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Maxon GPTWR-25 Installation Manuals

Gpt series
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See also: Operating Manual
M-17-06
JULY 2017
To fi nd maintenance & parts information for your GPTWR Liftgate,
go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY &
GPTWR buttons. Open the Maintenance Manual in the PRODUCT
DOCUMENTATION window. For parts, click on the PARTS PORTAL,
TUK-A-WAY & GPTWR buttons.
© MAXON Lift Corp. 2017

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Summary of Contents for Maxon GPTWR-25

  • Page 1 To fi nd maintenance & parts information for your GPTWR Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY & GPTWR buttons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A-WAY & GPTWR buttons. © MAXON Lift Corp. 2017...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SUMMARY OF CHANGES: M-17-06 ................... 4 WARNINGS ........................... 5 SAFETY INSTRUCTIONS ....................6 NOTICE ..........................6 STANDARD LIFTGATE COMPONENTS ................7 GPTWR INSTALLATION PARTS BOX .................. 8 GPTWR-SERIES MANUALS & DECALS................9 VEHICLE REQUIREMENTS ....................10 CENTER OF MASS ......................13 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE ............
  • Page 3 APPLY DECALS ......................... 60 DECALS & PLATES ......................62 TOUCH-UP PAINTED OR GALVANIZED FINISH .............. 63 SYSTEM DIAGRAMS ......................64 PUMP & MOTOR SOLENOID OPERATION ............... 64 HYDRAULIC SCHEMATIC (POWER DOWN) ..............65 ELECTRICAL SCHEMATIC (POWER DOWN) ..............66 GPTWR ELECTRICAL VALUES ..................67 OPTIONS ..........................

  • Page 4: Summary Of Changes: M-17-06

    SUMMARY OF CHANGES: M-17-06 PAGE DESCRIPTION OF CHANGE Changed WARNING for welding galvanized steel to reference AWS D19.0. Main assembly shows new bolt-on mounting plates. Added Installation Parts Box Tables A, B & C. Added new molded, toggle switch assembly, Added new 1/2” X 5/16” fl at washer, 1-1/2” long self-tapping screws for control switch assembly, and 1/2”...

  • Page 5: Warnings

    Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates. See Operation Manual for operating safety requirements. WARNINGS WARNING • Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your feet are clear of the Liftgate. •...

  • Page 6: Safety Instructions

    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.

  • Page 7: Standard Liftgate Components

    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...

  • Page 8: Gptwr Installation Parts Box

    GPTWR INSTALLATION PARTS BOX ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER REF PARTS BOX A 297502-01 SPRING CLIP, 1/2” x 1-3/8” 050079 PLASTIC TIE 206864 #10 RUBBER LOOM CLAMP 801681 CABLE ASSEMBLY, 175 AMPS, 38 FT LG. 264422 SELF-TAPPING SCREW, 10 X 1/2” LG. 030458 GROUND CABLE ASSEMBLY, 2 GA X 48”...

  • Page 9: Gptwr-Series Manuals & Decals

    Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A-WAY & GPTWR buttons. ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER 297225-11 (GPTWR-25) 297225-12 (GPTWR-3) DECAL & MANUAL KIT 297225-13 (GPTWR-4) 297225-14 (GPTWR-5) INSTALLATION MANUAL (GPTWR) M-17-06 OPERATION MANUAL (GPT &...

  • Page 10: Vehicle Requirements

    Liftgate. 29-5/8” 15” 22” 14-3/4” 23-7/8” 55” MAX. BED HEIGHT 49” LOADED BED HEIGHT 12” 15-5/8” TO 21-5/8” GPTWR-25 & GPTWR-3 LIFTGATE CLEARANCE DIMENSIONS FIG. 10-1 39-1/2” 35-5/16” 27-7/8” 15” 22” 13-5/16” 22-3/8” 55” MAX. BED HEIGHT 49” LOADED BED HEIGHT 12”...
  • Page 11 VEHICLE REQUIREMENTS - Continued 2. Check for correct clearances between walk ramp, walk ramp box, and the extension plate (FIGS. 11-1A and 11-1B) to prevent interference. NOTCH (4 PLACES) 27-1/2” 20-1/2” 2-1/4” 2-1/4” EXTENSION PLATE 1-1/2” 1-1/2” SILL 8-3/8” 9-3/16” RAMP WALK RAMP PAD WALK RAMP...
  • Page 12 VEHICLE REQUIREMENTS - Continued WARNING Incorrect modifi cation of vehicle frame and/or body could contribute to serious mechanical failure of the vehicle. Serious injury to operator, motorists, and bystanders could result. Installer is responsible for ensuring vehicle body and frame modifi cation do not adversely affect the integrity of the body and frame. If unsure about modifying vehicle, installer should consult truck/trailer body manufacturer.

  • Page 13: Center Of Mass

    CENTER OF MASS CENTER OF MASS 10-1/4” 11-1/2” GPTWR-25 & GPTWR-3 CENTER OF MASS (PLATFORM AT BED HEIGHT) FIG. 13-1 17-1/4” CENTER OF MASS 16-1/8” GPTWR-25 & GPTWR-3 CENTER OF MASS (STOWED POSITION) FIG. 13-2...
  • Page 14 CENTER OF MASS - Continued CENTER OF MASS 11-3/8” 11-3/16” GPTWR-4 & GPTWR-5 CENTER OF MASS (PLATFORM AT BED HEIGHT) FIG. 14-1 CENTER OF MASS 22-3/4” 16-3/16” GPTWR-4 & GPTWR-5 CENTER OF MASS (STOWED POSITION) FIG. 14-2...

  • Page 15: Step 1 - Attach Extension Plate To Vehicle

    CAUTION To preserve the corrosion-resistant properties of the galvanized fi nish, MAXON recommends bolting the galvanized extension plate to vehicle. NOTE: GPTWR Liftgate extension plate comes with bolt holes so it can be bolted to vehicle body with optional bolt kit. GRADE 8 bolts are re- quired.
  • Page 16 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued 102” 100-1/2” 95-1/2” 85” 80” 75” 65” 58” 51” 44” 37” 27” 22” 17” 1-1/4” 1-1/2” 6-1/2” 6-1/2” USE 9/16” DRILL REAR (19 PLACES) SILL 3-1/8” REAR SILL - HOLE LOCATIONS FOR 102” WIDE VEHICLE FIG.
  • Page 17 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued CAUTION CAUTION The mating surface between the bolt-on extension plate and vehicle rear sill must be as fl at as possible. Interference between the mating surfaces could result in a distorted top surface of extension plate when all the bolts are tightened.

  • Page 18: Weld Extension Plate (Alternate Method)

    WELD EXTENSION PLATE (ALTERNATE METHOD) CAUTION To preserve the corrosion-resistant properties of the galvanized fi nish, MAXON recommends bolting the galvanized extension plate to vehicle. CAUTION To protect the original paint system if equipped, a 3” wide area of paint must be removed from all sides of the weld area before welding.
  • Page 19 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued EXTENSION PLATE VEHICLE BODY WELD LENGTH & SPACE: 2”- 11 3/4” ( 96”W VEHICLE) 3/16” 2”- 12 1/2” (102”W VEHICLE) EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH FIG. 19-1 NOTE: During installation of liftgate, installation brackets keep the heel of the plat- form level with extension plate and maintain a ¾”...

  • Page 20: Step 2 - Weld Liftgate To Vehicle

    Ensure you have the correct mounting plate kit for your application. If it’s necessary to unbolt mounting plates from main frame (FIG 20-1), torque mounting plate nuts and bolts 220-240 lb-ft (GPTWR-25/GPTWR-3) or 350-375 lb-ft (GPTWR-4/GPTWR-5). BOLT &...
  • Page 21 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued 1. Unfold the platform and fl ipover (FIG. 21-1). LOCKING ANGLES (REF) PLATFORM MOUNTING PLATES FLIPOVER STOP (2 PLACES) OPENER FLIPOVER PLATFORM & FLIPOVER UNFOLDED FIG. 21-1 2. Unbolt opener from mounting bracket (shipping position) and save to reinstall (FIG.
  • Page 22 Wrap chain around plat- form (FIG. 22-1). VEHICLE FLOOR INCORRECT (HORIZONTAL) MOUNTING HOIST CHAIN FLIPOVER PLATE PLATFORM * 23-7/8” (GPTWR-25/-3) * 22-3/8” (GPTWR-4/-5) C-CLAMP (2 PLACES) MAIN FRAME FLOOR JACK (CENTERED ON 4. Hoist the Liftgate. Then, MAIN FRAME TUBE) place fl...
  • Page 23 BED LEVEL 2” LG. 4 PLACES in FIG. 23-1. (TYPICAL - RH & LH 5/16” MOUNTING PLATES) MOUNTING PLATE * 23-7/8” (GPTWR-25/-3) * 22-3/8” (GPTWR-4/-5) VEHICLE FRAME CUTOUT (TYPICAL TRUCK FRAME SHOWN) MAIN FRAME * TOLERANCE IS +/- 1/4” WELD TO VEHICLE FRAME AND MAIN FRAME (RH SIDE SHOWN) FIG.

  • Page 24: Step 3 - Attach Optional Battery Box & Frame To Vehicle (If Equipped)

    STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) RECOMMENDED 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.
  • Page 25 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued 2. Select holes on top of battery box LOCK NUT frame to align mounting brackets fl ush to cross members. Refer WASHER CROSS to FIGS. 25-1A & 25-1B for trail- MEMBER ers and FIG.
  • Page 26 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued NOTE: If welding mounting brackets to cross members, skip instruction 3. 3. Using mounting brackets as a tem- plate mark and drill holes through CROSS cross members (FIG.
  • Page 27 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued WARNING Recommended practices for welding on steel parts are contained in the cur- rent 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.
  • Page 28 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued WARNING Remove all rings, watches and jewelry before doing any electrical work. NOTE: Always connect fused end of power cable to battery positive (+) terminal. NOTE: To connect charge lines, refer to instructions provided with each charge line kit.
  • Page 29 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued GROUND CABLE TO PUMP BOX OR COMMON CHASSIS GROUND, 74” LG. (BATTERY BOX KIT ITEM) (-) BATTERY CABLE TO COMMON GROUND FUSED CABLE (SEE NOTE) 150 AMP CIRCUIT BREAKER...
  • Page 30 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued WARNING Explosive hydrogen gas from charging batteries can accumulate in battery box if not vented from the box. To prevent hydrogen gas from accumulating, ensure the 3 ventilation holes in battery box are not plugged or covered. VENTILATION HOLES BATTERY BOX ASSEMBLY (REAR VIEW SHOWN)
  • Page 31 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued BATTERY BOX ASSEMBLY LOCK NUT, 1/4”-20 175 AMP FUSED (2 PLACES) FLAT WASHER CABLE TO PAN HEAD SCREW CHARGE LINE FROM 1/4” PUMP BOX 1/4”-20 X 1” LG. VEHICLE BATTERY (4 PLACES) (2 PLACES)

  • Page 32: Step 4 - Run Power Cable

    STEP 4 - RUN POWER CABLE 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. RECOMMENDED CONFIGURATION 1. Liftgate powered from truck batteries is typically TRACTOR BATTERIES, installed on trailers as TYPICAL LOCATION...
  • Page 33 STEP 4 - RUN POWER CABLE - Continued 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, fi...

  • Page 34: Step 5 - Connect Power Cable

    STEP 5 - CONNECT POWER CABLE Unbolt and remove pump cover (FIG. 34-1). UNBOLTING PUMP COVER FIG. 34-1 2. On the bare wire end of fused power cable, keep enough length to attach copper terminal lug and reach motor solenoid switch without putting tension on cable (after connection) (FIG.
  • Page 35 STEP 5 - CONNECT POWER CABLE - Continued CAUTION Do not over-tighten the terminal nuts on solenoid switch. For the load terminals, torque nuts to 35 lb.-in. max. Torque the nuts on #10-32 control terminals to 15 lb-in. NOTE: Do not remove fl at washer from the battery power terminal.

  • Page 36: Step 6 - Connect Ground Cable (Recommended)

    STEP 6 - CONNECT GROUND CABLE (RECOMMENDED) NOTE: To ensure power unit is correctly grounded, MAXON recommends connecting 2 gauge ground cable from grounding connection on pump mounting plate to a grounding point on the frame, or negative battery terminal in the optional battery box.

  • Page 37: Step 7 - Install Control Switch

    STEP 7 - 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. 37-1. VEHICLE BODY VERTICAL POST (CURB SIDE) DRILLING MOUNTING HOLES FIG. 37-1...
  • Page 38 STEP 7 - INSTALL CONTROL SWITCH - Continued SELF-TAPPING 2. Insert control switch wir- SCREW, 1-1/2” LG. ing into the 3/4” hole on the (2 PLACES) corner post and run it under the vehicle body to the pump CONTROL SWITCH assembly.

  • Page 39: Step 8 - Checking Hydraulic Fluid

    STEP 8 - CHECKING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydrau- lic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination.
  • Page 40 STEP 7 - CHECKING HYDRAULIC FLUID - Continued ISO 32 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 EXXON UNIVIS N-32 DTE-13M, DTE-24, MOBIL HYDRAULIC OIL-13 TABLE 40-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS...

  • Page 41: Step 9 - Connect Power Cable To Battery

    STEP 9 - CONNECT POWER CABLE TO BATTERY 1. Remove nut from negative (-) POSITIVE (+) battery terminal (FIG. 41-1). Dis- BATTERY CABLE connect negative (-) battery cable (FIG. 41-1). POSITIVE (+) BATTERY TERMINAL NEGATIVE (-) BATTERY CABLE NEGATIVE (-) BATTERY TERMINAL 2.

  • Page 42: Step 10 - Remove Locking Angles & Knuckle Bolts, Check For Interference

    STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR INTERFERENCE CAUTION Check for leaking hydraulic fl 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 fl...
  • Page 43 STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR INTERFERENCE - Continued 4. Remove fl oor jack and hoist supporting Liftgate (FIG. 43-1). FLOOR JACK REMOVING JACK FIG. 43-1 5. Lower platform to the ground (FIG. 43-2). Look for any interference be- tween liftgate and vehicle as platform is lowered.
  • Page 44 STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR INTERFERENCE - Continued 6. Lower platform to the ground (FIG. 44-1). LOWERING PLATFORM FIG. 44-1 7. Unbolt the 2 installation brackets EXTENSION PLATE from extension plate (FIG. 44-2). BRACKET & NUT (2 PLACES) BOLT (2 PLACES)
  • Page 45 NOTE: Correct any fi t and interference problems before continuing with installation. 8. Raise the platform to vehicle fl oor level (FIG. 45-1). (Refer to GPT-25, GPT-3, GPT-4, GPT-5, GPTWR-25, GPTWR-3, GPTWR-4 & GPTWR-5 OPERATION MANUAL.) Check for 5/8” gap between platform and edge of extension plate (FIG.
  • Page 46 STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR INTERFERENCE - Continued NOTE: Correct any fi t and interference problems before continuing with installation. 9. Ensure top surface of platform and extension plate are fl ush at SURFACES FLUSH the RH &...

  • Page 47: Step 11 - Install Opener & License Plate Bracket With Icc Bumper Or Underride

    STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER OR UNDERRIDE NOTE: If Liftgate is equipped with underride, skip these instructions for installation with ICC bumper. Go to the instructions for INSTALLATION WITH UNDERRIDE. INSTALLATION WITH ICC BUMPER 1.
  • Page 48 STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d NOTE: License plate bracket can be bolted in 4 positions on the ICC bumper brackets. License plate bracket can be bolted on the inside or outside of the LH bumper bracket or RH bumper bracket.

  • Page 49: Installation With Underride

    STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d INSTALLATION WITH UNDERRIDE 1. Lower platform to ground level. Refer to operating instructions in Operation Manual. POSITIVE (+) BATTERY CABLE WARNING To prevent accidental personal injury and equipment damage, disconnect (-) battery cable and (+) cable from POSITIVE (+)
  • Page 50 STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d INSTALLATION WITH UNDERRIDE - Continued 4. Reconnect power to the pump by POSITIVE (+) POSITIVE (+) BATTERY CABLE reconnecting positive (+) and nega- BATTERY POST tive (-) cables to battery (FIG.

  • Page 51: Step 12 - Adjust Platform (If Required)

    STEP 12 - ADJUST PLATFORM (IF REQUIRED) NOTE: Before doing the following proce- dure, make sure vehicle is parked OUTBOARD EDGE 1” MAX (UP TO 53” BED HT.) on level ground. 0” LEVEL (OVER 53” BED HT.) VEHICLE 1. Lower platform to the ground. With the EXTENSION FLOOR (REF) platform and fl...
  • Page 52 STEP 12 - ADJUST PLATFORM - Continued 4. Compare measurement “B” (FIG. EXTENSION PLATE (REF) 52-1) with the distances and grinding VEHICLE “B” depths in TABLE 52-1. For example: FLOOR (REF) If measurement “B” (FIG. 52-1) is 3” above bed level and you want to lower the outboard edge of platform to 1”...

  • Page 53: Step 13 - Finish Welding Liftgate To Vehicle

    STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE CAUTION 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.

  • Page 54: Step 14 - Bolt Steps To Extension Plate

    STEP 14 - BOLT STEPS TO EXTENSION PLATE 1. Lower platform to the ground (FIG. 54-1). PLATFORM LOWERED TO GROUND FIG. 54-1 WARNING To prevent accidental personal injury and equipment damage, disconnect (-) battery cable and (+) cable from battery. POSITIVE (+) 2.
  • Page 55 STEP 14- BOLT STEPS TO EXTENSION PLATE - Continued CAUTION To prevent interference with Liftgate and possible damage, maintain 90º angle between steps and extension plate. Tighten bolts only in the order shown in illustration. NOTE: If 102” extension kit is to be installed for 102” wide vehicle, install the exten- sion kit before installing the steps.
  • Page 56 STEP 14 - BOLT STEPS TO EXTENSION PLATE - Continued 4. Bolt the support (Kit item) to mounting channel (Kit item) (FIG. 56-1). REAR SILL I-BEAM (VEHICLE BODY) LOCK NUT (3 PLACES) FLAT WASHER (3 PLACES) MOUNTING 1/2” X 3-1/2” LG. CHANNEL LH STEP FRAME BOLT...
  • Page 57 STEP 14 - BOLT STEPS TO EXTENSION PLATE - Continued NOTE: Before welding mounting channel to WELD TO AS MUCH vehicle body, ensure step is straight 3/16” I-BEAM FLANGE & and steps are in vertical position. 3/16” REAR SILL AS POSSIBLE 7.

  • Page 58: Step 15 - Adjust Walk Ramp Pads

    STEP 15 - ADJUST WALK RAMP PADS 1. Stow the platform (FIG. 58-1A). NOTE: If necessary to lower each walk ramp pad, the steel shim under each pad can be removed. 2. Loosen the socket head screws and lock nuts (FIG. 58-1B). Slide the pads toward the outside of the walk ramp box (FIG.

  • Page 59: Step 16 - Lube Grease Fittings As Needed

    STEP 16 - LUBE GREASE FITTINGS AS NEEDED NOTE: Lube fi ttings are shown for the RH cylinder, lift arm, and parallel arm. There are also lube fi ttings at the same places on the LH cylinder, lift arm, and parallel arm. Refer to lubrication diagram (FIG.

  • Page 60: Apply Decals

    APPLY DECALS NOTE: Ensure there is no residue, dirt or corrosion where decals are attached. If necessary, clean surface before attaching decals. NOTE: Preferred decal layout is shown. Decals on the Liftgate are attached at the factory. If vehicle does not permit this layout, decals in the manual and decal kit must be applied so that they are easily visible when approaching vehicle to operate Liftgate.
  • Page 61 APPLY DECALS - Continued DECAL SHEET P/N 297207-01 FIG. 61-1 CAPACITY MODEL DECAL P/N DECAL GPTWR-25 220382 2500 POUNDS GPTWR-3 220388 3000 POUNDS GPTWR-4 296274-01 4000 POUNDS GPTWR-5 296274-02 5000 POUNDS CAPACITY DECAL TABLE 61-1...

  • Page 62: Decals & Plates

    DECALS & PLATES NOTE: Preferred decal layout is shown. Decals on the Liftgate are attached at the factory. MAXON NAME PLATE P/N 280004-01 SERIAL PLATE (REF) PLATFORM WARNING DECAL P/N 281189-02 (2 PLACES) PLATFORM LOADING DECAL P/N 281326-01 (2 PLACES)

  • Page 63: Touch-Up Painted Or Galvanized Finish

    • If bare metal is exposed on galvanized portions of the Liftgate, touch up the galvanized fi nish. To maintain the protection provided by the original galvanized fi nish, MAXON recommends cold galvanize spray.

  • Page 64: System Diagrams

    SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION POWER DOWN MODULE PORT A MOTOR “S2” VALVE “S1” VALVE SOLENOID SWITCH PORT B POWER UNIT FIG. 64-1 NOTE: Hydraulic lock valve is on the RH cylinder. POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE...

  • Page 65: Hydraulic Schematic (Power Down)

    HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDERS HYDRAULIC LOCK VALVE PORT B - LOWER (POWER DOWN) PORT A - RAISE VALVE S2 4 GPM FLOW CONTROL RELIEF VALVE 2 VALVE (SET AT 1100 PSI) VALVE S1 RELIEF VALVE 1 (SET AT 2750 PSI) AUX.

  • Page 66: Electrical Schematic (Power Down)

    ELECTRICAL SCHEMATIC (POWER DOWN) FIG. 66-1...

  • Page 67: Gptwr Electrical Values

    SYSTEM DIAGRAMS GPTWR ELECTRICAL VALUES Solenoid Switch 5.4Ω @70ºF. ±15% 20.1Ω @70ºF. ±15% Coil Resistance: 2.2A 1.2A Ampere: Coil terminal torque: 10-15 lb-in max. Contact terminal torque: 30-35 lb-in max. Solenoid Valves (A, S1, & S2) 4.0Ω @ 70ºF. ±15% 26.7Ω...

  • Page 68: Options

    OPTIONS OPTIONAL LIFTGATE COMPONENTS MISCELLANEOUS KITS PART NO. FRAMELESS TRAILER BRACKET, MOUNTING (GALVANIZED) 282665-01G FRAMELESS TRAILER BRACKET, MOUNTING (GALVANIZED) (REFRIGERATOR TRAILERS) 282970-01G FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS (GALVANIZED) 282372-01G FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS, NO FINISH (HAS RUST PREVENTIVE COAT) 282372-03 HAND PUMP, GPT SERIES 296075-01...
  • Page 69 OPTIONAL LIFTGATE COMPONENTS - Continued DUAL STEP DOCK BUMPER KITS WITH BUMPERS - CONTINUED DUAL FLEX STEP (GALVANIZED), STREET SIDE, NO STEPS, 14” LG. RUBBER BUMPERS 288705-23G DUAL FLEX STEP (PAINTED), STREET SIDE, NO STEPS, 13.5” LG. RUBBER BUMPERS 288705-24G DUAL STEP W/LIGHT, (GALVANIZED) CURB SIDE, 14”...

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