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Maxon GPC X1-LDF Installation Manual

Liftgate, mercedes benz sprinter
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GPC X1-LDF liftgate
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Mercedes Benz Sprinter

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Summary of Contents for Maxon GPC X1-LDF

  • Page 1 GPC X1-LDF liftgate Installation Manual Mercedes Benz Sprinter...
  • Page 2 LIFT CORP. 11921 Slauson Avenue Santa Fe Springs, CA 90670-2221 P 800.227.4116 / 562.464.0099 Date 07.2019 F 888.771.7713 Part No. 20 912 027...

  • Page 3: Santa Fe Springs, Ca

    Contact information Contact information MAXON LIFT CORP. Corporate Office 11921 Slauson Avenue Santa Fe Springs, CA 90670-2221 P 800.227.4116 / 562.464.0099 F 888.771.7713 Customer Service / Parts USA/Canada Mexico P 800.227.4116 F 888.771.7713 P 01.664.231.6039...

  • Page 4: Table Of Contents

    Contents Contents Contact information ....................III Contents ........................IV Safety ........................1 1.1 Intended use ....................1 1.2 Requirements for personnel ................. 1 1.3 Requirements for installation and commissioning ........2 1.4 Fundamental hazards................... 2 1.5 Emergency procedure .................. 2 1.6 Presentation of warning notices ..............
  • Page 5 Contents 4.5 Securing the axle assemblies ..............27 4.6 Securing the installation adapters .............. 27 4.7 Connecting the cables to the lifting gear ............ 28 4.7.1 Installing and connecting the service switch ........28 4.7.3 Installing and connecting the control panel ........29 4.7.4 Connecting the handheld control (optional) ........
  • Page 6 Contents 6.5 Entry in inspection record book ..............61 Recommendations and instructions regarding the liftgate ......62 7.1 Hydraulic oil recommendations ..............62 7.2 Painting the lifting gear ................62 7.3 Rating plate ....................62 Useful information ................... 63 8.1 About the service switch................63 8.2 Assembly drawings of installation adapters ..........

  • Page 7: Safety

    Safety 1 Safety 1.1 Intended use This liftgate was specially developed for cargo vans. It may be used only on the vehicles for which it was designed.  To determine whether the liftgate may be installed on a specific vehicle, please contact the manufacturer or customer service.

  • Page 8: Requirements For Installation And Commissioning

    Safety 1.3 Requirements for installation and commissioning  Follow the vehicle manufacturer’s current installation guidelines for the relevant vehicle. Pay particular attention to safety instructions and warnings.  Changes to the liftgate’s axle assemblies and to the necessary installation adapters are prohibited and invalidate approval by the German Federal Motor Transport Authority.

  • Page 9: Presentation Of Warning Notices

    Safety 1.6 Presentation of warning notices The following types of notices are used in this manual to identify hazards and complications: WARNING  Failure to heed this notice can result in death or serious injury. CAUTION  Failure to heed this notice can result in minor or moderate injury.

  • Page 10: Introduction

    Introduction 2 Introduction 2.1 Scope of delivery IMPORTANT: All illustrations of the lifting gear are shown without factory-installed cables and hydraulic hoses. 2.1.1 Lifting gear 2.1.2 Platform Fig. 1 2.1.3 Bridge plates (20 909 431) Fig. 2 Fig. 3...

  • Page 11: Accessories Kit

    Introduction Fig. 4 2.1.4 Accessories kit...
  • Page 12 Introduction Parts list – accessories kit Item Part No. Description Standard Qty. Hexagon nut 80 000 046 DIN 934 - M5 - A2 Hexagon flange bolt 20 908 251 DIN 6921 - M10x15 - 10.9 - ZN Ground roller 20 907 616 Bushing 20 907 615 d20/16x32...

  • Page 13: Installation Adapter Kit (22 911 216)

    Introduction 2.1.5 Installation adapter kit (22 911 216) Fig. 5...

  • Page 14: Damage During Transport

    Introduction Parts list – installation adapter kit (Part No. 22 911 216) Item Part No. Description Standard Qty. Bracket 20 908 103 Installation adapter 20 908 322 Spacer ring 20 908 395 Installation adapter 20 908 398 Installation adapter 20 908 639 Installation adapter 20 908 640 Cheese-head screw...

  • Page 15: Preparing For Installation

    Preparing for installation 3 Preparing for installation 3.1 Requirements for installation  The vehicle exhaust must not be located at the rear of the vehicle.  Line the vehicle floor with wood panels. For other types of flooring, verify whether installation is possible.

  • Page 16: Remove Spare Tire

    Preparing for installation 3.3.1 Remove spare tire  If the vehicle has a spare tire between the rear axle and the rear bumper, remove the tire (see Fig. 6). Fig. 6 3.3.2 Move exhaust pipe  If the exhaust pipe is at the rear, move it to the side.

  • Page 17: Remove Trailer Hitch Or Step

    Preparing for installation because the lifting gear interferes with the sensors (see Fig. 9). 3.3.6 Remove trailer hitch or step  If a trailer hitch or step is mounted on the vehicle, remove it (see Fig. 10). Fig. 10 3.4 Unpacking the lifting gear, installation adapters, and accessories kit CAUTION Unsecured, heavy parts...
  • Page 18 Preparing for installation Spacer ring 20 908 395 Installation adapter 20 908 398 Installation adapter 20 908 639 Installation adapter 20 908 640 Cheese-head screw DIN 912 - M10x90 - 8.8 - ZN - 20 909 327 with hexagon socket PRE80 Hexagon head screw ISO 4017 - M12x25 - 8.8 -...
  • Page 19 Preparing for installation Depending on requirements, different installation options are available for the front installation adapters (2 and 4) in the installation adapter kit (Part No. 22 911 216) (see Fig. 12). Fig. 12...
  • Page 20 Preparing for installation Vehicle with maximum authorized mass of 5 tons (for 3.5 ton vehicles, see previous page) Fig. 13 Depending on requirements, different installation options are available for the front installation adapters (2 and 4) in the installation adapter kit (Part No. 22 911 216) (see Fig.

  • Page 21: Installing The Cables/Preparation

    Preparing for installation 3.6 Installing the cables/preparation IMPORTANT: Excess cable must not be wound up in a coil but must be placed in slings. (Fig. 15). 3.6.1 Cable to the platform Fig. 15  Route the control unit cable for platform connection (white plastic cover) to the swing-arm assembly in the center of the...

  • Page 22: Routing The Cables To The Front Of The Vehicle

    Preparing for installation 3.6.3 Routing the cables to the front of the vehicle For more information, look online under http://www.taillift.org/en/electrical-vehicle-interface Follow the vehicle manufacturer’s installation guidelines. IMPORTANT: NOTICE  When installing cables, make sure they are safe from chafing.  Do not install cables near heat-dissipating components. With preparation according to ETMA Code A and Code B ...
  • Page 23 Preparing for installation No preparation according to ETMA Code A and Code B Power cable  Insert the positive cable (25 mm² red) (“power unit cable”) for the power supply into a length of slit corrugated tubing (see Fig. 19). Fig.

  • Page 24: Control Panel Cable On The Control Unit

    Preparing for installation Cable for cabin switch unit  Route the cabin switch cable from the accessories kit (Item No. 11) to the driver’s cabin (see Fig. 21).  Connect the cabin switch cable to the 7-pin connector (DIN 72585) from the control unit.
  • Page 25 Preparing for installation (optional) Prepare the cable on the control unit  Sever the control unit cable (1, red marking with cable tie) for connecting the handheld control (see Fig. 23) Leave the end without a cable tie blank. Fig. 23 ...

  • Page 26: Aligning The Lifting Gear

    Preparing for installation Handheld control  Determine the installation location for the handheld control and route the cable to the installation location (see Fig. 25).  Find the bushing into the cargo area. Fig. 25 3.7 Aligning the lifting gear ...

  • Page 27: Mounting Holes On The Vehicle

    Preparing for installation  Line up the installation adapters on the lifting gear with the manufacturer’s holes in the vehicle chassis (see Fig. 27). Fig. 27 3.8 Mounting holes on the vehicle Follow the vehicle manufacturer’s installation guidelines. IMPORTANT:  Find the mounting holes on the vehicle. ...

  • Page 28: Installation

    Installation 4 Installation 4.1 Positioning the lifting gear  Place the prepared lifting gear (on a pallet) under the vehicle using a suitable means of transport, e.g. pallet truck, forklift, etc. (see Fig. 28). Fig. 28...

  • Page 29: Tightening The Lifting Gear Fittings Until Hand-Tight

    Installation 4.2 Tightening the lifting gear fittings until hand-tight WARNING Installation at crushing and shearing points Fingers are at risk of being crushed or sheared when the lifting gear is installed on the vehicle.  Be careful at the connecting points between the lifting gear and vehicle. ...
  • Page 30 Installation  Insert the front bolts (installation adapter kit – Part No. 22 911 216) as viewed in the forward direction of travel and tighten until hand-tight as shown in Fig. 30. NOTICE  Do not damage cables. Fig. 30 Excerpt from parts list: Installation adapter kit (Part No.
  • Page 31 Installation Optional: Insert the front bolts (installation adapter kit – Part No. 22 911 216) as viewed in the forward direction of travel and tighten until hand-tight as shown in Fig. 31. NOTICE  Do not damage cables Fig. 31 Legend: Welded-on bushing as per manufacturer’s installation guidelines Excerpt from parts list: Installation adapter kit (Part No.

  • Page 32: Securing The Lifting Gear To The Vehicle

    Installation 4.3 Securing the lifting gear to the vehicle  Secure the lifting gear (with adapters) to the vehicle and tighten to a torque of 115 Nm in the rear and 70 Nm in front (see Fig. 32). Fig. 32...

  • Page 33: Laterally Aligning The Lifting Gear

    Installation 4.4 Laterally aligning the lifting gear  Shift the lifting gear to the left so that the brand emblem on the rear door does not collide with the platform (see Fig. 33). Fig. 33 4.5 Securing the axle assemblies ...

  • Page 34: Connecting The Cables To The Lifting Gear

    Installation 4.7 Connecting the cables to the lifting gear 4.7.1 Installing and connecting the service switch  Disconnect the service switch box from the cable by loosening the screw terminals in the housing (see Fig. 36). Legend: Terminal 30 Black cable Terminal Y1 Blue cable Terminal KM Gray cable Terminal YA Brown cable...

  • Page 35: Installing And Connecting The Control Panel

    Installation 4.7.3 Installing and connecting the control panel WARNING Penetration of water Over the long term, the improper installation of cables can result in water penetrating the control panel and causing it to malfunction. Risk of serious injury in subsequent operation. ...
  • Page 36 Installation IMPORTANT: A release tool is required for disassembling the SUPERSEAL connector. IMPORTANT: When reassembling, pay attention to the position of the individual wires! Return the wires to their original positions (see Fig. 39 for 1 and Fig. 38 for 2). Legend: Item 1 Socket housing...
  • Page 37 Installation  For the pin housing, release the latches on the contact pins and pull the wires out of the back of the housing (Fig. 45 and Fig. 46). Fig. 45 Fig. 46  Reassemble the control panel SUPERSEAL connector and the control unit SUPERSEAL connector.
  • Page 38 Installation  Connect the control panel connector (1) to the control unit connector (2) (see Fig. 47). Legend: Item 1 Connector from control panel for connection to control unit Item 2 Connector from control unit for connection to control panel click! Fig.

  • Page 39: Connecting The Handheld Control (Optional)

    Installation 4.7.4 Connecting the handheld control (optional)  Connect the cable from the handheld control (2) to the stripped control unit cable section (1) with the red marking at the installation location (see Fig. 49). Fig. 49 Legend: Item 1 Control unit Connection Function Control unit cable...
  • Page 40 Installation vehicle) WARNING Vehicle battery short-circuit Improper connection of the device to the vehicle battery can cause a short-circuit and explosion of the battery. Risk of damage to property, fire, and injury.  Follow the vehicle manufacturer’s instructions for correctly handling the battery. With preparation according to ETMA Code A and Code B ...
  • Page 41 Installation No preparation according to ETMA Code A and Code B Power cable  Route the “power unit cable,” positive cable, and negative cable (25 mm²) for the power supply to the terminals provided for the battery and connect (see example Fig.

  • Page 42: Unpacking The Platform

    Installation 4.8 Unpacking the platform  Check the scope of delivery for completeness (see pages 4f.) IMPORTANT: Dispose of all packing materials in accordance with environmental regulations. 4.9 Raising the platform  Lift the platform using suitable means, e.g. crane, assembly table, or pallet truck and pallet (see Fig.

  • Page 43: Installing The Platform

    Installation 4.10 Installing the platform WARNING Installation at crushing and shearing points Fingers are at risk of being crushed or sheared when the platform is installed on the lifting gear.  Be careful at the connecting points between the platform and lifting gear. ...
  • Page 44 Installation  Loosen the platform stop (1) and push it toward the vehicle (see Fig. 57). Fig. 57 Legend: Item 1 Platform stop  Thoroughly grease the bearing bushes with the special assembly grease (accessories kit parts list – Item No. 13) (see Fig. 58). Fig.
  • Page 45 Installation  Align the top bearing points of the platform (platform attachment points) with the swing-arm bearing points (top attachment points of the lifting gear) (see Fig. 59). Fig. 59  Insert the two pins (a, b) through the top attachment points of the platform and the attachment points of the swing-arm assembly.
  • Page 46 Installation  Lift the tip of the platform until the closing-rod bearing point (attachment point for the closing rod) is aligned with the swing-arm bearing point (bottom attachment point on the platform) (see Fig. 61). IMPORTANT: If necessary, slightly retract or extend the closing rod. Fig.

  • Page 47: Mounting The Platform Lock On The Closing Arm

    Installation  Move the 6 pre-fitted O-rings (accessories kit parts list – Item No. 10) into their correct positions (see Fig. 63). IMPORTANT: All bearing points are sealed with O-rings. Fig. 63 Excerpt from parts list: accessories kit Item No. Part No. Description Standard Qty.

  • Page 48: Mounting The Ground Rollers

    Installation  Mount the screw (1) for the platform lock, including the spring washer (2), washers (3), and sleeve (4), on the platform bearing (see Fig. 65). Legend: Item 1 Hexagon head screw Item 2 Spring washer Item 3 Washer Item 4 Sleeve Fig.

  • Page 49: Installing Supports (Vehicle-Dependent)

    Installation 4.13 Installing supports (vehicle-dependent) With some vehicle types and installation versions, maximum loading of the platform can cause the front of the vehicle to lift up. WARNING Shift in center of gravity and lifting up of front end of the vehicle Unexpected movements of the vehicle can result in the severe injury or death of bystanders.

  • Page 50: Connecting The License Plate Light

    Installation 4.14.2 Connecting the license plate light  Find the cable connection point for the license plate light in the C column (a) on the Mercedes Benz Sprinter (see Fig. 68). Fig. 68  Route the license plate light cable (2) (cable outlet from platform’s aluminum torsion box) along the closing arm...

  • Page 51: Mounting The License Plate Holder

    Installation 4.15 Mounting the license plate holder  Mount the license plate holder below the license plate light. IMPORTANT: When positioning the holder, make sure the license plate is sufficiently illuminated. 4.16 Mounting the bridge plates (20 909 431)  Fasten the bridge plate with the non-skid coating (2) on the right side. The non- skid coating must face upward when the bridge plate is folded shut (see Fig.
  • Page 52 Installation  Close the liftgate (place in driving position).  Align the warning flag holder (14c). IMPORTANT: Comply with the mounting specifications.  Transfer the existing holes in the warning flag holder to the platform and pre-drill holes for the 2 blind rivets. ...
  • Page 53 Installation  Move the liftgate to the horizontal position.  Fold out (open) the liftgate.  Bring the open liftgate as far as necessary into the vertical position to comfortably mount the right warning flag. CAUTION Not a normal operating position Risk of injuring yourself or damaging the vehicle or liftgate.

  • Page 54: Affixing The Danger Notice Sticker

    Installation 4.18 Affixing the danger notice sticker  Affix the danger notice sticker “Safe handling of the liftgate.” IMPORTANT: This sticker is supplied with all new liftgates. The installing company must place it in an easily visible location on the inside of the vehicle cargo area. The danger notice sticker uses pictograms to indicate potential incorrect and correct use of the liftgate.

  • Page 55: Adjusting The Liftgate

    Adjusting the liftgate 5 Adjusting the liftgate 5.1 Setting the lift height to the vehicle floor level using the adjustable stop on the axle assembly Use the adjustment screw (1) pre-mounted on the axle assembly of the X1A 600F/GPC X1 and an appropriate tool (e.g. a ring wrench) to set the lifting gear to the desired height with relation to the vehicle floor.

  • Page 56: Aligning The Platform (Foldover Section) Parallel To The Vehicle Floor

    Adjusting the liftgate  Loosen the hex bolt (3).  Rotate the adjustment screw (1) to the left or right.  Rotating the adjustment screw (1) to the right moves the right side of the platform closer to the vehicle chassis. This slightly lifts the platform on the right side of the vehicle (see Fig.
  • Page 57 Adjusting the liftgate If necessary, adjust the height of the foldover section on the right side of the platform using the right-hand adjustment fork (2) (adjustment screw accessible from below) Fig. 78 (see Fig. 78). Legend: Item 1 Adjustment screw Item 2 Adjustment fork Item 3...

  • Page 58: Checking The Stop On The Foldover Section Of The Platform

    Adjusting the liftgate 5.4 Checking the stop on the foldover section of the platform  Check the stop on the foldover section of the platform. IMPORTANT: The roller (1) on the support arm (2) must remain against the stop (3) throughout the entire lifting process.

  • Page 59: Setting The End Stop For The Closed Platform

    Adjusting the liftgate 5.5 Setting the end stop for the closed platform The end stop for the platform in the closed position is mounted on the closing arm. The platform requires no additional stops on the vehicle. IMPORTANT: Adjust the platform so that it stands vertically behind the vehicle when closed and in the driving position.
  • Page 60 Adjusting the liftgate  Retighten the 2 screws (1) on the clamping plate (2) on the platform stop to a torque of 195 Nm (see Fig. 83). Fig. 83 When you reclose the platform, it will stand vertically behind the vehicle (see Fig. 84). Fig.

  • Page 61: Adjusting The Stopper For Fastening The Platform

    Adjusting the liftgate 5.6 Adjusting the stopper for fastening the platform The stopper fastens the right-hand foldover section of the closed platform and keeps the platform from hitting the vehicle while driving. IMPORTANT: Make the adjustment with the platform folded and closed (driving position).

  • Page 62: Programming The Tilt Sensor

    Adjusting the liftgate Adjust the support arm (1) so that it can be pulled as close to the vehicle as desired when the platform is closed. The adjustment is made outside at the Bowden cable (2) and, if applicable, also at the screw on the lever (3). While making the adjustment, release the Bowden cable (2) and open the platform (see Fig.
  • Page 63 Adjusting the liftgate  Using the manual control, move the platform to a horizontal position. Fig. 88  On the control panel (a), press button 1 (top left) 3 times, then  On trol (a), butt (top Fig. 89 righ t) 3 times (see Fig.

  • Page 64: Testing The Liftgate

    Testing the liftgate 6 Testing the liftgate 6.1 Function test  Test: opening, lifting, lowering, tilting down, tilting up, closing CAUTION Platform at ground level In the fully lowered position, the platform is easily overlooked and may cause people to trip, resulting in injury. ...

  • Page 65: Load Tests

    Testing the liftgate 6.3 Load tests WARNING High loading of components Incorrect installation or defective components may cause components to fail and break. Risk of injury when operating the liftgate.  Perform all the load tests specified here. 6.3.1 Static test ...

  • Page 66: Explanation Of Diagnostic Led On The Control Unit

    Testing the liftgate 6.4 Explanation of diagnostic LED on the control unit Cabin switch in driver’s cabin or LED monitoring function LED on LED off flashing key switch Platform closed (90°) Platform closed Platform open (90° to 60°) Platform open (60° to 0°) Platform tilted down (0°...

  • Page 67: Checking Tilt Sensors S1 And S2 In The Platform

    Testing the liftgate 6.4.1 Checking tilt sensors S1 and S2 in the platform  Platform closed and liftgate switched on: LED on. Power supply is functioning correctly.  Platform position 0 ° to approx. 60 °: LED off Tilt sensor S1 in switching position is functioning correctly. Corner lights are activated.

  • Page 68: Recommendations And Instructions Regarding The Liftgate

    Recommendations and instructions regarding the liftgate 7 Recommendations and instructions regarding the liftgate IMPORTANT: To ensure safe operation of the liftgate read the safety instructions and warnings in the accompanying user manual. 7.1 Hydraulic oil recommendations HLPD 22 (ISO-VG 22) “detergent” so that free water remains emulsified (e.g. to prevent ice formation in winter) and to improve oil film adhesion.

  • Page 69: Useful Information

    Useful information 8 Useful information 8.1 About the service switch The service switch mounted in a housing enables trained service personnel to control and test the functioning of the liftgate directly (see Fig. 92). If the liftgate’s handheld control malfunctions, a trained person can operate the liftgate to any position using the service switch (emergency function).
  • Page 70 Useful information Function ● Power light green ● ● Lift ● ● Lower ● ● ● Open/tilt down ● ● Close/tilt up Please follow the sequence shown. Always operate KM last.

  • Page 71: Assembly Drawings Of Installation Adapters

    Useful information 8.2 Assembly drawings of installation adapters...

  • Page 72: Electrical Circuit Diagram

    Useful information 8.3 Electrical circuit diagram...

  • Page 73: Hydraulic Circuit Diagram

    Useful information 8.4 Hydraulic circuit diagram ®...

  • Page 74: Torque Table

    Useful information 8.5 Torque table Valid torque table for all the bolts and screws supplied and installed on our liftgates Screw size Tightening torque Thread sizes Tightening torque in Nm DIN 3852 in Nm G1/4“ 2.7 ± 0.1 40 ± 1.2 G3/8“...

  • Page 75: Activating The Liftgate

    Useful information 8.6 Activating the liftgate Switch on the liftgate control unit using the pushbutton in the driver’s cabin. When the red indicator light is illuminated, the liftgate is ready to operate. 8.7 Operation using the control panel From the control panel, all functions are initiated by pressing two different pushbuttons simultaneously.

  • Page 76: Operation Using The Optional Handheld Control

    Useful information 8.8 Operation using the optional handheld control The 3-button handheld control can be used to operate the lifting and lowering functions as well as the tilting up and down functions when the platform is open. Lift Tilt up/tilt down Lower...

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