Maxon GPTLR Series Maintenance Manual
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Maxon GPTLR Series Maintenance Manual

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M-16-26
OCTOBER 2018
© MAXON Lift Corp. 2018

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Summary of Contents for Maxon GPTLR Series

  • Page 1 M-16-26 OCTOBER 2018 © MAXON Lift Corp. 2018...
  • Page 3 MAXON agrees to replace any components which are found to be defective during the fi rst 2 years of service, and will reimburse for labor based on MAXON’s Liftgate Warranty Flat Rate Schedule.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SUMMARY OF CHANGES: M-16-26 ..................6 WARNINGS ........................... 8 SAFETY INSTRUCTIONS ....................9 LIFTGATE TERMINOLOGY ....................10 PERIODIC MAINTENANCE ....................11 PERIODIC MAINTENANCE CHECKS .................11 PERIODIC MAINTENANCE CHECKLIST ................14 CHECKING HYDRAULIC FLUID ..................16 CHANGING HYDRAULIC FLUID ..................18 PLATFORM TORSION SPRING ADJUSTMENT ..............
  • Page 5 PLATFORM WILL NOT RAISE, BUT MOTOR RUNS ............43 PLATFORM RAISES BUT LEAKS DOWN ................44 PLATFORM RAISES PARTIALLY AND STOPS ..............46 LIFTGATE WILL NOT LIFT RATED CAPACITY ..............48 PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY ....50...

  • Page 6: Summary Of Changes: M-16-26

    SUMMARY OF CHANGES: M-16-26 PAGE DESCRIPTION OF CHANGE Cover Updated date of release. Removed galvanized warning decal. Added notes for recommended practices for weld- ing galvanized steel to refer to AWS (American Welding Society) D19.0 Welding Zinc-Coated Steel. Added California Proposition 65 WARNING. Main assembly shows new bolt-on mounting plates and horizontal power unit.
  • Page 7 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 8: Warnings

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

  • Page 9: Safety Instructions

    Listen for scraping, grat- ing and binding noises and correct the problem before continuing to operate Liftgate. • Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial num- ber information with your parts order. Order replacement parts from: MAXON LIFT CORP.

  • Page 10: Liftgate Terminology

    LIFTGATE TERMINOLOGY EXTENSION PLATE CONTROL SWITCH PUMP LIFT CYLINDER PARALLEL PLATFORM BOLT ON MOUNTING PLATE SPRING ASSIST TORSION BAR TORSION SPRING HYDRAULIC LOCK MAIN FRAME LIFT PLATFORM OPENER PLATFORM SUPPORT FLIPOVER WITH FIXED RAMP...

  • Page 11: Periodic Maintenance

    Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it off. If bare metal is exposed on galvanized portions of the Liftgate, touch up the galvanized fi nish. To maintain original galvanized fi nish, MAXON recommends cold galvanize spray. Semi-annually or 2500 Cycles (whichever occurs fi rst) Visually check the platform hinge pins for excessive wear and broken welds.
  • Page 12 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHECKS - Continued Annually or 5000 Cycles (whichever occurs fi rst) Visually check the entire Liftgate for excessively worn parts and broken welds, especially hinge pins. See 1/4” (MAX.) PARTS BREAKDOWN section for replacement parts. TIP OF (SEE NOTE) STANDARD FLIPOVER...
  • Page 13 To prevent unnecessary wear on parallel arms, check for worn THRUST BEARINGS thrust bearings as follows. Po- sition the platform 1”-2” above ground (FIG. 13-1). Push against the shackle (Item 1, FIG. 13-1A) PARALLEL and measure clearance (Item 1, FIG. 13-1A). Then, push against other side of shackle (Item 2, FIG.

  • Page 14: Periodic Maintenance Checklist

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHECKLIST NOTE: Make sure vehicle is parked on level ground while performing maintenance checks. Quarterly or 1250 Cycles (whichever occurs fi rst) Check the level and condition of the hydraulic fl uid. Visually check all hoses and fi ttings for chafi ng and fl uid leaks, and check hydraulic lock. Check electrical wiring for chafi...
  • Page 15 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 the PERIODIC MAINTENANCE CHECKS and PERIODIC MAINTENANCE CHECKLIST for the recommended grease and maintenance interval.

  • Page 16: Checking Hydraulic Fluid

    PERIODIC MAINTENANCE 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 17 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 17-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON FLUID A, AW-MV-15 KENDALL GLACIAL BLU SHELL TELLUS S2 VX 15...

  • Page 18: Changing Hydraulic Fluid

    PERIODIC MAINTENANCE CHANGING 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 19 GRAVITY DOWN LIFTGATES FILLER CAP 1. Lower platform to ground. Pull out (no RESERVOIR threads) drain plug (FIG. 19-1). Drain hydraulic fl uid from system. Reinstall drain plug. 2. Pull out (no threads) fi ller cap (FIG. 19-1) 3”(PD) and refi ll reservoir with hydraulic fl uid to 1-1/2”(GD) level shown in FIG.
  • Page 20 PERIODIC MAINTENANCE GRAVITY DOWN & POWER DOWN LIFTGATES CAUTION Pump cover must be correctly secured to prevent it from becoming a hazard. To secure pump cover, the long side of the holder fl ats must butt against pump cover as shown in the illustration. Bolt on the pump cover as shown in FIG.
  • Page 21 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 22: Platform Torsion Spring Adjustment

    PERIODIC MAINTENANCE PLATFORM TORSION SPRING ADJUSTMENT NOTE: Perform the following adjustment if platform feels heavy as you start to fold it for stowing. If adjusted as follows, the torsion springs will reduce the amount of effort you need to start folding the platform. 1.
  • Page 23 WARNING To prevent possible injury and damage to Liftgate, have another qualifi ed person hold platform in position to keep it from falling open. 3. Position platform and fl ipover to 90 de- grees, +2 / -0 degrees (FIG. 23-1A). Get a second person to hold the platform in place while you take measurements.
  • Page 24 PLATFORM TORSION SPRING ADJUSTMENT - Continued 5. If necessary, adjust the torsion SHACKLE BRACKET springs to lower the platform to 4” or less above the ground. Unbolt pin PIN BRACKET bracket (FIG. 24-1). Then, rotate the BOLT pin bracket away from the shackle bracket until the free leg of the torsion spring makes contact with the new block welded to the platform support.
  • Page 25 NOTE: If shimming is not possible, the spring contact surface on the new stops may be ground in small 1/16” increments to lower the platform closer to the ground. 8. If shimming is not possible, grind the CONTACT SURFACE contact surface on the support blocks LH BLOCK (FIGS.
  • Page 26 PLATFORM TORSION SPRING ADJUSTMENT - Continued CAUTION Stow Liftgate under hydraulic pressure. 9. Fold platform as shown in FIG. 26-1. Then, stow Liftgate as shown in FIG. 26-2. FOLDING PLATFORM FIG. 26-1 LIFTGATE STOWED FIG. 26-2...
  • Page 27 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 28: Periodic Maintenance

    PERIODIC MAINTENANCE REPLACING PLATFORM TORSION SPRING NOTE: The following procedure shows how to replace torsion spring on RH side of platform. Use this procedure for replacing torsion spring on the LH side. PLATFORM 1. Fold fl ipover onto platform. LOCK NUT SUPPORT BOLT 2.
  • Page 29 PLATFORM 5. Install the new torsion spring SUPPORT CHAMFERED LOCK NUT and bushing as shown in FIG. BOLT 29-1. Make sure non-cham- fered leg of the spring is insert- ed in the spring bracket (FIG. 29-1). Make sure chamfered leg of the spring is visible and resting against the platform BUSHING support (FIG.

  • Page 30: Decals

    DECALS CONTROL SWITCH DECAL P/N 264507 INSTRUCTION DECAL P/N 251867-09 DECAL SHEET CAPACITY DECAL (SMALL, WARNING & CAUTION) (SEE TABLE 30-1) P/N 282522-01 CAPACITY DECALS CAPACITY PART NO. 2500 LB 220382 3300 LB 220388-02 4400 LB 253155 STOW WARNING DECAL 5500 LB 253161 P/N 282847-02...
  • Page 31 WARNING DECAL P/N 265736-03 PARTS QR CODE DECAL P/N 299348-07 SERIAL PLATE (REF) CAUTION DECAL WARNING DECAL (FLIPOVER EQUIPPED WITH LATCH ONLY) P/N 265736-02 P/N 267694-01 FIG. 31-1...

  • Page 32: Nonskid & Safety Striping

    NONSKID & SAFETY STRIPING NONSKID (LH) P/N 281204-01 NONSKID (RH) P/N 281204-02 SAFETY STRIPE TAPE (2 PLACES) P/N 096018-10 FIG. 32-1...
  • Page 33 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 34: System Diagrams

    SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) STARTER SOLENOID “A” VALVE MOTOR DIRECTION OF CONTROLLED FLOW GRAVITY DOWN POWER UNIT FIG. 34-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE LOCK MOTOR “A”...

  • Page 35: Pump & Motor Solenoid Operation (Power Down)

    PUMP & MOTOR SOLENOID OPERATION (POWER DOWN) STARTER SOLENOID MOTOR “S2” VALVE “S1” VALVE DIRECTION OF CONTROLLED FLOW POWER DOWN POWER UNIT FIG. 35-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE VALVE LOCK MOTOR “S2”...

  • Page 36: Hydraulic Schematic (Gravity Down)

    HYDRAULIC SCHEMATIC (GRAVITY DOWN) HYDRAULIC CYLINDERS HYDRAULIC LOCK VALVE 4.5 GPM FLOW CONTROL VALVE FILL HOLE PORT B - RETURN VENT (PLUGGED) (PLUGGED) PORT PORT A - RAISE VALVE A RELIEF VALVE CHECK VALVE (SET AT 3250 PSI) AUX. HAND PUMP PORT (PLUGGED) MOTOR...

  • Page 37: Hydraulic Schematic (Power Down)

    HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDERS HYDRAULIC LOCK VALVE 4.5 GPM FLOW CONTROL VALVE PORT B - POWER DOWN PORT A - RAISE VALVE “S2” FILTER RELIEF VALVE 2 (SET AT 1100 PSI) VALVE “S1” RELIEF VALVE 1 (SET AT 3250 PSI) AUX.

  • Page 38: Electrical Schematic (Gravity Down)

    ELECTRICAL SCHEMATIC (GRAVITY DOWN) CONTROL SWITCH (UP) (DOWN) GREEN BLACK JUNCTION BLOCK WHITE CYCLE SOLENOID LOCK COUNTER VALVE “A” VALVE FUSE HOLDER WITH 10 AMP FUSE CABLE WITH 175 AMP FUSE STARTER SOLENOID MOTOR BATTERY BLACK FIG. 38-1...

  • Page 39: Electrical Schematic (Power Down)

    ELECTRICAL SCHEMATIC (POWER DOWN) NOTE: One cycle is counted when the down switch is activated for 5-7 continuous seconds. FIG. 39-1...

  • Page 40: Gptlr Electrical Values

    GPTLR 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) 6.6Ω @ 70ºF. ±15% 26.7Ω @ 70ºF. ±15% S1 Coil Resistance: 1.8A 0.9A...

  • Page 41: Recommended Bolt Torques

    RECOMMENDED BOLT TORQUES CAUTION The torque values in the following table are provided for torquing grade 8 bolts on Liftgate mechanical parts. To prevent damage, never use the infor- mation in this table for torquing electrical or hydraulic hose connections on the pump assembly.

  • Page 42: Troubleshooting

    TROUBLESHOOTING PLATFORM WILL NOT RAISE & MOTOR WILL NOT RUN 1. Connect voltmeter between motor solenoid terminal “B” and ground STARTER SOLENOID wires connection on pump (FIG. 42-1). TERMINAL “A” LOAD Verify that full battery voltage is at TERMINAL “D” “B”.

  • Page 43: Platform Will Not Raise, But Motor Runs

    PLATFORM WILL NOT RAISE, BUT MOTOR RUNS 1. Do the CHECKING HYDRAULIC FLUID procedure in this manual. If necessary, add hydraulic fl uid. RESERVOIR 2. Check for structural damage and replace worn parts. CAUTION Keep dirt, water and other contaminants from entering the hydraulic system.

  • Page 44: Platform Raises But Leaks Down

    TROUBLESHOOTING PLATFORM RAISES BUT LEAKS DOWN 1. Check if the “A” (lowering) solenoid valve is constantly STARTER SOLENOID energized. Connect voltmeter TERMINAL “A” LOAD negative (-) lead to ground (-) wires connection on pump and TERMINAL “D” TERMINAL “B” SWITCHED BATTERY positive (+) lead to (+) terminal BATTERY (+) on the “A”...
  • Page 45 VALVE CAUTION CARTRIDGE Keep dirt, water and other contaminants from entering the hydraulic system. Be- fore opening the hydraulic fl uid reservoir COIL fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance.

  • Page 46: Platform Raises Partially And Stops

    TROUBLESHOOTING PLATFORM RAISES PARTIALLY AND STOPS 1. Lower the opened platform to the ground. Do the CHECKING HYDRAULIC FLUID procedure in RESERVOIR this manual. If necessary, add hydraulic fl uid. 2. Use voltmeter to verify the battery voltage is 12.6 volts or more under load from pump motor. 3.
  • Page 47 5. Check the hydraulic cylinder. With the plat- LOWER PORT form at vehicle fl oor level, remove the hy- draulic line from the LOWER port on the cyl- RAISE PORT inder (FIG. 47-1). Hold the control switch in the “RAISE” position for two seconds while you watch for hydraulic fl...

  • Page 48: Liftgate Will Not Lift Rated Capacity

    TROUBLESHOOTING LIFTGATE WILL NOT LIFT RATED CAPACITY 1. Use voltmeter to verify the battery voltage is 12.6 volts or more under load from pump motor. 2. Check for structural damage or lack of lubrica- tion. Replace worn parts. RELIEF VALVE ADJUST SCREW CAUTION Keep dirt, water and other contaminants...
  • Page 49 5. Check the hydraulic cylinder. With the platform at vehicle fl oor level, remove the hydraulic line from the LOWER port on the cylinder (FIG. 49-1). Hold the control switch in the “RAISE” position for LOWER PORT two seconds while you watch for hydraulic fl uid at the LOWER port.

  • Page 50: Platform Will Not Lower, Lowers Too Slowly, Or Too Quickly

    TROUBLESHOOTING PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY 1. Connect voltmeter (+) lead to STARTER TERMINAL “A” motor solenoid terminal “B” and SOLENOID TERMINAL “D” LOAD the (-) lead to the ground wires SWITCHED BATTERY connection on pump (FIG. 50- TERMINAL “B”...
  • Page 51 FLOW CAUTION CONTROL VALVE Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydraulic lines, clean up contaminants that can get in the open- ings. Also, protect the openings from acci- dental contamination during maintenance.

This manual is also suitable for:

Gptlr-25Gptlr-33Gptlr-44Gptlr-55

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