installation manual

installation manual
M-09-08
REV. A
JANUARY 2011
INSTALLATION MANUAL
GPT-25, GPT-3, GPT-4 & GPT-5
© MAXON Lift Corp. 2011
TABLE OF CONTENTS
WARNINGS ........................................................................................................................... 3
SAFETY INSTRUCTIONS .................................................................................................... 4
NOTICE ................................................................................................................................. 4
STANDARD LIFTGATE COMPONENTS .............................................................................. 5
GPT-SERIES INSTALLATION PARTS BAGS ....................................................................... 6
GPT-SERIES MANUALS & DECALS .................................................................................... 8
VEHICLE REQUIREMENTS ................................................................................................. 9
STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE ....................................................... 12
BOLT EXTENSION PLATE (PRE-DRILLED) ....................................................... 12
WELD EXTENSION PLATE (PRE-DRILLED, ALTERNATE METHOD) .............. 15
WELD EXTENSION PLATE (NOT PRE-DRILLED) ............................................. 16
STEP 2 - WELD LIFTGATE TO VEHICLE .......................................................................... 17
STEP 3 - RUN POWER CABLE .......................................................................................... 23
STEP 4 - CONNECT POWER CABLE ................................................................................ 24
STEP 5 - INSTALL CONTROL SWITCH ............................................................................. 26
STEP 6 - CONNECT POWER CABLE TO BATTERY ......................................................... 29
STEP 7 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS ........................................... 30
STEP 8 - BOLT PLATFORM OPENER TO LIFTGATE........................................................ 31
STEP 9 - FINISH WELDING LIFTGATE TO VEHICLE ....................................................... 34
STEP 10 - ADJUST PLATFORM (IF REQUIRED) .............................................................. 35
STEP 11 - BOLT STEPS TO EXTENSION PLATE (AS EQUIPPED) .................................. 37
STEP 12 - BOLT ON RUBBER BUMPERS (AS EQUIPPED) ............................................. 41
STEP 13 - ADDING HYDRAULIC FLUID ............................................................................ 44
ATTACH DECALS ............................................................................................................... 46
TOUCHUP PAINT ............................................................................................................... 48
SYSTEM DIAGRAMS ......................................................................................................... 49
PUMP & MOTOR SOLENOID OPERATION ....................................................................... 49
HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 50
ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 51
OPTIONS ............................................................................................................................ 52
OPTIONAL LIFTGATE COMPONENTS .............................................................................. 52
RECOMMENDED LIFTGATE POWER CONFIGURATION ................................................ 54
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.
!
WARNING
• Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your
feet are clear of the Liftgate.
• Keep f ngers, 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.
• 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 can result from welds that are done incorrectly.
• Welding on galvanized parts gives off especially hazardous fumes. Comply with WARNING decal
on the galvanized part (FIG. 3-1). To minimize hazard remove galvanizing from weld area, provide
adequate ventilation, and wear suitable respirator.
FIG. 3-1
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WARNINGS
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
• 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.
• 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.
NOTICE
NOTICE
• Maxon Lift is responsible for the instructions to correctly install MAXON Liftgates on
trucks or trailers only.
• Liftgate installers, not Maxon Lift, are responsible for reviewing and complying with all
applicable Federal, State, and Local regulations pertaining to the trailer or truck.
4
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
• Read and understand the instructions in this Installation Manual before installing Liftgate.
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 cservice@maxonlift.com
OPENER ASSEMBLY
EXTENSION PLATE
(BOLT-ON SHOWN)
BOXED COMPONENTS
MAIN
ASSEMBLY
PUMP ASSEMBLY
(COVER IS SHOWN)
TYPICAL LIFTGATE PACKAGED FOR SHIPMENT
FIG. 5-1
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
!
GPT-SERIES INSTALLATION PARTS BAGS
ITEM NOMENCLATURE OR DESCRIPTION
QTY. PART NUMBER
1
FRAME CLIP, 1/2” X 1-3/8”
7
050079
2
FLAT, 2-1/2” X 1” X 1/8” THK.
2
201999
EXTENSION PLATE HARDWARE KIT (96” WIDE VEH)
1
283257-01
EXTENSION PLATE HARDWARE KIT (102” WIDE VEH)
1
283257-02
TEARDROP (1/2”-13 LOCK NUT) (96” WIDE VEH KIT)
13
283700-01
TEARDROP (1/2”-13 LOCK NUT) (102” WIDE VEH KIT)
15
283700-01
HEX FRAME BOLT, 1/2”-13 X 1-3/4” LG. (96” WIDE VEH KIT)
13
901024-1
HEX FRAME BOLT, 1/2”-13 X 1-3/4” LG. (102” WIDE VEH KIT)
15
901024-1
4
HEAT SHRINK TUBING, 3/4” X 1-1/2” LG.
1
253316-04
5
FUSED POWER CABLE, 175 AMP, 38’ LG.
1
264422
6
SHIM, 2-1/2” X 1” X 1/16” THK.
2
264732
7
MOLDED SWITCH ASSEMBLY
1
264951-04
8
SELF-TAPPING SCREW, 10-24 X 1” LG.
4
900057-5
9
CLAMP, #10 RUBBER LOOM
2
801681
10
COPPER LUG (2GA)
1
906497-02
11
BRACKET (INSTALLATION)
2
283307-01
12
LOCK NUT, 1/2”-13
2
901010
13
HEX HEAD CAP SCREW, 1/2”-13 X 1-1/2” LG.
2
900035-3
14
FLAT WASHER, 1/2”
2
902000-13
15
FLANGE LOCK NUT, 1/2”-13
2
901023
16
FRAME HEX BOLT, 1/2”-13 X 2-3/4” LG.
2
901024-9
3
3A
3B
TABLE 6-1
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATES WITH BOLT-ON EXTENSION PLATE (PRE-DRILLED)
GPT-SERIES INSTALLATION PARTS BAGS - Continued
ITEM
NOMENCLATURE OR DESCRIPTION
QTY.
PART NUMBER
1
HEAT SHRINK TUBING, 3/4” X 1-1/2" LG.
1
253316-04
2
MOLDED SWITCH ASSEMBLY
1
264951-04
3
SHIM, 3-1/2” X 1-3/4” X 1/4”
2
264731
4
SHIM, 2-1/2” X 1” X 1/16”
2
264732
5
FLAT, 2-1/2" 1” X 1/8”
2
201999
6
FLAT, 5" X 4” X 3/8”
2
229295
7
COPPER LUG (2GA)
1
906497-02
8
SELF-TAPPING SCREW, 10-24 X 1” LG.
4
900057-5
9
CLAMP, #10 RUBBER LOOM
2
801681
10
FRAME CLIP, 1/2” X 1-3/8”
7
050079
11
FUSED POWER CABLE, 175 AMP, 38’ LG.
1
264422
12
RUBBER DOCK BUMPER KIT
1
203410
TABLE 7-1
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
LIFTGATES WITH WELD-ON EXTENSION PLATE (NOT PRE-DRILLED)
GPT-SERIES MANUALS & DECALS
NOMENCLATURE OR DESCRIPTION
QTY.
PART NUMBER
283256-01 (GPT-3)
REF
DECAL & MANUAL KIT
1
283256-02 (GPT-25)
283256-03 (GPT-4)
283256-04 (GPT-5)
1
INSTALLATION MANUAL
1
M-09-08
2
OPERATION MANUAL
1
M-09-09
3
MAINTENANCE MANUAL
1
M-09-10
282848-01 (GPT-25)
4
DECALS (SEE DECAL PAGES IN THIS MANUAL)
1
282848-02 (GPT-3)
282848-03 (GPT-4)
282848-04 (GPT-5)
TABLE 8-1
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ITEM
NOTE: BODY maximum and minimum operating bed height:
For all GPT models 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. 9-1 & 9-2) on vehicle
to prevent interference between vehicle and Liftgate.
33-3/4”
30-3/16”
14”
22-3/16”
15”
55” MAX. BED HEIGHT
46” MIN. BED HEIGHT
12-5/8” TO 21-5/8”
GPT-25 & GPT-3 CLEARANCES
FIG. 9-1
36”
32-1/2”
14”
24-1/2”
13-3/4”
55” MAX. BED HEIGHT
46” MIN. BED HEIGHT
13”-22”
GPT-4 & GPT-5 CLEARANCES
FIG. 9-2
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
VEHICLE REQUIREMENTS
VEHICLE REQUIREMENTS - Continued
• To prevent aluminum platform from being damaged, make sure vehicle frame
is cut correctly and rear sills are modif ed if over 4-1/8” in height. If the cutouts
are incorrect, platform may hit vehicle frame or underbody when stowing the
Liftgate. If the rear sill is over 4-1/8” in height, bottom of the platform may hit
the sill.
• Installer is responsible for ensuring that vehicle body and frame modif cations
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. 10-1.
NOTE: See the next page for interference areas that can result from rear sills over
TRUCK
4”BODY
in height.
BODY FLOOR
REAR SILL
4-1/8” (SEE CAUTION)
BODY CROSSMEMBERS
6-5/16”
11-3/4”
LONG SILL
PLATFORM CLEARANCE
CUTOUT AREA
(WITHIN DASHED LINES)
WOODEN SPACER
85º
TRUCK
FRAME
20-5/8” (MIN.)
VEHICLE FRAME CUTOUT FOR PLATFORM CLEARANCE
(TRUCK FRAME IS SHOWN)
FIG. 10-1
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CAUTION
3. If the rear sill is over 4-1/8” in height, measure and mark the areas to be modified
on the sill as shown in FIG. 11-1. A side view of the interference areas is shown in
FIG. 11-2.
6-3/4”
(2 PLACES)
CENTER
LINE
40-1/2”
40-1/2”
REAR SILL
4-1/8”
BODY
FRAME
VEHICLE
FRAME
AREA TO
MODIFY
(4 PLACES)
2-1/2”
(4 PLACES)
FRONT VIEW - REAR SILL MORE THAN 4-1/8” IN HEIGHT
(LIFTGATE & EXTENSION PLATE NOT SHOWN)
FIG. 11-1
REAR
SILL
MARK
4-1/8”
MEASURE “H”
NOTE: L= 3.75 x H
“L”
SIDE VIEW - REAR SILL MORE THAN 4-1/8” IN HEIGHT
FIG. 11-2
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VEHICLE REQUIREMENTS - Continued
NOTE: GPT Liftgates may be equipped with two types of extensions plates. The
first type has pre-drilled bolt holes so it can be bolted to vehicle body. Vehicle body must be drilled according to instructions. If necessary, pre-drilled
extension plate may also be welded to vehicle body. The second type of
extension plate is not pre-drilled. Weld it, only, to vehicle body. Do the following bolting or welding instructions that apply to your extension plate.
BOLT EXTENSION PLATE (PRE-DRILLED)
1. Mark and drill holes into rear sill as shown in FIGS. 12-1 and 11-1.
96”
94-1/2”
82”
77”
72”
62”
55”
48”
41”
34”
24”
19”
14”
1-1/4”
1-1/2”
USE 19/32” DRILL
(13 PLACES)
REAR
SILL
HOLE ONLY REQUIRED
WHEN BOLTING
THROUGH CORNER POST.
3-1/8”
HOLE ONLY REQUIRED
WHEN BOLTING
THROUGH CORNER POST.
REAR SILL - HOLE LOCATIONS FOR 96” WIDE VEHICLE
FIG. 12-1
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STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE
102”
100-1/2”
97-1/2”
85”
80”
75”
65”
58”
51”
44”
37”
27”
22”
17”
4-1/2”
1-1/4”
1-1/2”
USE 19/32” DRILL
(13 PLACES)
REAR
SILL
3-1/8”
HOLES ONLY REQUIRED
WHEN BOLTING
THROUGH CORNER POST.
HOLES ONLY REQUIRED
WHEN BOLTING
THROUGH CORNER POST.
REAR SILL - HOLE LOCATIONS FOR 102” WIDE VEHICLE
FIG. 13-1
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STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE Continued
NOTE: Do not tighten extension plate bolts and lock nuts until:
• All the bolts and lock nuts are in place.
• Top of extension plate is flush with top of rear sill.
2. Bolt extension plate to vehicle as shown in FIG. 14-1. If necessary, reposition
extension plate so top surface is flush with top surface of sill. Then, torque bolts
and lock nuts to 105 lb.-ft.
EXTENSION
PLATE
BOLTS
(KIT ITEM)
VEHICLE
BODY
LOCK NUTS
(KIT ITEMS)
IF NO CORNER POST ACCESS FOR
BOLT & NUT, PLUG WELD 1 HOLE FOR
96” WIDE / 2 HOLES FOR 102” WIDE
BOLTING EXTENSION PLATE (96” WIDE EXTENSION PLATE SHOWN)
FIG. 14-1
NOTE: An optional 102” wide extension kit is available for 102” wide vehicles. Refer to
Instruction Sheet M-09-06 supplied with kit.
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE Continued
WELD EXTENSION PLATE (PRE-DRILLED, ALTERNATE METHOD)
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.
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 FIGS. 15-1 and 15-2.
3/16”
3/16”
WELD LENGTH & SPACE:
2”- 11 3/4” ( 96”W VEHICLE)
2”- 12 1/2” (102”W VEHICLE)
EXTENSION
PLATE
VEHICLE
BODY
EXTENSION PLATE WELDS - VIEWED FROM ABOVE
FIG. 15-1
3/16”
EXTENSION
PLATE
VEHICLE
BODY
3/16”
WELD LENGTH & SPACE:
2”- 11 3/4” ( 96”W VEHICLE)
2”- 12 1/2” (102”W VEHICLE)
EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH
FIG. 15-2
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STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE Continued
STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE Continued
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 FIGS. 16-1 and 16-2.
4” LG. LOCATED ABOVE EACH
OF 3 RECTANGULAR TUBES
(TUBES ARE SHOWN SHADED
IN FIG. 16-2)
1/4”
4” LG.
SILL
(PART OF VEHICLE BODY)
1/4”
2” LG. CENTERED
BETWEEN 4” WELDS 1/4”
4” LG.
1/4”
EXTENSION PLATE WELDS - VIEWED FROM ABOVE
FIG. 16-1
1/4”
2” LG, 12 PLACES
EQUAL SPACING 1/4”
(TYP.)
1/4”
MAKE 1” GAP
WHERE SHOWN
MAKE 1” GAP
WHERE SHOWN
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. 16-2
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
WELD EXTENSION PLATE (NOT PRE-DRILLED)
NOTE: GPT Liftgates may be equipped with two types of extensions plates. The
first type has pre-drilled bolt holes so it can be bolted to vehicle body. Bolton installation brackets are provided with parts bags. The second type of
extension plate is not pre-drilled. Weld-on support straps and spacers (flats)
are provided with parts bags.
1. Refer to the following instructions that apply to the
your extension plate. Attach installation brackets or
support straps and spacers to extension plate
BOLT-ON EXTENSION PLATE (PRE-DRILLED)
Bolt 2 installation brackets (parts bag items) on the
extension plate as shown in FIG. 17-1. Tighten hex
nuts securely.
CAP SCREW
1/2”-13 X 1-1/2” LG.
(2 PLACES)
BRACKET
(2 PLACES)
FLAT WASHER
1/2”-13
(2 PLACES)
HEX NUT
1/2”-13
(2 PLACES)
EXTENSION
PLATE
BOLTING ON INSTALLATION BRACKETS
FIG. 17-1
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STEP 2 - WELD LIFTGATE TO VEHICLE
STEP 2 - WELD LIFTGATE TO VEHICLE - Continued
Place 2 temporary support straps (5” x 4” x 3/8”
flats from parts bag) on the extension plate as
shown in FIG. 18-1A. Also, put 2 temporary
spacers (2” x 1” x 1/8” flats from parts bag) between platform and extension plate as shown in
FIG. 18-1B. (Spacers keep 1/8” between platform and extension plate while welding Liftgate
to vehicle frame.) Weld the straps and spacers
to extension plate (FIG. 18-1B).
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. 18-1B
EXTENSION
PLATE
SUPPORT
STRAPS
WELDING ON SUPPORT STRAPS & SPACERS
FIG. 18-1A
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WELD-ON EXTENSION PLATE (NOT PRE-DRILLED)
2. Remove split looms from mounting
plates (FIG. 19-1). (Split looms will be
reinstalled later after final welding.)
MOUNTING
PLATES
SPLIT LOOMS
FIG. 19-1
3. Unfold the platform and flipover (FIG. 19-2).
PLATFORM
(UNFOLDED)
LOCKING ANGLES
(REF)
MOUNTING
PLATES
FLIPOVER
(UNFOLDED)
PLATFORM & FLIPOVER UNFOLDED
FIG. 19-2
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STEP 2 - WELD LIFTGATE TO VEHICLE - Continued
STEP 2 - WELD LIFTGATE TO VEHICLE - Continued
CAUTION
To prevent damage to aluminum f ipover, NEVER hoist the Liftgate by the
f ipover as shown in the NO illustration. Hoist the Liftgate by the platform only
as shown in the YES illustration.
4. Make sure hoist is
not being set up
VEHICLE FLOOR
the incorrect way
(HORIZONTAL)
(FIG. 20-2). Place
FLIPOVER
HOIST CHAIN
MOUNTING
a “C”-clamp on
PLATE
each side of platform as shown
in FIG. 20-1.
(Clamps prevent
C-CLAMP
hoist chain from slipping
PLATFORM
(2 PLACES)
off platform.) Place chain all
PINS
around platform (FIG. 20-1).
(LINED UPVERTICAL)
MAIN FRAME
FLOOR JACK
(CENTERED ON
MAIN FRAME TUBE)
CCORRECT WAY TO HOIST LIFTGATE
FIG. 20-1
5. Hoist the Liftgate.
Then, place floor jack
under main frame
(FIG. 20-1). Jack the
Liftgate into position.
Make sure vehicle
floor is horizontal
and pins are lined up
(FIG. 20-1).
FLIPOVER
HOIST CHAIN
INCORRECT WAY TO HOIST LIFTGATE
FIG. 20-2
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
!
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.
6. Check if both mounting
VEHICLE FRAME CUTOUT
plates line up with the vehicle
(TYPICAL TRUCK FRAME SHOWN)
frame. If the mounting plates
do not line up, remove
the tack welds from one
mounting plate (FIG.
ORIGINAL TACK WELDS
(REMOVE TO REPOSITION
21-1). Make sure LiftMOUNTING PLATE)
gate stays centered on
TACK
vehicle. Reposition the
(TYPICAL - RH & LH
mounting plate against
5/16”
MOUNTING PLATES)
vehicle frame. Tack
MOUNTING
MAIN FRAME
PLATE
weld as shown in FIG.
(CUT-AWAY VIEW)
21-1. Repeat for second
mounting plate (reposiREPOSITIONING MOUNTING PLATE
tion and tack weld).
(RH SIDE SHOWN)
FIG. 21-1
21
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!
NOTE: Weld both mounting plates to
vehicle frame before welding
mounting plates to main frame.
7. Clamp both mounting plates
to vehicle frame. Check
the distance between bed
level and top of main frame.
Maintain the 23-7/8” distance shown in FIG. 22-1.
Weld the mounting plates
to vehicle frame as shown
in FIG. 22-1. Next, weld
both mounting plates to
main frame (FIG. 22-1).
Remove clamps.
2” LG. 4 PLACES
(TYPICAL - RH & LH
MOUNTING PLATES)
BED LEVEL
5/16”
MOUNTING
PLATE
5/16”
VEHICLE FRAME CUTOUT
(TYPICAL TRUCK FRAME SHOWN)
MAIN FRAME
(CUT-AWAY VIEW)
WELD TO VEHICLE FRAME AND MAIN FRAME
(RH SIDE SHOWN)
FIG. 22-1
22
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STEP 2 - WELD LIFTGATE TO VEHICLE - Continued
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, f rst check behind the drilling surface to prevent damage to any
fuel lines, vent lines, brake lines or wires.
NOTE: Make sure cable is long enough to reach positive terminal on Liftgate pump box
without putting tension on the cable.
Install vehicle charge line by running the line along the inside of vehicle frame (FIG.
23-1). Make sure 175 amp fuse (FIG. 23-1) end of cable is by the battery. Run the
charge line from vehicle battery to Liftgate pump box positive terminal. Use frame clips
(parts box item) and plastic ties (as required) from charge line kit to secure cable.
VEHICLE FRAME
CHARGE LINE TO
PUMP BOX OR
BATTERY BOX
175 AMP
FUSE
FRAME
CLIPS
FRONT OF VEHICLE
REAR OF VEHICLE
18” - 24”
SPACING
CHARGE LINE
TO VEHICLE
BATTERY
FIG. 23-1
23
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!
1. Unbolt and remove pump cover
(FIG. 24-1).
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)
UNBOLTING PUMP COVER
FIG. 24-1
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. 24-2A). Measure (if needed), and then cut excess cable from bare wire end of
cable. Put heatshrink tubing (parts bag item) (FIG. 24-2B) 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. 24-2C).
COPPER
TERMINAL
LUG
HEATSHRINK
TUBING
FIG. 24-2B
FIG. 24-2C
FUSED
POWER CABLE
TYPICAL FUSED POWER CABLE ROUTING
FIG. 24-2A
24
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STEP 4 - CONNECT POWER CABLE
STEP 4 - CONNECT POWER CABLE - Continued
Do not over-tighten the terminal nuts on starter solenoid. For the load
terminals, torque nuts to 40 lb.-in. max. Torque the nuts on #10-32 control
terminals 15-20 lb.-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.
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. 251. Reinstall and tighten lock
washer and hex nut.
LOCK
WASHER
HEX NUT
BATTERY
POWER TERMINAL
STARTER
SOLENOID
TYPICAL FUSED POWER
CABLE ELECTRICAL CONNECTION
FIG. 25-1
25
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CAUTION
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. 26-1A. Use template shown in
FIG. 26-1B.
VEHICLE BODY
VERTICAL POST
(CURB SIDE)
18”
FIG. 26-1A
7/8”
1-3/4”
HOLE DRILLING TEMPLATE
FIG. 26-1B
WIRING
HARNESS
GROMMET
TIE
STRAP
NOTE: Hydraulic lines and electrical lines
must run into pump box through
sealing grommets (FIG. 26-2). To
ensure a good seal on hydraulic &
electrical lines, never cut the sealing
grommets.
2. Cut tie strap on coiled wiring harness
(FIG. 26-2). Pull the wiring harness through grommet on the pump
mounting plate (FIG. 26-2).
PUMP MOUNTING
PLATE
FIG. 26-2
26
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 5 - INSTALL CONTROL SWITCH
STEP 5 - INSTALL CONTROL SWITCH - Continued
3. Run wiring harness under
vehicle body (see dashed
line - FIG. 27-1) and up
through inside of vertical
post. Pull control switch
wiring harness out the 3/4“
hole drilled in vertical post
(FIG. 27-1). Connect the
control switch wiring to the
wiring harness as shown
in FIG. 27-2. 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.
27-2).
WIRING HARNESS
3/4” HOLE
VEHICLE BODY
VERTICAL POST
PUMP BOX
ROUTING CONTROL SWITCH WIRING
FIG. 27-1
CONTROL SWITCH
BLACK
BLACK
WHITE
WHITE
DECAL
(SEE DECALS PAGE)
SCREW,
SELF-TAPPING
GREEN
GREEN
RED
CONTROL SWITCH WIRING CONNECTIONS
FIG. 27-2
27
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NOTE: MAXON recommends using dielectric grease on all electrical connections.
STEP 5 - INSTALL CONTROL SWITCH - Continued
Pump cover must be correctly secured to prevent it from becoming a hazard.
To secure pump cover, the long side of the holder f ats must butt against
pump cover as shown in the illustration.
4. Bolt on the pump cover as shown in
FIG. 28-1. Torque the 5/16”-18 cover
bolts from 10 to 14 lb.-ft.
POWER UNIT
(REF)
HEX NUTS
(2 PLACES)
FLAT
WASHERS
(2 PLACES) PUMP
COVER
LONG SIDE OF
HOLDER FLATS
BUTT AGAINST
COVER
CAP SCREWS
(2 PLACES)
BOLTING ON PUMP COVER
FIG. 28-1
28
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
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. 29-1). Reinstall and tighten nut.
POSITIVE (+)
BATTERY TERMINAL
FUSED
POWER CABLE
BOLT
NUT
CONNECTING POWER CABLE
FIG. 29-1
29
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 f uid 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 lift arms and
shipping bolt must be removed from both knuckles.
2. Remove locking angles from lift arms (FIG. 30-1A).
3. With platform open (FIG. 30-1A), unbolt each knuckle as shown in FIG. 30-1B.
LOCKING
ANGLES
PLATFORM
(UNFOLDED)
FLIPOVER
(UNFOLDED)
FIG. 30-1A
BOLT
LOCK
WASHER
FLAT
WASHER
UNBOLTING KNUCKLE
FIG. 30-1B
30
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CAUTION
1. Remove floor jack and hoist
supporting Liftgate (FIG. 31-1).
FLOOR JACK
FIG. 31-1
2. Lower the platform to the ground.
Remove both installation brackets,
or support straps and spacers, from
extension plate (FIG. 31-2).
BRACKET & FASTENERS
(2 PLACES)
EXTENSION PLATE
PLATFORM
REMOVING INSTALLATION BRACKETS
(BOLT-ON EXTENSION PLATE SHOWN)
FIG. 31-2
3. Bolt opener (parts bag
items) to bracket on the
main frame as shown in FIG.
31-3. Then, torque bolts
and lock nuts to 105 lb.-ft.
BOLT,
1/2”-13 X 2-3/4” LG.
OPENER
FLANGE LOCK
NUT, 1/2”-13
OPENER
BRACKET
MAIN
FRAME
BOLTING ON OPENER
FIG. 31-3
31
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STEP 8 - BOLT PLATFORM OPENER TO LIFTGATE
If there is any interference with the platform while stowing Liftgate, check for
damage on bottom of platform, f ipover, and the hinge in between. A damaged
platform or f ipover 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
CHECKING FOR MINIMUM CLEARANCES BETWEEN PLATFORM &
MODIFIED AREAS ON REAR SILL
(EXTENSION PLATE NOT SHOWN)
FIG. 32-1
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. 32-1.
4. Stow and unfold Liftgate several times
to verify there is no interference. If you
notice the platform lowering with a jerking motion, do step 5 on the next page.
32
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STEP 8 - BOLT PLATFORM OPENER TO LIFTGATE
- Continued
! CAUTION
5. 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 (FIG.
33-1). Raise the platform (FIG. 33-2).
Repeat this step until there is no air left in the
system and platform lowers smoothly.
LOWERING PLATFORM
FIG. 33-1
RAISING PLATFORM
FIG. 33-2
33
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STEP 8 - BOLT PLATFORM OPENER TO LIFTGATE
- Continued
STEP 9 - FINISH WELDING LIFTGATE TO VEHICLE
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. 34-1A).
VEHICLE FRAME CUTOUT
(DASHED LINES)
MOUNTING PLATE
5/16”
VEHICLE FRAME
(TYPICAL TRUCK FRAME
SHOWN)
TYPICAL
- BOTH
MOUNTING
PLATES
WELDING MOUNTING PLATE
FIG. 34-1A
FIBERGLASS
SLEEVES
2. After welding is done and mounting plates are cool, remove the 4
fiberglass sleeves shown in FIG.
34-1B. Next, reinstall the split
looms removed in STEP 2 (FIG.
34-1B).
SPLIT
LOOMS
FIBERGLASS
SLEEVES
MOUNTING
PLATES (REF)
REINSTALLING SPLIT LOOMS
FIG. 34-1B
34
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CAUTION
NOTE: Before doing the following procedure, make sure vehicle is parked
on level ground.
EXTENSION
PLATE (REF)
1. With the platform and flipover unfolded,
OUTBOARD EDGE
VEHICLE
1” MAX (UP TO 53” BED HT.)
raise platform to bed level (FIG. 35-1).
FLOOR (REF)
0” LEVEL (OVER 53” BED HT.)
Measure how much the outboard edge
of platform rises above bed level (FIG.
35-1). The outboard edge must be level
or a maximum of 1” above bed level (FIG. LEVEL LINE
35-1). If indication is correct, Liftgate is
installed correctly and no adjustment is
PLATFORM EDGE AT OR
needed. If the outboard edge is below
ABOVE BED LEVEL
bed level, do instructions 2, 3, and 6. If
FIG. 35-1
outboard edge is higher than 1”, do instructions 4 through 6.
EXTENSION
PLATE (REF)
2. Compare measurement “A” (FIG.
35-2) with the distances and shims
in TABLE 35-1. For example: If
measurement “A” (FIG. 35-2) is
1” below level and you want to raise
outboard edge of platform 1” above
level, use 1/8” shim to raise 2”
(TABLE 35-1).
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”)
VEHICLE
FLOOR (REF)
“A”
LEVEL LINE
PLATFORM EDGE BELOW BED LEVEL
FIG. 35-2
SHACKLE
(REF)
TABLE 35-1
3. Weld shims (parts bag item) on both
platform stops (FIG. 35-3) to raise
outboard edge of platform to correct
position.
NEW SHIM
(TABLE 35-1)
2 PLACES
“W”
(TABLE 35-1)
WELDING SHIMS (CURBSIDE SHOWN)
FIG. 35-3
35
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STEP 10 - ADJUST PLATFORM (IF REQUIRED)
4. Compare measurement “B” (FIG.
36-1) with distances and grinding
depths in TABLE 36-1. For example:
If measurement “B” (FIG. 36-1) 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 36-1).
LOWER PLATFORM
EDGE (OUTBOARD)
THIS DISTANCE (“B”)
GRIND METAL
FROM PLATFORM
STOP
1”
1/16”
2”
1/8”
3”
3/16”
4”
1/4”
EXTENSION
PLATE (REF)
“B”
VEHICLE
FLOOR (REF)
LEVEL LINE
PLATFORM EDGE ABOVE BED LEVEL
FIG. 36-1
TABLE 36-1
5. Grind metal from platform stops (FIG.
36-2) to lower outboard edge of platform to correct position.
SHACKLE
(REF)
GRIND THIS FACE
(SEE TABLE 36-1)
GRINDING PLATFORM STOPS
(CURBSIDE SHOWN)
FIG. 36-2
OUTBOARD EDGE
1” MAX (UP TO 53” BED HT.)
0” LEVEL (OVER 53” BED HT.)
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. 36-3).
EXTENSION
PLATE (REF)
VEHICLE
FLOOR (REF)
LEVEL LINE
PLATFORM EDGE ABOVE BED LEVEL
FIG. 36-3
36
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STEP 10 - ADJUST PLATFORM - Continued
NOTE: GPT Liftgates may be equipped with two types of extensions plates. The
first type has pre-drilled bolt holes so it can be bolted to vehicle body. Bolton 2-step dock bumpers are provided. The second type of extension plate
(not pre-drilled) is welded on. A weld-on 2-step dock bumper kit, with separate installation instructions, is provided. The following instructions only apply to bolt-on, 2-step dock bumpers for bolt-on extension plate. If you have
the weld-on extension plate (not pre-drilled) and 2-step dock bumper kit,
refer to Instruction Sheet M-02-16.
1. Lower platform to the ground
(FIG. 37-1).
PLATFORM LOWERED TO GROUND
FIG. 37-1
!
WARNING
To prevent personal injury and
equipment damage, keep the
Liftgate from being operated while
installing steps on extension plate.
2. Disconnect power from pump box by
removing positive (+) battery terminal
connector and disconnect power cable
(FIG. 37-2). Reinstall nut on positive
(+) battery terminal connector.
POSITIVE (+) BATTERY
TERMINAL
FUSED POWER
CABLE
BOLT
NUT
DISCONNECTING POWER
FIG. 37-2
37
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STEP 11 - BOLT STEPS TO EXTENSION PLATE
(AS EQUIPPED)
NOTE: If 102” extension kit is to be installed for 102” wide vehicle, install the extension kit before installing the steps. Refer to Instruction Sheet M-09-06
for installing the extensions.
3. Line up the step (Kit item) on side
of the extension plate. Bolt it to the
extension plate (FIG. 38-1).
PART OF
EXTENSION
PLATE
LOCK NUT
PART OF
STEP
1-1/4” LG
FRAME BOLT
1-1/4” LG
FRAME BOLT
(3 PLACES)
LOCK NUT
(3 PLACES)
LH STEP
BOLTING STEP TO EXTENSION PLATE
(LH STEP SHOWN)
FIG. 38-1
38
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STEP 11 - BOLT STEPS TO EXTENSION PLATE
(AS EQUIPPED) - Continued
4. Bolt the support (Kit item) to
mounting channel (Kit item)
(FIG. 39-1).
REAR SILL
I-BEAM
(VEHICLE BODY)
1” SPACER
(SEE NOTE)
MOUNTING
CHANNEL
LOCK NUT
(2 PLACES)
1-1/4” LG
FRAME BOLT
(2 PLACES)
SUPPORT
LH STEP
SLOTTED
HOLE
1-1/4” OR 2-1/4” LG
FRAME BOLT
(2 PLACES,
SEE NOTE)
LOCK NUT
(2 PLACES)
BOLTING SUPPORT TO MOUNTING CHANNEL &
STEP (LH STEP & SUPPORT SHOWN)
FIG. 39-1
5. Butt the flat part of the mounting
channel against bottom of vehicle
rear sill and I-beams. Then, butt the
support against back of the step
(FIG. 39-1).
NOTE: If holes in the support and
slotted holes in the step cannot be lined up, use 1” spacer
and 2-1/4” long frame bolts
(Kit items) as illustrated.
6. Ensure holes in the support are lined
up with the slotted holes on the step
(FIG. 39-1). Then, bolt the support to
step (FIG. 39-1). Torque the 4 lock
nuts (FIG. 39-1) from 85 to 128 lb-in
force.
39
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 11 - BOLT STEPS TO EXTENSION PLATE
(AS EQUIPPED) - Continued
NOTE: Before welding mounting channel to
vehicle body, ensure step is straight
and steps are in vertical position.
7. Weld the flat part of the mounting
channel to vehicle body as shown
in FIG. 40-1.
WELD TO AS MUCH
I-BEAM FLANGE &
REAR SILL AS POSSIBLE
3/16”
REAR SILL
I-BEAM
(VEHICLE BODY)
WELDING FLAT OF MOUNTING CHANNEL
TO VEHICLE BODY (LH STEP SHOWN)
FIG. 40-1
8. Repeat instructions 3 through 7
for RH step.
POSITIVE (+) BATTERY
TERMINAL
FUSED POWER
CABLE
BOLT
NUT
9. Remove nut from positive (+)
battery terminal connector. Reconnect the fused power cable to
positive (+) battery terminal connector (FIG. 40-2). Reinstall and
tighten nut.
RECONNECTING POWER
FIG. 40-2
40
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 11 - BOLT STEPS TO EXTENSION PLATE
(AS EQUIPPED) - Continued
NOTE: Rubber dock bumper kits P/N 203410 and P/N 281305-01 contain 2 rubber
bumpers with 2 sets of bushings, and 2 sets of fasteners for each bumper. Illustrations in FIGS. 41-1, 42-1 & 43-1 show how to bolt rubber bumpers to the
bolt-on and weld-on dock bumpers.
NOTE: Rubber bumpers in Kit P/N 203410 can be bolted to the bolt-on dock bumpers
in a high-mount or low-mount position as illustrated below.
• For steps equipped with lights or vehicle with low bed height, use low mount
position.
• For standard steps (no lights) or vehicle with high bed height, use high
mount position.
If necessary, bumpers from 2 kits can be bolted in the high and low positions.
NOTE: Ensure tops of 4 bushings are flush with top of bolt holes in each bumper.
Bolt a rubber bumper to each of the 2 dock bumpers (FIG. 41-1). Torque the 4 hex nuts
(FIG. 41-1) from 21 to 32 lb-ft force.
EXTENSION PLATE
(REFERENCE)
MAIN FRAME
(REFERENCE)
1/2”-20 HEX NUT
(2 PLACES)
HIGH
LOW
1/2”-20 HEX NUT
(2 PLACES)
BUMPER
BUSHING
(2 PLACES)
BUMPER
1/2”-20 BOLT
(2 PLACES)
1/2”
FLAT WASHER
(2 PLACES)
1/2” X 1-1/4” O.D.
FLAT WASHER
(2 PLACES)
1/2”
LOCK WASHER
(2 PLACES)
1/2”
FLAT WASHER
(2 PLACES)
1/2” LOCK WASHER
(2 PLACES)
1/2”-20 BOLT
(2 PLACES)
1/2” X 1-1/4” O.D.
FLAT WASHER
(2 PLACES)
BUSHING
(2 PLACES)
BOLTING RUBBER BUMPERS TO BOLT-ON DOCK BUMPERS
(KIT P/N 203410 SHOWN WITH BUMPERS AT LOW-MOUNT POSITION)
FIG. 41-1
41
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 12 - BOLT ON RUBBER BUMPERS (AS EQUIPPED)
NOTE: The rubber dock bumpers kit P/N 203410 contains 2 rubber bumpers, 2 sets
of bushings, and 2 sets of fasteners.
NOTE: Ensure tops of 4 bushings are flush with top of bolt holes in each bumper.
Bolt a rubber bumper to each of the 2 dock bumpers angles (FIG. 42-1). Torque the 4 hex
nuts (FIG. 42-1) from 21 to 32 lb-ft force.
1/2”-20 HEX NUT
(2 PLACES)
1/2” X 1-1/4” O.D.
FLAT WASHER
(2 PLACES)
BUSHING
(2 PLACES)
1/2”
LOCK WASHER
(2 PLACES)
1/2”
FLAT WASHER
(2 PLACES)
1/2”-20 BOLT
(2 PLACES)
DOCK
BUMPER ANGLE
RUBBER
BUMPER
BOLTING RUBBER BUMPER TO WELD-ON DOCK BUMPER
(KIT P/N 203410 SHOWN WITH RIGHT HAND SIDE DOCK BUMPER)
FIG. 42-1
42
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STEP 12 - BOLT ON RUBBER BUMPERS (AS EQUIPPED)
- Continued
NOTE: Ensure tops of 4 bushings are flush with top of bolt holes in each bumper.
Bolt a rubber bumper to each of the 2 dock bumpers (FIG. 43-1). Torque the 4 lock nuts
(FIG. 43-1) from 21 to 32 lb-ft force.
EXTENSION PLATE
(REFERENCE)
MAIN FRAME
(REFERENCE)
BUMPER
BUMPER
1/2”-13
FLANGE
LOCK NUT
(2 PLACES)
BUSHING
(2 PLACES)
1/2”-13 BOLT
(2 PLACES)
1/2”-13
FLANGE
LOCK NUT
(2 PLACES)
1/2”-13 BOLT
(2 PLACES)
BUSHING
(2 PLACES)
BOLTING RUBBER BUMPERS TO BOLT-ON DOCK BUMPERS
(KIT P/N 281305-01 IS SHOWN)
FIG. 43-1
43
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 12 - BOLT ON RUBBER BUMPERS (AS EQUIPPED)
- Continued
STEP 13 - ADDING HYDRAULIC FLUID
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic f uid reservoir f ller 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 45-1 & 45-2 for recommended brands.
1. Unbolt and remove pump cover
(FIG. 44-1).
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. 44-2.
HEX NUTS
(2 PLACES)
FLAT
WASHERS
(2 PLACES)
3. If needed, add fluid to the reservoir as
follows. Pull out (no threads) filler cap
(FIG. 44-2). Fill the reservoir with hydraulic fluid until reservoir looks about
half full (FIG. 44-2). Reinstall filler cap
(FIG. 44-2).
PUMP
COVER CAP SCREWS
(2 PLACES)
UNBOLTING / BOLTING PUMP COVER
FIG. 44-1
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 f ats
must butt against pump cover as
shown in the illustration.
RESERVOIR
HALF
FULL
4. Bolt on the pump cover as shown in
FIG. 44-1. Torque the 5/16”-18 cover
bolts from 10 to 14 lb-ft.
POWER UNIT FLUID LEVEL
FIG. 44-2
44
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
ISO 32 HYDRAULIC OIL
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 45-1
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 45-2
45
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
STEP 13 - ADDING HYDRAULIC FLUID - Continued
DECAL “H” (2 PLACES)
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. 46-1
46
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH DECALS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ATTACH DECALS - Continued
DECAL SHEET
FIG. 47-1
MODEL
DECAL SHEET P/N
DECAL “B”
GPTB-25
282848-01
2500 POUNDS
GPTB-3
282848-02
3000 POUNDS
GPTB-4
282848-03
4000 POUNDS
GPTB-5
282848-04
5000 POUNDS
DECAL SHEET
TABLE 47-1
47
TOUCHUP PAINT
Damaged cylinder seals and contaminated hydraulic f uid 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 908134-01.
48
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
CAUTION
SYSTEM DIAGRAMS
PORT A
MOTOR
“A” VALVE
“E” VALVE
STARTER
SOLENOID
PORT B
POWER UNIT
FIG. 49-1
NOTE: Hydraulic lock valve is on the RH cylinder.
POWER UNIT MOTOR & SOLENOID OPERATION
LIFTGATE
FUNCTION
PORT
SOLENOID OPERATION
( MEANS ENERGIZED)
MOTOR
RAISE
A
LOWER
B
VALVE
“A”
VALVE
“E”
-
-
REFER TO VALVES SHOWN ON
HYDRAULIC SCHEMATIC
TABLE 49-1
49
LOCK
VALVE
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
PUMP & MOTOR SOLENOID OPERATION
HYDRAULIC
CYLINDERS
HYDRAULIC
LOCK VALVE
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 2750 PSI)
MOTOR
(REF)
PUMP
FILTER
RESERVOIR
DRAIN HOLE
(PLUGGED)
FIG. 50-1
50
AUX. HAND
PUMP PORT
(PLUGGED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
HYDRAULIC SCHEMATIC (POWER DOWN)
RED
(DOWN)
(UP)
BLACK
WHITE
CONTROL SWITCH
GREEN
WHITE
RED
BLACK
GREEN
CABLE
ASSEMBLY
WHITE
WHITE
THERMAL
SWITCH
(IN MOTOR
CASING)
BLACK
SOLENOID,
VALVE A
STARTER
SOLENOID
BLACK
WHITE
GREEN
CABLE WITH
175 AMP FUSE
BATTERY
FIG. 51-1
51
SOLENOID,
LOCK VALVE
BLACK
SOLENOID,
VALVE E
BLACK
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
ELECTRICAL SCHEMATIC (POWER DOWN)
OPTIONS
MISCELLANEOUS KITS
PART NO.
IN CAB ON-OFF SWITCH
250477
LOW VOLTAGE THERMAL SWITCH (LVTS), GPT
282473-01
FRAMELESS TRAILER BRACKET MOUNTING
282665-01
CIRCUIT BREAKER (150 AMP)
251576
HAND PUMP, GPT POWER DOWN
283330-01
TRAFFIC CONES
268893-01
FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS
282372-01
GROUND CABLE, 2 GA UGE X 38’ LG.
269190-01
EXTRA CONTROLS & CONTROL KITS
HAND HELD CONTROL, POWER DOWN
263260-11
STREET SIDE CONTROL, POWER DOWN
280265-04
DUAL SWITCH CONTROL, POWER DOWN
264845-02
BUMPER/UNDERRIDE KITS
UNDERRIDE, (GPT-4 & GPT-5, 102” W VEH ONLY) NOTE: MEETS FMVSS & CANADIAN SAFETY REGS.
282838-01
UNDERRIDE, (GPT-4 & GPT-5, 96” W VEH ONLY) NOTE: MEETS FMVSS & CANADIAN SAFETY REGS.
282838-01-90
UNDERRIDE (GPT-25 & GPT-3, 102” W VEH ONLY) NOTE: MEETS FMVSS REAR IMPACT GUARD ONLY
282838-02
UNDERRIDE (GPT-25 & GPT-3, 96” W VEH ONLY) NOTE: MEETS FMVSS REAR IMPACT GUARD ONLY
282838-02-90
LIFTGATE BUMPER (ICC-STYLE, ALL GPT & GPTWR MODELS)
282734-01
2 STEP DOCK BUMPER KIT
STEP WITH OVAL LIGHTS (GPT & GPTWR WITH BOLT-ON EXTENSION PLATE, ONLY)
283997-02
STEP
(GPT & GPTWR WITH BOLT-ON EXTENSION PLATE, ONLY)
283997-01
2-STEP DOCK BUMPER
(GPT & GPTWR WITH WELD-ON EXTENSION PLATE, ONLY)
266220-01
RUBBER DOCK BUMPER
203410
RUBBER DOCK BUMPER (GPTLR)
281305-01
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
267580-01
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
BATTERY
BATTERY, 12V HD (SEALED, MAINTENANCE FREE, GROUP SZ 31)
267318-01
CYCLE COUNTER KIT
CYCLE COUNTER, GPT
282520-01
52
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
OPTIONAL LIFTGATE COMPONENTS
EXTENSION 102” KIT
EXTENSION 102”
283134-01
LIGHT KITS FOR 2 STEP DOCK BUMPERS (LISTED ABOVE)
OVAL LED LIGHTS (CONTAINS 4 GROTE SERIES 60 LIGHTS)
265926
OVAL LED LIGHTS (CONTAINS 4 TRUCK-LITE LIGHTS)
266945-01
TOUCH-UP PAINT KIT
TOUCH-UP PAINT (BCG) WITH ALUMINUM PRIMER, SMALL
53
908134-01
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
OPTIONAL LIFTGATE COMPONENTS - Continued
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. 54-1 and
on trucks as shown in
FIG. 54-2. See the following page for battery
and cable connections.
TRAILER-MOUNTED
CIRCUIT BREAKER,
ADDITIONAL RECOMMENDED LOCATION
POWER CABLE
(175 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. 54-1
TRUCK BATTERY
CIRCUIT BREAKER REQUIRED LOCATION
POWER CABLE
(175 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. 54-2
54
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. 55-1.
(+)
BATTERY
CABLES
150 AMP CIRCUIT BREAKER
(NEAR TRUCK OR
150 AMP CIRCUIT
TRACTOR
BATTERY AND/OR
BREAKER
NOSE OF TRAILER)
175 AMP FUSED POWER CABLE
(SEE NOTE)
CHARGE LINE TO
TRUCK OR TRACTOR
BATTERY
POWER CABLE
TO PUMP BOX
(-) BATTERY
CABLE
6 VOLT BATTERY CONNECTIONS
FIG. 55-1
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. 55-2.
150 AMP CIRCUIT
(+)
BREAKER
BATTERY
CABLES
150 AMP CIRCUIT BREAKER
(NEAR TRUCK OR
TRACTOR BATTERY AND/OR
NOSE OF TRAILER)
175 AMP FUSED POWER CABLE
(SEE NOTE)
CHARGE LINE TO
TRUCK OR TRACTOR
BATTERY
POWER CABLE
TO PUMP BOX
(-) BATTERY
CABLES
12 VOLT BATTERY CONNECTIONS
FIG. 55-2
55
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued
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