORM

(UNFOLDED)

LOCKING ANGLES

(REF)

SPLIT LOOMS

MOUNTING

PLATES

FLIPOVER

(UNFOLDED)

PLATFORM & FLIPOVER UNFOLDED

FIG. 12-2

12

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 incorrect way

(FIG.

13-2). Place a “C”-clamp on each side of plat-

FLIPOVER form as shown in FIG. 13-1.

(Clamps prevent hoist chain from slipping off platform.) Place chain all around platform

(FIG.

13-1).

HOIST CHAIN

PLATFORM

C-CLAMP

(2 PLACES)

VEHICLE FLOOR

(hORIZONTAL)

PINS

(LINED UPvERTICAL)

MOUNTING

PLATE

MAIN FRAME

NOTE: Ensure pins stay lined up vertical (see illustration) while Liftgate is being welded to vehicle frame.

FLOOR JACK

(CENTERED ON

MAIN FRAME TUBE)

C CORRECT WAY TO HOIST LIFTGATE

FIG. 13-1

4. Hoist the Liftgate.

Then, place floor jack under main frame

(FIG. 13-1). Jack the

Liftgate into position.

Make sure vehicle floor is horizontal and pins are lined up

vertical

(FIG. 13-1).

FLIPOVER

HOIST CHAIN

INCORRECT WAY TO HOIST LIFTGATE

FIG. 13-2

13

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 damage to hydraulic hoses. If welding next to hydraulic hoses, use a protective cover such as a welding blanket to cover the hoses.

CAUTION

To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.

5. Check if both mounting plates line up with the vehicle frame. If the mounting plates do not line up, remove the tack welds from one mounting plate

(FIG.

14-1). Make sure Liftgate stays centered on vehicle. Reposition the mounting plate against vehicle frame. Tack

ORIGINAL TACK WELDS

(REMOvE TO REPOSITION

MOUNTING PLATE)

TACK

(TYPICAL - Rh & Lh

MOUNTING PLATES)

5/16” weld as shown in FIG.

14-1. Repeat for second mounting plate (reposition and tack weld).

VEHICLE FRAME CUTOUT

(TYPICAL TRUCK FRAME ShOWN)

MAIN FRAME

(CUT-AWAY vIEW)

REPOSITIONING MOUNTING PLATE

(Rh SIDE ShOWN)

FIG. 14-1

MOUNTING

PLATE

14

STEP 2 - WELD LIFTGATE TO vEhICLE - Continued

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 frame does not block the 2 slotted holes in mounting plate

(FIG. 15-1). Weld the mounting plates to

2” LG. 4 PLACES

(TYPICAL - Rh & Lh

MOUNTING PLATES) vehicle frame as shown in FIG. 15-1. Next, weld both mounting plates to main frame

(FIG. 15-1).

Remove clamps.

5/16”

MAIN FRAME

(CUT-AWAY vIEW)

MOUNTING

PLATE

5/16”

WELDING TO VEHICLE FRAME AND

MAIN FRAME (Rh SIDE ShOWN)

FIG. 15-1

15

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 to prevent damage to 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. 16-1. 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

SHORTEST

CABLE END

TERMINAL LUG

(vEhICLE BATTERY

END)

FIG. 16-1

16

FRONT OF VEHICLE

REAR OF VEHICLE

STEP 4 - CONNECT POWER CABLE

1. Unbolt and remove pump cover

(FIG. 17-1).

POWER

UNIT

(REF)

FLAT

WASHERS

(2 PLACES)

LONG SIDE OF

HOLDER FLATS

BUTT AGAINST

COVER

NUTS

(2 PLACES) PUMP

COVER CAP SCREWS

(2 PLACES)

UNBOLTING PUMP COVER

FIG. 17-1

2. 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. 17-2A). Measure (if needed), and then cut excess cable from bare wire end of cable. Put heatshrink tubing (parts bag item)

(FIG. 17-2B) on the end of the cable and leave room for terminal lug. Crimp copper terminal lug (parts bag item) on the fused power cable and shrink the heatshrink tubing

(FIG. 17-2C).

COPPER

TERMINAL

LUG hEATShRINK

TUBING

FIG. 17-2B

FIG. 17-2C

FUSED

POWER CABLE

TYPICAL FUSED POWER CABLE ROUTING

FIG. 17-2A

17

STEP 4 - CONNECT POWER CABLE - Continued

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.

NOTE:

Do not remove flat washer from the battery power terminal.

LOCK

WASHER

3. 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. 18-

1. Reinstall and tighten lock washer and hex nut.

HEX NUT

BATTERY

POWER TERMINAL

STARTER

SOLENOID

TYPICAL FUSED POWER

CABLE ELECTRICAL CONNECTION

FIG. 18-1

18

STEP 5 - INSTALL CONTROL SWITCH

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. 19-1A. Use template shown in

FIG. 19-1B.

VEHICLE BODY

VERTICAL POST

(CURB SIDE)

18”

FIG. 19-1A

1-3/4”

7/8”

HOLE DRILLING TEMPLATE

FIG. 19-1B

NOTE: Hydraulic lines and electrical lines must run into pump box through sealing grommets

(FIG. 19-2). To ensure a good seal on hydraulic & electrical lines, never cut the sealing grommets.

2. Cut tie strap on coiled wiring harness

(FIG. 19-2). Pull the wiring harness through grommet on the pump mounting plate

(FIG. 19-2).

WIRING

HARNESS

GROMMET

TIE

STRAP

PUMP MOUNTING

PLATE

FIG. 19-2

19

STEP 5 - INSTALL CONTROL SWITCh - Continued

NOTE: MAXON recommends using dielectric grease on all electrical connections.

3. Run wiring harness under vehicle body

(see dashed

line - FIG. 20-1) and up through inside of vertical post. Pull control switch wiring harness out the 3/4“ hole drilled in vertical post

(FIG. 20-1). Connect the control switch wiring to the wiring harness as shown in FIG. 20-2. Push extended wiring back into the

¾” hole in the vertical post until control switch touches the post. Attach control switch to vertical post with

2 self-tapping screws

(FIG.

20-2).

WIRING HARNESS

3/4” HOLE

VEHICLE BODY

VERTICAL POST

PUMP BOX

ROUTING CONTROL SWITCH WIRING

FIG. 20-1

BLACK

WHITE

CONTROL SWITCH

DECAL

(SEE DECALS PAGE)

BLACK

WHITE

SCREW,

SELF-TAPPING

GREEN

GREEN

RED

CONTROL SWITCH WIRING CONNECTIONS

FIG. 20-2

20

STEP 5 - INSTALL CONTROL SWITCh - Continued

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.

POWER

UNIT

(REF)

FLAT

WASHERS

(2 PLACES)

LONG SIDE OF

HOLDER FLATS

BUTT AGAINST

COVER

4. Bolt on the pump cover as shown in

FIG. 21-1. Torque the 5/16”-18 cover bolts from 10 to 14 lbs.-ft.

NUTS

(2 PLACES) PUMP

COVER CAP SCREWS

(2 PLACES)

BOLTING ON PUMP COVER

FIG. 21-1

21

STEP 6 - CONNECT POWER CABLE TO BATTERY

NOTE: MAXON recommends using dielectric grease on all electrical connections.

Remove nut from positive

(+) battery terminal connector. Connect power cable to the positive

(+) battery terminal connector (FIG. 22-1). Reinstall and tighten nut.

POSITIvE (+)

BATTERY TERMINAL

BOLT

FUSED

POWER CABLE

NUT

FIG. 22-1

22

STEP 7 - REMOvE LOCKING ANGLES & KNUCKLE BOLTS

CAUTION

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. 23-1A).

3. With platform open

(FIG. 23-1A), unbolt each knuckle as shown in FIG. 23-1B.

PLATFORM

(UNFOLDED)

LOCKING

ANGLE

FLIPOVER

(UNFOLDED)

FLAT WASHER

(GPT 4/5 ONLY)

FIG. 23-1A

BOLT

LOCK WAShER

(GPT 25/3 ONLY)

FLAT WASHER

UNBOLTING KNUCKLE

(GPT 4/5 ShOWN)

FIG. 23-1B

LOCK NUT

(GPT 4/5 ONLY)

23

STEP 8 - WELD PLATFORM OPENER TO LIFTGATE

1.

Remove floor jack and hoist supporting Liftgate

(FIG. 24-1).

FLOOR JACK

FIG. 24-1

2. Lower the platform to the ground.

Remove both support straps and both spacers from extension plate

(FIG. 24-2).

PLATFORM

SUPPORT STRAPS

& SPACERS

(BOTh SIDES)

FIG. 24-2

3.

Fold flipover (FIG. 24-3).

FLIPOVER

24

FOLDING FLIPOVER

FIG. 24-3

STEP 8 - WELD PLATFORM OPENER TO LIFTGATE

- Continued

NOTE: Platform opener may only be installed on center of main frame (see the illustrations on this page).

4. Position the opener on main frame as shown in FIG. 25-1.

OPENER

13”

MAIN

FRAME

POSITIONING OPENER

FIG. 25-1

5. Fold the platform against opener

(FIG. 25-2A). Make sure opener is entered on protective plate as shown in FIG. 25-2B. Reposition the opener if necessary. Clamp opener to main frame.

PROTECTIVE

PLATE

OPENER

PLATFORM

OPENER

MAIN

FRAME

FIG. 25-2A

CENTERING OPENER

ON PLATE

FIG. 25-2B

25

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 additional damage to Liftgate.

1” (MIN, EACh SIDE)

1/4”

(MIN.)

REAR SILL

PLATFORM

SIDE PLATE

PLATFORM

SUPPORT GUSSET

CAUTION

To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.

NOTE: If the rear sill is over 4” in height and needs to be modified, check the modified areas for the minimum clearances shown in

FIG. 26-1.

6. Stow and unfold Liftgate several times to verify there is no interference. If there is no interference, weld opener to main frame

(FIG. 26-2).

ChECKING FOR MINIMUM CLEAR-

ANCES BETWEEN PLATFORM &

MODIFIED AREAS ON REAR SILL

(EXTENSION PLATE NOT ShOWN)

FIG. 26-1

3/16”

1” LG.

4 PLACES

OPENER

MAIN

FRAME

WELDING OPENER TO MAIN FRAME

FIG. 26-2

26

STEP 8 - WELD PLATFORM OPENER TO LIFTGATE

- Continued

7. If the platform lowers 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. Repeat this step until there is no air left in the system and platform lowers smoothly.

27

STEP 9 - FINISH WELDING LIFTGATE TO VEHICLE

CAUTION

Prevent damage to hydraulic hoses. Before welding next to hydraulic hoses, protect the hoses with a heat-resistant cover such as a welding blanket.

CAUTION

To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.

1. Weld each of the two mounting plates to vehicle frame

(FIG. 28-1A).

VEHICLE FRAME CUTOUT

(DAShED LINES)

MOUNTING PLATE

VEHICLE FRAME

(TYPICAL TRUCK FRAME

ShOWN)

5/16”

TYPICAL

- BOTH

MOUNTING

PLATES

WELDING MOUNTING PLATE

FIG. 28-1A

FIBERGLASS

SLEEVES

2. After welding is done and mounting plates are cool, remove the 4 fiberglass sleeves shown in FIG.

28-1B. Next, reinstall the split looms removed in STEP 2

(FIG.

28-1B).

28

FIBERGLASS

SLEEVES

SPLIT

LOOMS

MOUNTING

PLATES (REF)

REINSTALLING SPLIT LOOMS

FIG. 28-1B

STEP 10 - INSTALL & ADJUST SADDLES

!

CAUTION

Make sure mounting plates have cooled before installing saddles. hot surface can result in personal injury and damaged saddles.

1. Stow the platform as shown in

FIG. 29-1A

. Use floor jack positioned at center of platform

(near hinge) to raise platform 1/8” above roller

(FIG. 29-1B). Install saddle, bolts and lock nuts on RH side mounting plate

(FIG.

29-1A). Repeat for saddle on

LH side. Butt each saddle against platform, and tighten lock nuts.

HINGE

MOUNTING

PLATE

2. Install saddle, bolts and lock nuts on RH side mounting plate

(FIG.

29-1A). Repeat for saddle on

LH side. Butt each saddle against platform, and tighten lock nuts.

SADDLE BOLTS &

LOCK NUTS

STOWED LIFTGATE - SIDE VIEW

(Rh SIDE ShOWN)

FIG. 29-1A

LIFTING FRAME

BRACKET

ROLLER

PLATFORM

GAP BETWEEN PLATFORM & ROLLER

FIG. 29-1B

1/8”

GAP

29

STEP 11 - WELD ON SADDLE SUPPORTS

CAUTION

Prevent damage to hydraulic hoses. Before welding next to hydraulic hoses, protect the hoses with a heat-resistant cover such as a welding blanket.

CAUTION

To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.

1. Position a support plate (parts bag item) against the bottom of the first saddle and weld as shown in FIG. 30-1. Repeat this step for the second saddle on LH side of

Liftgate.

SADDLE

1/2”

1/4”

SUPPORT

PLATE

TACK WELDING SUPPORT

PLATE TO MOUNTING PLATE

(Rh SIDE ShOWN)

FIG. 30-1

TACK WELD

2.

Lower the floor jack. Move floor jack out of the way so it will not interfere with Liftgate or vehicle.

3. Lower platform to the ground.

Unfold platform and flipover

(FIG. 30-2).

PLATFORM & FLIPOVER UNFOLDED

AT GROUND LEVEL

FIG. 30-2

30

STEP 11 - WELD ON SADDLE SUPPORTS

- Continued

4. Loosen upper bolt on the RH saddle. Then, remove the lower bolt

(FIG. 31-1). Rotate saddle up and away from support plate

(FIG. 31-1).

BOLT & LOCK

NUT REMOVED

SADDLE

MOUNTING

PLATE

5. Weld support plate to mounting plate as shown in FIG. 31-2.

SUPPORT

PLATE

ROTATING SADDLE AWAY FROM

SUPPORT PLATE (Rh SIDE ShOWN)

FIG. 31-1

MOUNTING

PLATE

SADDLE

SUPPORT

PLATE

2 PLACES

1/4”

2 PLACES

1/4”

WELDING SUPPORT PLATE TO

MOUNTING PLATE (Rh SIDE ShOWN)

FIG. 31-2

SADDLE

MOUNTING

PLATE

6. When mounting plate is cool to the touch, rotate saddle into place against the support plate

(FIG. 31-3). Bolt the saddle to mounting plate

(FIG. 31-3).

Tighten lock nuts and bolts.

7. Repeat steps 4 through 6 for the LH saddle.

BOLT & FLANGE

LOCK NUT

(2 PLACES)

BOLTING SADDLE TO MOUNTING

PLATE (Rh SIDE ShOWN)

FIG. 31-3

31

STEP 12 - ADJUST PLATFORM (IF REQUIRED)

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. 32-1).

Measure how much the outboard edge of platform rises above bed level

(FIG.

32-1). The outboard edge must be level or a maximum of 1” above bed level

(FIG.

32-1). 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)

OUTBOARD EDGE

0” (LEvEL) - 1” MAX.

VEHICLE

FLOOR (REF)

LEVEL LINE

PLATFORM EDGE AT OR

ABOVE BED LEVEL

FIG. 32-1

2. Compare measurement “A”

(FIG.

32-2) with the distances and shims in TABLE 32-1. For example: If measurement

“A” (FIG. 32-2) is

1” below level and you want to raise outboard edge of platform 1” above level, use 1/8” shim to raise 2”

(TABLE 32-1).

RAISE PLATFORM

EDGE (OUTBOARD)

ThIS DISTANCE (“A”)

1”

2”

3”

4”

REQUIRED SHIM

ThICKNESS

WELD SIZE

“W”

1/16”

1/8”

3/16”

1/4”

1/16”

1/8”

3/16”

1/4”

TABLE 32-1

3. Weld shims (parts bag item) on both platform stops

(FIG. 32-3) to raise outboard edge of platform to correct position.

“A”

LEVEL LINE

EXTENSION

PLATE (REF)

VEHICLE

FLOOR (REF)

PLATFORM EDGE BELOW BED LEVEL

ShACKLE

(REF)

FIG. 32-2

32

NEW SHIM

(TABLE 32-1)

2 PLACES

“W”

(TABLE 32-1)

WELDING ShIMS (CURBSIDE ShOWN)

FIG. 32-3

STEP 12 - ADJUST PLATFORM - Continued

4. Compare measurement “B”

(FIG.

33-1) with distances and grinding depths in TABLE 33-1. For example:

If measurement

“B” (FIG. 33-1) 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 33-1).

“B”

LEVEL LINE

EXTENSION

PLATE (REF)

VEHICLE

FLOOR (REF)

PLATFORM EDGE ABOVE BED LEVEL

FIG. 33-1

LOWER PLATFORM

EDGE (OUTBOARD)

ThIS DISTANCE (“B”)

1”

2”

3”

4”

GRIND METAL

FROM PLATFORM

STOP

1/16”

1/8”

3/16”

1/4”

TABLE 33-1

5. Grind metal from platform stops

(FIG.

33-2) to lower outboard edge of platform to correct position.

ShACKLE

(REF)

GRIND THIS FACE

(SEE TABLE 33-1)

GRINDING PLATFORM STOPS

(CURBSIDE ShOWN)

FIG. 33-2

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. 33-3).

OUTBOARD EDGE

0” (LEvEL) - 1” MAX.

EXTENSION

PLATE (REF)

VEHICLE

FLOOR (REF)

LEVEL LINE

PLATFORM EDGE ABOVE BED LEVEL

FIG. 33-3

33

STEP 13 - 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.

+50 to +120 Degrees F - Grade ISO 32

Below + 70 Degrees F - Grade ISO 15 or MIL-h-5606

See TABLES 35-1 & 35-2 for recommended brands.

1. Unbolt and remove pump cover

(FIG. 34-1).

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. 34-2.

POWER

UNIT

(REF)

LONG SIDE OF

HOLDER FLATS

BUTT AGAINST

COVER

3.

If needed, add fluid to the reservoir as follows. Pull out (no threads) filler cap (FIG.

34-2). Fill the reservoir with hydraulic fluid until reservoir looks about half full

(FIG. 34-

2). Reinstall filler cap (FIG. 34-2).

HEX NUTS

(2 PLACES)

FLAT

WASHERS

(2 PLACES)

PUMP

COVER CAP SCREWS

(2 PLACES)

UNBOLTING / BOLTING PUMP COVER

FIG. 34-1

FILLER

CAP

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.

4. Bolt on the pump cover as shown in

FIG. 34-1. Torque the 5/16”-18 cover bolts from 10 to 14 lbs.-ft.

RESERVOIR

POWER UNIT FLUID LEVEL

FIG. 34-2

HALF

FULL

34

STEP 13 - ChECKING hYDRAULIC FLUID - Continued

MOBIL

ISO 32 HYDRAULIC OIL

RECOMMENDED

BRANDS

AMSOIL

CHEVRON

KENDALL

SHELL

EXXON

PART NUMBER

AWH-05

HIPERSYN 32

GOLDEN MV

TELLUS S2 V32

UNIVIS N-32

DTE-13M, DTE-24,

HYDRAULIC OIL-13

TABLE 35-1

ISO 15

OR MIL-h-5606 HYDRAULIC OIL

RECOMMENDED

BRANDS

PART NUMBER

AMSOIL AWF-05

CHEVRON

KENDALL

SHELL

EXXON

MOBIL

FLUID A, AW-MV-15

GLACIAL BLU

TELLUS S2 V15

UNIVIS HVI-13

DTE-11M

ROSEMEAD THS FLUID 17111

TABLE 35-2

35

STEP 14 - WELD hOOK AND EYE TO LIFTGATE

CAUTION

To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.

1. Stow the Liftgate under hydraulic pressure

(FIG. 36-1).

INBOARD SIDE OF

TUBING ONLY

3/16” hOOK

(WITh ChAIN)

KNUCKLE

BASE OF

PAD EYE ONLY 1/4”

EXTENSION PLATE

PAD EYE

RH SIDE VIEW OF STOWED LIFTGATE

FIG.

36-1

2. Weld the pad eye (from installation parts bag) to knuckle as shown in

FIG.

36-1.

3. Insert the safety hook through the pad eye

(FIG. 36-1). Next, position the safety hook chain on the extension plate as shown in FIG.

36-1. 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.

36

STEP 15 - WELD DOCK BUMPERS TO LIFTGATE

CAUTION

To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.

1. Lower the platform to the ground

(see Operation Manual).

2. Clamp a dock bumper to left hand (LH) side of extension plate as shown in FIG. 37-

1A. Weld the dock bumper to extension plate as shown in FIG. 37-1B. 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

SHARP

CORNERS

2 PLACES

Lh & Rh DOCK

BUMPER

3/16”

EXTENSION

PLATE

BRACE

DOCK BUMPER

3/16”

WELDING ANGLE TO EXTENSION PLATE

FIG. 37-1B

2 PLACES

LH & RH BRACES

LINE UP BOTTOM EDGES AT

THIS POINT

MAIN FRAME

TYPICAL DOCK BUMPER & BRACE

POSITIONING (Lh SIDE ShOWN)

FIG. 37-1A

37

STEP 15 - WELD DOCK BUMPERS TO LIFTGATE -

Continued

3. Clamp open end of brace to dock bumper as shown in

FIG. 38-1A. Clamp closed end of brace to main frame

(FIG. 38-1A). Weld the brace to dock bumper (FIG. 38-1A) and main frame

(FIG. 38-1B). Repeat step for brace and dock bumper on RH side of extension plate.

4. Raise and lower platform. Next, stow Liftgate

(see Operation Manual). Make sure dock bumper does not interfere with Liftgate.

EXTENSION

PLATE

BRACE

DOCK BUMPER

3/16”

2 PLACES

LH & RH BRACES

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. 38-1A

BRACE

(CENTERED

BETWEEN 2 PINS)

PINS

FIG. 38-1B

38

STEP 16 - BOLT RUBBER BUMPERS TO LIFTGATE

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. 39-1).

FLAT WASHER

(1/2”)

CAP SCREW

(1/2”- 20 x 2”)

DOCK

BUMPER

RUBBER

BUMPER

BOLTING RUBBER BUMPER TO DOCK BUMPER

(RIGhT hAND SIDE DOCK BUMPER ShOWN)

FIG. 39-1

HEX NUT

(1/2”- 20)

LOCK WAShER

(1/2”)

39

STEP 17 - VEHICLE TAILLIGHT POSITIONING

(IF REQUIRED)

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.

Install vehicle taillights

(FIG. 40-1) as shown in

FIG. 40-2 and FIG. 40-3.

OPTIONAL

UNDERRIDE

(REFERENCE)

MAIN

FRAME

TAILLIGHTS

VEHICLE TAILLIGHTS INSTALLED ON LIFTGATE

FIG. 40-1

ANGLE STEEL

(NOT SUPPLIED)

PLATFORM OPENER

(REFERENCE)

EXTENSION

PLATE

(REFERENCE)

14”

TAILLIGHTS

TAILLIGhTS POSITION (TOP vIEW)

FIG. 40-2

ANGLE STEEL

(NOT SUPPLIED)

PLATFORM OPENER

(REFERENCE)

OPTIONAL

UNDERRIDE

(REFERENCE)

24” 24”

TAILLIGHT TAILLIGHT

30”

GROUND LEVEL

TAILLIGhTS hORIZONTAL SPACING (FRONT vIEW)

FIG. 40-3

40

DECAL “h” (2 PLACES)

P/N 268308-01

ATTACH DECALS

DECAL “D”

DECAL “F”

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. 41-1

41

ATTACh DECALS - Continued

(See TABLE 42-1)

DECAL SHEET

FIG. 42-1

MODEL DECAL SHEET P/N

GPT-25

GPT-3

GPT-4

GPT-5

268308-01

268308-02

268308-03

268308-04

DECAL SHEET

TABLE 42-1

DECAL “B”

2500 POUNDS

3000 POUNDS

4000 POUNDS

5000 POUNDS

42

TOUCHUP PAINT

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.

43

SYSTEM DIAGRAMS

PUMP & MOTOR SOLENOID OPERATION

MOTOR

POWER UNIT

FIG. 44-1

“A” VALVE

STARTER

SOLENOID

“E” VALVE

POWER UNIT MOTOR & SOLENOID OPERATION

LIFTGATE

FUNCTION

PORT

SOLENOID OPERATION

( MEANS ENERGIZED)

MOTOR

VALVE

“A”

VALVE

“E”

RAISE A -

LOWER B

REFER TO VALVES SHOWN ON

HYDRAULIC SCHEMATIC

TABLE 44-1

-

44

hYDRAULIC SChEMATIC (POWER DOWN)

HYDRAULIC

CYLINDERS

PORT B - LOWER

(POWER DOWN)

VALVE A

PORT A - RAISE

4 GPM FLOW

CONTROL

VALVE

VALVE E

RELIEF VALVE 2

(SET AT 1100 PSI)

RELIEF VALVE 1

(SET AT 3200 PSI)

MOTOR

(REF)

FILTER

PUMP

RESERVOIR

DRAIN HOLE

(PLUGGED)

FIG. 45-1

45

AUX. HAND

PUMP PORT

(PLUGGED)

ELECTRICAL SChEMATIC (POWER DOWN)

RED

(UP)

CONTROL SWITCH

GREEN

GREEN

CABLE

ASSEMBLY

THERMAL

SWITCH

(IN MOTOR

CASING)

(DOWN)

WHITE

WHITE

STARTER

SOLENOID

WHITE

GREEN

CABLE WITH

175 AMP FUSE

BLACK

BLACK

SOLENOID,

VALVE A

RED

SOLENOID,

VALVE E

FIG. 46-1

BATTERY

46

OPTIONS

OPTIONAL LIFTGATE COMPONENTS

MISCELLANEOUS KITS

PART NUMBER

IN CAB ON-OFF SWITCH 250477

LOW VOLTAGE SWITCH (LVS), GPT 267494-01

FRAMELESS TRAILER SUBFRAME MOUNTING KIT

102” WIDE TRAILER

CIRCUIT BREAKER (150 AMP)

HAND PUMP, GPT POWER DOWN

GREASE-ABLE PINS (GPT-25 & GPT-3 ONLY)

FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS

280010

263552

251576

267491-01

281946-01

282372-01

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

STREET SIDE CONTROL, 4-WIRE MOLDED SWITCH

DUAL SWITCH CONTROL, 4-WIRE MOLDED SWITCH

263260-04

265378

265380

BUMPER/UNDERRIDE KITS

UNDERRIDE (GPT-4 & GPT-5 ONLY)

UNDERRIDE (GPT-25 & GPT-3 ONLY)

LIFTGATE BUMPER (ALL GPT MODELS)

2 STEP DOCK BUMPER

DOCK BUMPER, 2-STEP

266043-01

266042-01

265860-01

266220-01

BATTERY BOX KITS

TRUCK BATTERY BOX WITHOUT BATTERY (FOR 6V BATTERY)

TRUCK BATTERY BOX WITHOUT BATTERY (FOR 12V BATTERY)

TRAILER ChARGE LINE KITS

TRAILER, SINGLE POLE CHARGE LINE

TRAILER, DUAL POLE CHARGE LINE

TRAILER, SINGLE & DUAL POLE CHARGE LINE

TRAIL CHARGER

HIGH PERFORMANCE CHARGER

TRACTOR ChARGE LINE KIT

TRACTOR SINGLE POLE CHARGE LINE

TRACTOR DUAL POLE CHARGE LINE

TRACTOR CHARGE LINE WITH ADAPTER

EXTENSION KIT

30’ EXTENSION, SAE, POWER DOWN

251154-03

251154-05

280275-01

280275-02

280275-06

267370-01

267850-01

280275-03

280275-04

280275-05

266389-01

BATTERY

BATTERY, 12V HD (SEALED, MAINTENANCE FREE, GROUP SZ 31) 267318-01

CYCLE COUNTER KIT

CYCLE COUNTER, GPT 280590-02

47

RECOMMENDED LIFTGATE POWER CONFIGURATION

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. 48-1 and on trucks as shown in

FIG. 48-2. See the following page for battery and cable connections.

POWER CABLE

(175 AMP IN-LINE

FUSE ShOWN)

TRAILER-MOUNTED

CIRCUIT BREAKER,

ADDITIONAL RECOM-

MENDED LOCATION

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. 48-1

POWER CABLE

(175 AMP IN-LINE

FUSE ShOWN)

CIRCUIT

BREAKER

TRUCK BATTERY

CIRCUIT BREAKER -

REQUIRED LOCATION

LIFTGATE

LIFTGATE

POWER UNIT

ADDITIONAL BATTERY BOX

- TYPICAL LOCATION

TRUCK BATTERIES

- TYPICAL LOCATION

CHARGE LINE

RECOMMENDED LIFTGATE & BATTERY BOX

INSTALLATION ON TRUCK

FIG. 48-2

48

RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued

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. 49-1.

175 AMP FUSED POWER CABLE

(SEE NOTE)

(+)

BATTERY

CABLES

150 AMP CIRCUIT

BREAKER

150 AMP CIRCUIT BREAKER

(NEAR TRUCK OR

TRACTOR BATTERY AND/OR

NOSE OF TRAILER)

POWER CABLE

TO PUMP BOX

CHARGE LINE TO

TRUCK OR TRACTOR

BATTERY

6 vOLT BATTERY CONNECTIONS

FIG. 49-1

(-) BATTERY

CABLE

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. 49-2.

175 AMP FUSED POWER CABLE

(SEE NOTE)

(+)

BATTERY

CABLES

150 AMP CIRCUIT

BREAKER

150 AMP CIRCUIT BREAKER

(NEAR TRUCK OR

TRACTOR BATTERY AND/OR

NOSE OF TRAILER)

POWER CABLE

TO PUMP BOX

(-) BATTERY

CABLES

12 VOLT BATTERY CONNECTIONS

FIG. 49-2

CHARGE LINE TO

TRUCK OR TRACTOR

BATTERY

49