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Maxon GPSLR Series Installation Manual

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M-08-12
REV. H
APRIL 2020
INSTALLATION MANUAL
GPSLR-33 & GPSLR-44
© MAXON Lift Corp. 2020

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  • Page 1 M-08-12 REV. H APRIL 2020 INSTALLATION MANUAL GPSLR-33 & GPSLR-44 © MAXON Lift Corp. 2020...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SUMMARY OF CHANGES: M-08-12, REVISION H ............. 4 WARNINGS ........................... 5 SAFETY INSTRUCTIONS ....................6 NOTICE ..........................6 GPSLR INSTALLATION PARTS BOX ................... 7 VEHICLE REQUIREMENTS ....................8 REAR IMPACT GUARD ...................... 12 STEP 1 - REMOVE SIDE PLATES ..................13 STEP 2 - WELD SIDE PLATE .....................
  • Page 3 ELECTRICAL SCHEMATIC ....................57 OPTIONS ..........................58 OPTIONAL LIFTGATE COMPONENTS ................58 PRE-DELIVERY INSPECTION FORM ................59...

  • Page 4: Summary Of Changes: M-08-12, Revision H

    SUMMARY OF CHANGES: M-08-12, REVISION H PAGE DESCRIPTION OF CHANGE COVER Updated REV, date of release and cover image. Cover image and applicable Illustrations throughout manual are updated to show new impact-absorbing tubes on the back of the slider frame. This contents of this manual applies only to GPSLR liftgates equipped with standard control switches.

  • Page 5: Warnings

    Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates. See Operation Manual for operating safety requirements. WARNING Installing and maintaining a liftgate can expose you to chemicals, including lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To mini- mize exposure, install and maintain liftgate in a well-ventilated area and wear proper Personal protective equipment (PPE).

  • 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: Gpslr Installation Parts Box

    GPSLR INSTALLATION PARTS BOX NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER REF PARTS BOX, GPSLR MOUNTING (NO CONTROLLER) 268801-02 FLAT WASHER, 1/2” 902013-13 FLANGE LOCK NUT 901023 HEX FRAME BOLT, 1/2”-13 X 1-3/4” LG. 901024-2 SUPPORT PLATE, 7-7/8” LG. 268675-02 TAP SCREW, 10-24 X 1” LG. 030444-01 ANGLE, 2”...

  • Page 8: Vehicle Requirements

    VEHICLE REQUIREMENTS CAUTION The sliding axle assembly on a trailer can collide with a Liftgate mounted on the slide rails. To prevent damage to Liftgate and trailer, install stops on the slide rails to keep the sliding axles from hitting Liftgate. Refer to Liftgate clearance dimensions in this section of the manual.
  • Page 9 VEHICLE REQUIREMENTS - Continued MOUNT FRAME CLEARANCE “X” “A” “B” 53” MAX. BED HEIGHT TOP SLOT POSITION 46” MIN. BED HEIGHT MIDDLE SLOT POSITION BOTTOM SLOT POSITION GROUND “Y” CLEARANCES FOR GPSLR MOUNTED ON DRY TRAILER FIG. 9-1 DRY TRAILER GROUND MAX SILL SLOT...
  • Page 10 VEHICLE REQUIREMENTS - Continued MOUNT FRAME CLEARANCE “X” “A” “B” 53” MAX. BED HEIGHT TOP SLOT POSITION 46” MIN. BED HEIGHT MIDDLE SLOT POSITION BOTTOM SLOT POSITION GROUND “Y” CLEARANCES FOR GPSLR MOUNTED ON REFRIGERATED TRAILER FIG. 10-1 REFRIGERATED TRAILER GROUND MAX SILL SLOT...
  • Page 11 VEHICLE REQUIREMENTS - Continued MOUNT FRAME CLEARANCE “X” “A” “B” 53” MAX. BED HEIGHT TOP SLOT POSITION 46” MIN. BED HEIGHT MIDDLE SLOT POSITION BOTTOM SLOT POSITION GROUND “Y” CLEARANCES FOR GPSLR MOUNTED ON REFRIGERATED TRAILER FIG. 11-1 REFRIGERATED TRAILER GROUND MAX SILL SLOT...

  • Page 12: Rear Impact Guard

    VEHICLE REQUIREMENTS - Continued REAR IMPACT GUARD NOTE: The stowed GPSLR platform functions as a rear impact guard for vehicle. To comply with current Federal Motor Vehicle Safety Standards (FMVSS 223) and Canadian Motor Vehicle Safety Standards (CMVSS 223), the rear impact guard must be within the rear-end, side, and ground clearances shown in FIGS.

  • Page 13: Step 1 - Remove Side Plates

    STEP 1 - REMOVE SIDE PLATES 1. Disconnect conduit from right side plate as shown in FIG. 13-1. RIGHT SIDE PLATE CONDUIT FIG. 13-1...
  • Page 14 STEP 1 - REMOVE SIDE PLATES - Continued NOTE: Save bolts, nuts, and fl at washers for reinstallation. 2. Unbolt side plates as shown in FIG. 14-1. FLAT BOLT WASHERS (2 PLACES) (2 PLACES) SIDE PLATES FLAT WASHERS (2 PLACES) FLAT WASHERS (2 PLACES)

  • Page 15: Step 2 - Weld Side Plate

    STEP 2 - WELD SIDE PLATE NOTE: Parts box contains 2 angle steel pieces for position- ing side plates under vehicle body. The angles allow side plates to be positioned and clamped to bottom of chassis crossmembers before welding the side plates. 1.
  • Page 16 STEP 2 - WELD SIDE PLATE - Continued NOTE: The instruction below only applies to trailers with 3” crossmembers. If trailer has 4” crossmembers, go to the next page. NOTE: To mark a position between 2 crossmembers, attach tape from crossmember- to-crossmember.
  • Page 17 STEP 2 - WELD SIDE PLATE - Continued NOTE: The instruction below only applies to trailers with 4” crossmembers. If trailer has 3” crossmembers, go to the previous page. NOTE: To mark a position between 2 crossmembers, attach tape from crossmember- to-crossmember.
  • Page 18 STEP 2 - WELD SIDE PLATE - Continued 5. Refer to FIG. 18-1. Measure the distance (“D”) between slide rails. Then calculate dimension “Y” as follows: (52 7/8” - D) x 1/2 = Y Example where D = 50” : Y = (52 7/8”...
  • Page 19 STEP 2 - WELD SIDE PLATE - Continued CAUTION To avoid personal injury, use at least 2 people to position the side plate. 7. Line up end of the side plate with “X” mark on crossmem- ber (FIG. 19-1A) and with the slide rail (FIG. 19-1B). “X”...
  • Page 20 STEP 2 - WELD SIDE PLATE - Continued CAUTION To protect the original paint system on the Liftgate, a 3” wide area of paint must be removed from all sides of the weld area before welding. 8. Tack weld side plate as shown in FIG. 20-1. TACK 1/4”...
  • Page 21 STEP 2 - WELD SIDE PLATE - Continued 11. Ensure the correct dimensions are held. For 3” crossmembers, refer to FIG. 21-1 and TABLE 21-1. For 4” crossmembers, refer to FIG. 21-1 and TABLE 21-2. 52-7/8” SIDE SIDE (CENTER TO BODY) PLATE PLATE SLIDE...
  • Page 22 STEP 2 - WELD SIDE PLATE - Continued CAUTION To protect the original paint system on the Liftgate, a 3” wide area of paint must be removed from all sides of the weld area before welding. NOTE: Support plates were made for crossmembers positioned at 12” center dis- tance.
  • Page 23 STEP 2 - WELD SIDE PLATE - Continued 13. Weld RH side plate, support plates, and mount plates as shown in FIG. 23-1. Repeat step for LH side plate. 1/4” 1/4” 1/4” SUPPORT PLATES (3 PLACES) SIDE PLATE MOUNT PLATES (3 PLACES) 1/4”...

  • Page 24: Step 3 - Place Slider Assembly On Optional Jig

    STEP 3 - PLACE SLIDER ASSEMBLY ON OPTIONAL JIG NOTE: MAXON recommends using optional installation jig for lifting and maneu- vering slider assembly under the vehicle. Use forklift to place slider assembly on the installation jig. Ensure the slider assembly is: •...

  • Page 25: Step 4 - Bolt On Liftgate

    STEP 4 - BOLT ON LIFTGATE NOTE: Refer to TABLES 25-1 (3” Crossmembers), 25-2 (4” Crossmembers) & 25-3 (Re- MIDDLE frigerated Trailers) for correct mounting slot information. BOTTOM FIG. 25-1B 1. Raise Liftgate to line up the holes in the slider with the prop- er mounting slots on the side plates (FIGS.
  • Page 26 STEP 4 - BOLT ON LIFTGATE - Continued NOTE: Use the bolts, nuts, and fl at washers removed from the side plates in STEP 1, for bolting on the Liftgate. 2. Bolt Liftgate to RH side plate as shown in FIG. 26-1. Re- FLAT peat step for LH side plate.

  • Page 27: Step 5 - Weld On External Control & Bracket

    STEP 5 - WELD ON EXTERNAL CONTROL & BRACKET SIDE 1. Reconnect conduit to right side plate PLATE as shown in FIG. 27-1. CONDUIT RECONNECTING CONDUIT TO RH SIDE PLATE FIG. 27-1 CAUTION Prevent damage to control box. Make sure installed control box does not protrude from the vehicle body.

  • Page 28: Step 6 - Bolt On Internal Control Switch

    STEP 6 - BOLT ON INTERNAL CONTROL SWITCH 1. Use internal control switch bracket to INTERNAL mark and drill 4 holes for mounting next CONTROL SWITCH BRACKET to vertical post (curb side). Bolt internal control box to vehicle body with self-tap- ping screws (FIG.
  • Page 29 STEP 6 - BOLT ON INTERNAL CONTROL SWITCH - Continued 3. Run control cable from external control box, under ve- hicle body (see dashed line, FIG. 29-1A, FIG. 31-1A), and up through vehicle fl oor. Pull control cable through 3/4“ hole (FIG. 29-1A). 4.
  • Page 30 STEP 6 - BOLT ON INTERNAL CONTROL SWITCH - Continued NOTE: MAXON recommends using angle steel to protect control switch cable as shown in the illustration below. MAXON does not supply the angle steel. If necessary, installer may use an alternate method, such as loom clamps and screws, to secure cable to vehicle wall or vertical post.

  • Page 31: Step 7 - Attach Optional Battery Box & Frame To Vehicle (If Equipped)

    STEP 7 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) 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 32 STEP 7 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued 2. To correctly position battery box frame on trailer, refer to FIG. 32-1 and TABLE 32-1. OPTIONAL BATTERY BOX, MAX. DISTANCE TYPICAL LOCATION (REFER TO KITS, TABLE 32-1) 12”...
  • Page 33 STEP 7 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued 3. Select holes on top of battery box LOCK NUT frame to align mounting brackets WASHER fl ush to cross members. Refer CROSS to FIGS. 33-1A & 33-1B for trail- MEMBER ers and FIG.
  • Page 34 STEP 7 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued NOTE: If welding mounting brackets to cross members, skip instruction 3. 4. Using mounting brackets as a tem- CROSS plate, mark and drill holes through MEMBER cross members (FIG.
  • Page 35 STEP 7 - 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 36 STEP 7 - 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 37 STEP 7 - 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 38 STEP 7 - 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 1/4” PUMP BOX 1/4”-20 X 1” LG. (4 PLACES) (2 PLACES) GROUND CABLE...

  • Page 39: Step 8 - Run Power Cable

    STEP 8 - 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, fi...
  • Page 40 STEP 8 - RUN POWER CABLE - Continued NOTE: MAXON recommends using dielectric grease on all electrical connections. 3. Remove nut from negative (-) POSITIVE (+) BATTERY CABLE battery terminal (FIG. 40-1). Dis- connect negative (-) battery cable (FIG. 40-1).

  • Page 41: Step 9 - Connecting Power

    STEP 9 - CONNECTING POWER Connect power cable as shown in FIG. 41-1. POWER CABLE POWER CABLE FROM TO PUMP BOX BATTERY BOX FIG. 41-1...

  • Page 42: Step 10 - Checking Hydraulic Fluid

    STEP 10 - 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 43 STEP 10 - CHECKING HYDRAULIC FLUID - Continued ISO 32 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 EXXONMOBIL UNIVIS N-32, DTE-24 TABLE 43-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON...

  • Page 44: Step 11 - Leveling Platform

    STEP 11 - LEVELING PLATFORM CAUTION PLATFORM VEHICLE Operate Liftgate with caution FLOOR until installation is complete. NOTE: Refer to Operating Instructions decal and applicable WARNING & CAUTION decals. 1. Raise platform above vehicle fl oor height (FIG. 44-1). PLATFORM ABOVE VEHICLE FLOOR FIG.

  • Page 45: Step 12 - Final Bolting

    STEP 12 - FINAL BOLTING NOTE: Six holes must be drilled through each side of the slider SLOT frame to bolt RH and LH side USE TOP HOLES plates to slider frame on the Liftgate. (See FIGS. 45-1A, 45-1B, 45-1C & 45-1D.) NOTE: If middle slot is used for bolting Liftgate, and if trailer chassis interfers with bolts placed in...
  • Page 46 STEP 12 - FINAL BOLTING - Continued 2. Bolt RH side plate to slider BOLTS (6 PLACES) frame as shown in FIG. 46-1. FLAT WASHER (6 PLACES) Repeat for LH side. Torque each SIDE bolt to 120 lb-ft. PLATE FLAT WASHER (6 PLACES) SLIDER FRAME...

  • Page 47: Step 13 - Platform Adjustment

    STEP 13 - PLATFORM ADJUSTMENT NOTE: Park vehicle on level ground and unload vehicle before doing this procedure. 1. Lower platform to ground and unfold fl ipover (FIG. 47-1A). LIMIT BOLT 2. Loosen adjustment and limit bolts on both sides of platform (FIG.

  • Page 48: Step 14 - Attach Sliding Axle Stops (If Required)

    STEP 14 - ATTACH SLIDING AXLE STOPS (IF REQUIRED) CAUTION The sliding axle assembly on a trailer can collide with a Liftgate mounted on the slide rails. To prevent damage to Liftgate and trailer, install stops on the slide rails to keep the sliding axles from hitting Liftgate. Refer to Liftgate clearance dimensions in this section of the manual.

  • Page 49: Step 15 - Attach Safety Chain

    STEP 15 - ATTACH SAFETY CHAIN 1. Stow Liftgate all the way in until slide mechanism hits the rail stops (FIG. 49-1). BUMPER STOPS (2 PLACES) RAIL STOPS PLATFORM 2. Raise the platform until it presses LIFTGATE IN STOWED POSITION against the bumper stops (FIG.
  • Page 50 STEP 15 - ATTACH SAFETY CHAIN - Continued 6. When chain mounting weldment AS MUCH AS is in correct position, fi nish weld- POSSIBLE 1/4” ing to vehicle crossmembers as shown in FIG. 50-1. FINISH WELDING CHAIN MOUNTING WELDMENT FIG. 50-1...

  • Page 51: Attach Decals

    ATTACH DECALS CAUTION DECAL P/N 282682-01 CAUTION DECAL P/N 283989-01 CAUTION DECAL P/N 282683-01 DECAL “A” DECAL “C” DECAL “B” DECAL “F” DECAL “E” PARTS QR CODE DECAL P/N 299349-02 OPERATION DECAL P/N 282681-01 SERIAL PLATE (REF) FIG. 51-1...
  • Page 52 ATTACH DECALS - Continued GPSLR-33 & GPSTLR-33 ONLY GPSLR-44 & GPSTLR-44 ONLY MODEL DECAL SHEET P/N DECAL “B” GPSLR-33 267431-01 3300 POUNDS GPSLR-44 267431-02 4400 POUNDS GPSTLR-33 267431-01 3300 POUNDS GPSTLR-44 267431-02 4400 POUNDS TABLE 52-1...

  • Page 53: Decal Positions

    DECAL POSITIONS DECAL P/N 264507 DECAL “L” MAXGRIP DECAL DECAL P/N 283293-01 “K” DECAL “F” DECAL “L” DECAL DECAL DECAL “M” “I” DECAL “J” “A” DECAL “L” DECAL “K” DECAL DECAL “K” DECAL DECAL “B” “H” “L” DECAL DECAL “M” “H”...
  • Page 54 DECAL POSITIONS - Continued DECAL SHEET P/N 267432-01 FIG. 54-1...

  • Page 55: System Diagrams

    SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION “S2” VALVE “S1” VALVE “S3” VALVE PORT B PORT L PORT A MOTOR STARTER SOLENOID LOCK VALVE LOCK VALVE ON CYLINDER FIGURE 55-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) TAIL LIFT PORT FUNCTION...

  • Page 56: Hydraulic Schematic

    SYSTEM DIAGRAMS - Continued HYDRAULIC SCHEMATIC CYLINDERS LOCK VALVES LOCK HYDRAULIC CYLINDER MOTOR FLOW FLOW CONTROL CONTROL VALVE (2 GPM) VALVE (2 GPM) (OPEN) (CLOSE) VALVE CHECK CHECK VALVE VALVE FLOW CONTROL VALVE (4 GPM) 1500 1500 +/-150 +/-150 CHECK (TEST PORT) VALVE VALVE...

  • Page 57: Electrical Schematic

    SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC FIG. 57-1...

  • Page 58: Options

    OPTIONS OPTIONAL LIFTGATE COMPONENTS MISCELLANEOUS KITS PART NO. CIRCUIT BREAKER (150 AMP) 251576 GPSLR HARNESS (INTERNAL SWITCH) 287837-01 INSTALLATION JIG GPSLR INSTALLATION JIG ASSEMBY 268592-01 BATTERY CABLE KITS GPSLR 3’ BATTERY INSTALLATION 268802-01 GPSLR 10’ BATTERY INSTALLATION 268802-02 GPSLR 20’ BATTERY INSTALLATION 268802-03 GPSLR 60’...

  • Page 59: Pre-Delivery Inspection Form

    Important! This pre-delivery checklist is to aid the installer in confi rming the proper installation of this Maxon product. It is not a comprehensive list and does not replace the use of the installation manual. The installer is responsible for following all instructions in the installation manual.

This manual is also suitable for:

Gpslr-33Gpslr-44

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