Maxon GPT Series Installation Manual
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Maxon GPT Series Installation Manual

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M-99-49
REV. K
OCTOBER 2005
© MAXON Lift Corp. 2005

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Summary of Contents for Maxon GPT Series

  • Page 1 M-99-49 REV. K OCTOBER 2005 © MAXON Lift Corp. 2005...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS WARNINGS ......................... 3 STANDARD LIFTGATE COMPONENTS ................4 GPT-SERIES INSTALLATION PARTS BAGS ................ 5 STEP 1 - PREPARE VEHICLE ..................... 6 STEP 2 - WELD EXTENSION PLATE TO VEHICLE ............. 8 STEP 3 - WELD LIFTGATE TO VEHICLE ................10 STEP 4 - RUN POWER CABLE ..................

  • Page 3: Warnings

    • Comply with all WARNING and instruction decals attached to the Liftgate. • Keep decals clean and legible. If decals are defaced 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.

  • Page 4: 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 customersupport@maxonlift.com...

  • Page 5: Gpt-Series Installation Parts Bags

    GPT-SERIES INSTALLATION PARTS BAGS " 2 " 1 " 8 , T I " 4 " 2 " 8 " 2 " 2 " 4 " 4 " 2 " 1 " 6 " 5 " 4 " 8 & "...

  • Page 6: Step 1 - Prepare Vehicle

    STEP 1 - PREPARE VEHICLE NOTE: BODY Maximum and Minimum Operating Bed Height: For GPT-25, GPT-3, GPT-4, & GPT-5 With Standard Platform - Maximum height is 55” (Unloaded). Minimum height is 46” (Loaded). On Vehicle Bodies equipped with swing open doors, the Extension Plate and Vehicle Body must be modified to install this Liftgate.
  • Page 7 STEP 1 PREPARE VEHICLE - Continued CAUTION To prevent Aluminum Platform from being damaged, make sure Truck Frame is cut correctly as shown in the illustration below. If the Frame is cut incorrectly, Platform may hit the Truck Frame while stowing Liftgate. NOTE: If installing Liftgate on a trailer, skip frame cutting instructions in Item 2.

  • Page 8: Step 2 - Weld Extension Plate To Vehicle

    STEP 2 - WELD EXTENSION PLATE TO VEHICLE 1. Center the Extension Plate on vehicle body. Before welding Extension Plate to vehicle body, make sure top surface of Extension Plate is flush with floor of vehicle body. Weld the Extension Plate to vehicle body sill as shown in FIG. 8-1 and FIG. 8-2. 4”...
  • Page 9 STEP 2 - WELD EXTENSION PLATE TO VEHICLE - Continued 2. Place 2 temporary Support Straps (5” x 4” x 3/8” 1/4” LG. TACK, SUPPORT flats from Parts Box) on the Extension Plate as STRAP TO EXTENSION 1/4” PLATE (1 WELD ONLY), shown in FIG.

  • Page 10: Step 3 - Weld Liftgate To Vehicle

    STEP 3 - WELD LIFTGATE TO VEHICLE 1. Remove Split Looms from Mounting Plates (FIGS. 10-1A & 10-1B). (Split Looms will be reinstalled later after final welding). MOUNTING PLATE SPLIT LOOMS MOUNTING PLATES FIG. 10-1B RH SIDE VIEW OF LIFTGATE FIG.
  • Page 11 STEP 3 - WELD LIFTGATE TO VEHICLE - Continued CAUTION To prevent damage to Aluminum Flip Over, NEVER hoist the Liftgate by the Flipover as shown in the NO illustration. Hoist the Liftgate by the Platform only as shown in the YES illustration. 3.
  • Page 12 STEP 3 - WELD LIFTGATE TO VEHICLE - Continued WARNING Liftgate is shipped from factory with Mounting Plates that are only Tack Welded to Main Frame. Weld as shown in illustration before operating Liftgate. CAUTION Prevent damaged hydraulic hoses. If welding next to hydraulic hoses, use a protective cover such as a welding blanket to cover the hoses.
  • Page 13 STEP 3 - WELD LIFTGATE TO VEHICLE - Continued 7. At the tip of the Flipover, measure TIP OF FLIPOVER distance Flipover is raised above bed level. Tip of Flipover should be above level line shown in FIG. 13-1, and up to 1”...

  • Page 14: Step 4 - Run Power Cable

    STEP 4 - RUN POWER CABLE CAUTION Never route an energized wire. Make sure the vehicle battery is disconnected. Always route electrical wires clear of moving parts, brake lines, sharp edges and exhaust systems. Avoid making sharp bends in wiring. Attach securely. If drilling is necessary, first check behind the drilling surface so you do not damage any fuel lines, vent lines, brake lines or wires.

  • Page 15: Step 5 - Connect Power Cable

    TYPICAL FUSED POWER CABLE ROUTING (POWER DOWN PUMP BOX SHOWN) FIG. 15-1A NOTE: MAXON recommends using dielectric grease on all electrical connections. 2. Remove hex nut and lock washer from battery power post on the RAISE Motor Solenoid. Connect the Fused Power Cable to the RAISE Motor Solenoid as shown in FIG. 15-2.

  • Page 16: Step 6 - Install Control Switch

    STEP 6 - INSTALL CONTROL SWITCH 1. Drill one 3/4“ hole and two #21–size holes in the vertical VEHICLE BODY VERTICAL POST post on curb side of vehicle body as shown in FIG. 16-1A. (CURB SIDE) Use template shown in FIG. 16-1B. 18”...
  • Page 17 STEP 6 - INSTALL CONTROL SWITCH - Continued 2. Route the Control Switch cable through the ¾” hole in the Vertical Post (FIGS. 17-1B) and down the Vertical Post as shown in CONTROL SWITCH 3/4” HOLE (see dashed line in FIG. 17-1A). When the Control Switch is close to the Post, attach Control Switch to Vertical Post with 2 self-tapping screws (FIG.
  • Page 18 STEP 6 - INSTALL CONTROL SWITCH - Continued NOTE: MAXON recommends using dielectric grease on all electrical connections. NOTE: An extra crimp-on connector is supplied with the RED wire and BLACK wire on the Control Switch cable. Crimp each of the extra connectors to the correct wires shown in the illustration.

  • Page 19: Step 7 - Connect Power Cable To Battery

    STEP 7 - CONNECT POWER CABLE TO BATTERY NOTE: MAXON recommends using dielectric grease on all electrical connections. Remove nut from positive (+) battery terminal connector. Connect Power Cable to the positive (+) battery terminal connector (FIG. 19-1). Re-install and tighten nut.

  • Page 20: Step 8 - Remove Locking Angles & Welds

    STEP 8 - REMOVE LOCKING ANGLES & WELDS 1. Push Control Switch to RAISE position to pressurize Hydraulic System. Listen for Hydraulic Fluid flowing through the system. Check for fluid leaks. (If there are leaks, release the Control Switch and correct the leaks before fully pressurizing system.) When the sound of flowing fluid stops, release Control Switch.

  • Page 21: Step 9 - Weld Platform Opener To Liftgate

    STEP 9 - WELD PLATFORM OPENER TO LIFTGATE 1. Remove Floor Jack and Hoist supporting Liftgate (FIG. 21-1). FLOOR JACK FIG. 21-1 SUPPORT STRAPS & SPACERS (BOTH SIDES) 2. LOWER the Platform to the ground. Remove both support straps and both spacers from Extension Plate (FIG.
  • Page 22 STEP 9 - WELD PLATFORM OPENER TO LIFTGATE - Continued NOTE: Platform Opener may only be installed on Right Hand side of Main Frame (see the illustrations on this page). 4. Position the Opener on Main Frame as shown in FIG. 22-1 and TABLE 21-1. “L”...
  • Page 23 STEP 9 - WELD PLATFORM OPENER TO LIFTGATE - Continued CAUTION If there is any interference with the Platform while stowing Liftgate, check for dam- age on bottom of Platform, Flip Over, and the hinge in between. A damaged Platform or Flip Over may result in personal injury and more damage to Liftgate.

  • Page 24: Step 10 - Finish Welding Liftgate To Vehicle

    STEP 10 - FINISH WELDING LIFTGATE TO VEHICLE CAUTION Prevent damaged hydraulic hoses. Before welding next to hydraulic hoses, protect the hoses with a heat-resistant cover such as a welding blanket. 1. Weld each of the two Mounting VEHICLE FRAME CUTOUT Plates to Vehicle Frame (DASHED LINES) (FIG.

  • Page 25: Step 11 - Install & Adjust Saddles

    STEP 11 - INSTALL & ADJUST SADDLES CAUTION Make sure Mounting Plates are cooled before installing Saddles. Hot surface could result in personal injury and damaged Saddles. 1. Stow the Platform as shown in FIG. 25-1A. Use floor jack posi- tioned at center of Platform (near hinge) to raise Platform 1/8”...

  • Page 26: Step 12 - Check Hydraulic Fluid

    STEP 12 - CHECK HYDRAULIC FLUID NOTE: Use correct grade of hydraulic fluid for your location. +70 to +140 Degrees F - Grade ISO 32 +40 to +105 Degrees F - Grade ISO 15 Below + 70 Degrees F - Grade ISO 10 or MIL-H-5606 See TABLES 26-1, 26-2, &...

  • Page 27: Step 13 - Weld Hook And Eye To Liftgate

    STEP 13 - WELD HOOK AND EYE TO LIFTGATE 1. Stow the Liftgate under hydraulic pressure EXTENSION PLATE (FIG. 27-1). 3/16” INBOARD SIDE OF TUBING, ONLY HOOK (WITH CHAIN) KNUCKLE BASE OF 1/4” PAD EYE, ONLY PAD EYE 2. Weld the Pad Eye (from Installation RH SIDE VIEW OF STOWED LIFTGATE Parts Bag) to Knuckle as shown in FIG.

  • Page 28: Step 14 - Weld Dock Bumpers To Liftgate

    STEP 14 - WELD DOCK BUMPERS TO LIFTGATE 1. Lower the Platform to the ground (Operation Manual M-97-16). 2. Clamp a Dock Bumper to Left Hand (LH) side of Extension Plate as shown in FIG. 28-1A. Weld the Dock Bumper to Extension plate as shown in FIG. 28-1B. Make sure bolt holes in the Dock Bumper are visible from the rear of the vehicle.

  • Page 29: Step 15 - Bolt Rubber Bumpers To Liftgate

    STEP 15 - BOLT RUBBER BUMPERS TO LIFTGATE NOTE: The Rubber Dock Bumpers Kit P/N 203410 contains 2 Rubber Bumpers and 2 sets of fasteners. Bolt a Rubber Bumper to each of the 2 Dock Bumpers (FIG. 29-1). FLAT WASHER (1/2”) HEX NUT (1/2”- 20)

  • Page 30: Step 16 - Place Decals

    STEP 16 - PLACE DECALS INSTRUCTION DECAL P/N 251838 (REFERENCE) CAPACITY DECAL (REFERENCE) CAUTION DECAL P/N 263998 WARNING DECAL P/N 264081 FIG. 30-1...
  • Page 31 STEP 16 - PLACE DECALS - Continued UP/DOWN DECAL P/N 264507 WARNING DECAL P/N 264081 (REFERENCE) CAUTION DECAL P/N 263998 (REFERENCE) CAPACITY DECAL (SEE TABLE 31-1) CAPACITY DECALS CAPACITY PART NO. 220382 2500 LBS. INSTRUCTION DECAL 3000 LBS. 220388 P/N 251838 4000 LBS.

  • Page 32: Step 17 - Vehicle Taillight Positioning

    STEP 17 - VEHICLE TAILLIGHT POSITIONING (IF REQUIRED) NOTE: Positions are based on using taillights of 6-3/4” height by 5-3/4” width. Larger taillights may interfere with Liftgate. Taillights and attaching hardware are not provided with the Liftgate. Underride is optional equipment. OPTIONAL Install vehicle taillights (FIG.

  • Page 33: Hydraulic System Schematic

    HYDRAULIC SYSTEM SCHEMATIC HYDRAULIC CYLINDERS 4 GPM FLOW CONTROL VALVE ADJUSTABLE NEEDLE VALVE FILL HOLE (PLUGGED) PORT A- PORT B- RAISE LOWER VALVE “A” (PWR DN) FILTER VALVE “E” CHECK VALVE HAND PUMP MOTOR RELIEF PORT (REFERENCE) VALVE (SET AT HAND PUMP 2200 PSI) PORT...

  • Page 34: Electrical System Schematic

    ELECTRICAL SYSTEM SCHEMATIC GREEN CONTROL SWITCH BLACK CABLE WHITE ASSEMBLY SOLENOID, SOLENOID, VALVE A VALVE E MOTOR STARTER SOLENOID CABLE WITH 200 AMP FUSE BATTERY FIG. 34-1...

  • Page 35: Options

    OPTIONS OPTIONAL LIFTGATE COMPONENTS " 2 & TABLE 35-1...

  • Page 36: Recommended Liftgate Power Configuration

    OPTIONS RECOMMENDED LIFTGATE POWER CONFIGURATION 1. Liftgate and additional TRAILER-MOUNTED Battery Box are typically POWER CABLE TRACTOR BATTERY CIRCUIT BREAKER - (200 AMP IN-LINE CIRCUIT BREAKER - installed on trailers as SECONDARY LOCATION FUSE SHOWN) PRIMARY LOCATION shown in FIG. 36-1 and on trucks as shown in CIRCUIT FIG.
  • Page 37 OPTIONS RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued NOTE: If more than 10’ of cabling is required to connect Battery Box batteries to Liftgate Power Unit, and/or if cable is run through/along vehicle body crossmembers, use 200 Amp Fused Power Cable from Liftgate Parts Box. Always connect fused end of Cable to Battery.

This manual is also suitable for:

Gpt-25Gpt-3Gpt-4Gpt-5

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