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Maxon GPTLR Series Installation Manual

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M-18-14
JANUARY 2019
To fi nd maintenance & parts information for your GPTLR Liftgate, go to www.
maxonlift.com. Click the PRODUCTS, TUK-A-WAY & GPTLR buttons. Open the
Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts,
click on the PARTS PORTAL, TUK-A-WAY & GPTLR buttons.
© MAXON Lift Corp. 2019

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Summary of Contents for Maxon GPTLR Series

  • Page 1 To fi nd maintenance & parts information for your GPTLR Liftgate, go to www. maxonlift.com. Click the PRODUCTS, TUK-A-WAY & GPTLR buttons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A-WAY & GPTLR buttons. © MAXON Lift Corp. 2019...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS WARNINGS ........................... 4 SAFETY INSTRUCTIONS ....................5 NOTICE ..........................5 GPTLR LIFTGATE COMPONENTS ..................6 GPTLR-SERIES INSTALLATION PARTS BOXES ..............7 GPTLR-SERIES MANUALS & DECALS ................8 VEHICLE REQUIREMENTS ....................9 CENTER OF MASS ......................15 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE ............16 BOLT EXTENSION PLATE....................
  • Page 3 STEP 14 - ADJUST OPENER (IF REQUIRED) ..............59 STEP 15 - ADJUST UNDERRIDE ..................62 STEP 16 - VEHICLE TAILLIGHT POSITIONING (IF REQUIRED) ........76 ATTACH DECALS ....................... 77 DECALS & PLATES ......................78 ATTACH NONSKID & SAFETY STRIPING ................. 79 TOUCHUP GALVANIZED FINISH ..................

  • Page 4: 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 5: 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 6: Gptlr 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 7: Gptlr-Series Installation Parts Boxes

    GPTLR-SERIES INSTALLATION PARTS BOXES ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER PARTS BOX A 297502-01 SPRING CLIP 050079 PLASTIC TIE 206864 #10 LOOM CLAMP 801681 SCREW TAPPING #10 X 1/2” LG. 030458 GROUND CABLE ASSEMBLY, 2GA, 48” LG 251871-26 CABLE ASSEMBLY, 2GA, 49-3/4” LG. (GROUND) 268226-11 CAP SCREW, 5/16”-18 X 3/4”...

  • Page 8: Gptlr-Series Manuals & Decals

    GPTLR-SERIES MANUALS & DECALS NOTE: To fi nd maintenance & parts information for your GPTLR Liftgate, go to www.maxonlift.com. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A- WAY & GPTLR buttons. ITEM NOMENCLATURE OR DESCRIPTION QTY.

  • Page 9: Vehicle Requirements

    VEHICLE REQUIREMENTS NOTE: • BODY maximum and minimum operating bed height for GPTLR-25, GPTLR-33, GPTLR-44, & GPTLR-55 with standard platform: Maximum height is 55” (Unloaded). Minimum height is 44” (Loaded). If Liftgate is equipped with Canadian (CMVSS) underride, minimum height is 49”. Refer to Canadian underrides listed in OPTIONS, and underride adjustment procedure.
  • Page 10 VEHICLE REQUIREMENTS - Continued BODY FLOOR (REFERENCE) LIFT ARM 5-5/8” (GPTLR-44/-55) 6-1/8” (GPTLR-25/-33) BODY CORNER POST VEHICLE BODY CORNER POST CLEARANCE (FOR REFERENCE) FIG. 10-1...
  • Page 11 VEHICLE REQUIREMENTS - Continued 96” 79” 4-7/16” (GPTLR-25 & -33) 1/2” 1/2” 5-7/16” (GPTLR-44 & -55) GPTLR EXTENSION PLATE DIMENSIONS FOR 96” WIDE BODY FIG. 11-1 102” 85” 4-7/16” (GPTLR-25 & -33) 1/2” 1/2” 5-7/16” (GPTLR-44 & -55) GPTLR EXTENSION PLATE DIMENSIONS FOR 102” WIDE BODY FIG.
  • Page 12 VEHICLE REQUIREMENTS - Continued CAUTION • To prevent aluminum platform from being damaged, make sure vehicle frame is cut correctly and rear sills are modifi ed if over 5” in height. If the cutouts are incorrect, platform may hit vehicle frame or underbody when stowing the Liftgate.
  • Page 13 VEHICLE REQUIREMENTS - Continued REAR SILL BODY FLOOR BODY CROSS 5-1/2” MEMBERS LONG SILL 13” WOODEN SPACER TRUCK FRAME PLATFORM CLEARANCE CUTOUT AREA (WITHIN DASHED LINES) 24” VEHICLE FRAME CUT FOR GPTLR-44 & GPTLR-55 FIG. 13-1...
  • Page 14 VEHICLE REQUIREMENTS - Continued 3. If necessary, cut trailer rear sill as shown in FIG. 14-1. REAR SILL CUTS FOR ALL GPTLR LIFTGATES FIG. 14-1...

  • Page 15: Center Of Mass

    CENTER OF MASS 8-1/2” CENTER OF MASS 12-3/4” GPTLR-25 & GPTLR-33 CENTER OF MASS (STOWED POSITION) FIG. 15-1 8-1/2” CENTER OF MASS 12-1/2” GPTLR-44 & GPTLR-55 CENTER OF MASS (STOWED POSITION) FIG. 15-2...

  • Page 16: Step 1 - Attach Extension Plate To Vehicle

    MAXON recommends bolting the galvanized extension plate to vehicle. NOTE: Liftgate extension plate comes with bolt holes so it can be bolted to vehicle body with optional bolt kit. GRADE 8 bolts are required. MAXON recom- mends getting the optional extension plate hardware kit listed in OPTIONS section.
  • Page 17 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” USE 9/16” DRILL 6-1/2” (19 PLACES) REAR SILL 3-1/8” REAR SILL - HOLE LOCATIONS FOR 102” WIDE VEHICLE FIG.
  • Page 18 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 19: Weld Extension Plate (Alternate Method)

    STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued WELD EXTENSION PLATE (ALTERNATE METHOD) CAUTION To preserve the corrosion-resistant properties of the galvanized fi nish, MAX- ON recommends bolting the galvanized extension plate to vehicle. NOTE: Before welding extension plate to vehicle body, make sure: •...
  • Page 20 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued VEHICLE EXTENSION BODY PLATE 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. 20-1 NOTE: During installation of liftgate, installation brackets keep the heel of the platform level with extension plate and maintain a ¾”...

  • Page 21: Step 2 - Weld Liftgate To Vehicle

    STEP 2 - WELD LIFTGATE TO VEHICLE NOTE: GPTLR Liftgates are equipped with mounting plates installed at the factory. Mounting plate widths are shown based upon truck or trailer frame widths. Ensure you have the correct mounting plate kit for your application.
  • Page 22 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued 1. Unfold the platform and fl ipover (FIG. 22-1). OPENER OPENER MOUNTING BRACKET MOUNTING PLATFORM PLATES FLIPOVER PLATFORM & FLIPOVER UNFOLDED FIG. 22-1 2. Unbolt opener from mounting bracket (shipping position) and save to reinstall (FIG.
  • Page 23 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued CAUTION To prevent damage to aluminum fl ipover, NEVER hoist the Liftgate by the fl ipover as illustrated below. Hoist the Liftgate by the platform only as shown in the illustration below. CAUTION Maintain distance between vehicle fl...
  • Page 24 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued CAUTION Prevent damage to hydraulic hoses. If welding next to hydraulic hoses, use a protective cover such as a welding blanket to cover the hoses. 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 25: 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 26 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. 26-1A & 26-1B for trail- MEMBER ers and FIG.
  • Page 27 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- CROSS plate mark and drill holes through MEMBER cross members (FIG.
  • Page 28 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 29 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 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 1/4” PUMP BOX 1/4”-20 X 1” LG. (4 PLACES) CHARGE LINE FROM (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 installed on trailers as shown in FIG.
  • 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 1. Unbolt and remove pump cover as shown in FIG. 34-1. UNBOLTING PUMP COVER FIG. 34-1...
  • Page 35 STEP 5 - CONNECT POWER CABLE - Continued NOTE: Electrical lines must be run into pump box through sealing grom- mets (FIG. 35-3). To ensure a good seal on hydraulic & electrical lines, never cut the sealing grommets. COPPER TERMINAL LUG 2.

  • Page 36: Step 6 - Connect Ground Cable

    STEP 6 - CONNECT GROUND CABLE NOTE: Electrical lines must be run into pump box through sealing grommets (FIG. 36-1A). To ensure a good seal on the electrical lines, never cut the sealing grommets. NOTE: To ensure power unit is correctly grounded, connect 2 gauge ground cable to grounding connection on pump.
  • Page 37 STEP 6 - CONNECT GROUND CABLE - Continued NOTE: If there is a grounding point on the frame, use it to connect ground cable. Then, skip the step for drilling a hole. NOTE: Clean the ground cable connection point on the frame down to bare metal. 4.

  • Page 38: Step 7 - Install Control Switch

    STEP 7 - INSTALL CONTROL SWITCH 1. Measure, mark and drill one 3/4“ hole and two #21–size holes in the vertical post on curb side of vehicle body as shown in FIG. 38-1. VEHICLE BODY VERTICAL POST (CURB SIDE) 2. Insert control switch wir- ing harness (parts box) into 3/4”...
  • Page 39 STEP 7 - INSTALL CONTROL SWITCH - Continued NOTE: Electrical lines must be run into pump box through sealing grommets (FIGS. 39-1 & 39-2). To ensure a good seal on the electrical lines, never cut the sealing grommets. 5. Insert switch wiring through grom- BLACK met on pump mounting plate (FIGS.

  • Page 40: 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 41 STEP 8 - 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 41-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED PART NUMBER BRANDS CHEVRON...

  • Page 42: Step 9 - Connect Power Cable To Battery

    STEP 9 - CONNECT POWER CABLE TO BATTERY 1. Remove nut from negative (-) POSITIVE (+) BATTERY CABLE battery terminal (FIG. 42-1). Dis- connect negative (-) battery cable (FIG. 42-1). POSITIVE (+) BATTERY TERMINAL NEGATIVE (-) BATTERY CABLE NEGATIVE (-) BATTERY TERMINAL 2.

  • Page 43: Step 10 - Remove Locking Brackets & Check

    STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE 1. Remove fl oor jack and hoist supporting Liftgate (FIG. 43-1). FLOOR JACK REMOVING JACK FIG. 43-1 2. Lower platform to ground level (FIG. 43-2). Refer to operating in- structions in Operation Manual. LOWERING PLATFORM FIG.
  • Page 44 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued CAUTION To prevent damage to Liftgate, the locking bracket on each cylinder must be removed before operating Liftgate. 3. Unbolt the locking brackets from both cylinders (FIG. 44-1). LOCKING CAP NUT BRACKET...
  • Page 45 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued 4. Raise the platform (FIG. 45-1). Look for any interference between liftgate and vehicle as EXTENSION PLATE platform is raised. LIFT ARM FIG. 45-1 5. Lower platform to the ground (FIG. 45-2). Look for any interference between liftgate and vehicle as platform is lowered.
  • Page 46 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued 6. Lower platform to the ground (FIG. 46-1). LOWERING PLATFORM FIG. 46-1 7. Unbolt the 2 installation brackets from extension plate (FIG. 46-2). BOLT (2 PLACES) BRACKET & NUT (2 PLACES) EXTENSION PLATE...
  • Page 47 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued NOTE: Correct any fi t and interference problems before continuing with installation. 8. Raise the platform to vehicle fl oor level (FIG. 47-1). Refer to operating instruc- tions in Operation Manual. Check for 5/8”...

  • Page 48: Step 11 - Adjust Platform (If Required)

    STEP 11 - ADJUST PLATFORM (IF REQUIRED) NOTE: In most cases, if Liftgate is installed according to the instructions in this manual, platform will not require adjustment. Use the following instruc- 1/4” MAX. tions to check the platform. Adjust the platform only if required.
  • Page 49 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 2. Make sure platform is still at ground level. If the shack- les are not touching the ground, measure and com- pare distance “A” (FIG. 49-1) with TABLE 49-1 to determine the correct shim. RAISE TIP OF WELD FLIPOVER...
  • Page 50 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 5. Lower platform to the ground. Unfold platform and fl ipover. RAISE the platform to bed height, then LOWER it to the ground. The tip of fl ipover and shackle should touch the ground as shown in FIG.
  • Page 51 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 7. Reinstall locking brackets LOCKING on both cylinders (FIG. CAP NUT BRACKET 51- 1). Bolt each locking bracket in place. BOLT FLAT WASHER LH CYLINDER LOCKING BRACKET (2 PLACES) CYLINDER REINSTALLING LOCKING BRACKETS 8.
  • Page 52 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued WARNING To prevent accidental personal injury and equipment damage, make sure power is disconnected from Liftgate while installing parts. 10. Disconnect power to the pump by disconnecting negative (-) and POSITIVE (+) positive (+) cables from battery (FIG.
  • Page 53 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 12. Measure distance “C” from the tip of the fl ipover to ground level (FIG. 53-1). Next, subtract the distance “B” measured in instruction 6. The result is “C” distance “D” for the platform adjustment (FIG.
  • Page 54 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued CAUTION When using an electric welder, connect the welder ground to one of the parts being welded, as close to the weld as possible. Failure to comply could result in damage to cylinders and electrical parts. CAUTION Prevent damaged hydraulic hoses.
  • Page 55 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 18. LOWER the Liftgate to ground level (FIG. 55- 2A). Remove the installation brackets from RH side and LH side of plat- form (FIG. 55- 2B). BOLT (2 PLACES) BRACKET & NUT (2 PLACES) EXTENSION PLATE...
  • Page 56 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 19. Unbolt the locking brackets from both cylinders (FIG. 56- 1). Re- move the locking brackets. LOCKING CAP NUT BRACKET BOLT FLAT WASHER LH CYLINDER LOCKING BRACKET (2 PLACES) CYLINDER REMOVING LOCKING BRACKETS FIG.

  • Page 57: Step 12 - Finish Welding Liftgate To Vehicle

    STEP 12 - FINISH WELDING LIFTGATE TO VEHICLE WARNING Liftgate is shipped from factory with mounting plates bolted to the main frame. Weld the mounting plates as shown in illustrations before operating Liftgate. CAUTION When using an electric welder, connect the welder ground to one of the parts being welded, as close to the weld as possible.

  • Page 58: Step 13 - Weld Truck Body To Frame

    STEP 13 - WELD TRUCK BODY TO FRAME (TRUCKS ONLY) CAUTION When using an electric welder, connect the welder to one of the parts being welded, as close to the weld as possible. Failure to comply could result in damage to cylinders and electrical parts. CAUTION To prevent truck body from moving out of position, weld the C-channels on each side of truck body to truck frame.

  • Page 59: Step 14 - Adjust Opener (If Required)

    NOTE: The platform must always stow and unfold without hitting underside of vehicle. Platform should unfold as close as possible to position shown in FIG. 59-1, but must never be positioned so it falls open. 1. The MAXON-recommended proce- dure for repositioning the opener is as follows. Lower the platform from stowed position (FIG.
  • Page 60 STEP 14 - ADJUST OPENER (IF REQUIRED) - Continued CAUTION To prevent damage to ICC bumper, opener must not rub against bumper. Ensure the 3-position roller remains in contact with ICC bumper at fi rst contact and through the full range of motion to highest position. Bolt roller in one of the 3 hole positions that best maintains contact between roller and bumper.
  • Page 61 STEP 14 - ADJUST OPENER (IF REQUIRED) - Continued NOTE: Opener can be repositioned to best open the platform when vehicle bed heights are 44” to 55”. The platform must always stow and unfold without hitting underside of vehicle. Platform should unfold as close as possible to position shown in FIG.

  • Page 62: Step 15 - Adjust Underride

    STEP 15 - ADJUST UNDERRIDE NOTE: This underride adjustment procedure is for: • GPTLR-25 & GPTLR-33 with Federal Motor Vehicle Safety Standard (FMVSS) optional underride • GPTLR-44 & GPTLR-55 with standard FMVSS underride • GPTLR-44 & GPTLR-55 with Canadian Motor Vehicle Safety Standard (CMVSS) underride NOTE: For 5”...
  • Page 63 STEP 15 - ADJUST UNDERRIDE - Continued 1. Stow the Liftgate under hydraulic pressure (FIG. 63-1). LIFTGATE WITH PLATFORM STOWED (STANDARD UNDERRIDE SHOWN ) FIG. 63-1 2. Measure vehicle bed height (FIG. 63-2). BED HEIGHT (UNLOADED) NOTE: If underride is already bolted MEASURING BED HEIGHT in correct position for your (STANDARD UNDERRIDE SHOWN)
  • Page 64 STEP 15 - ADJUST UNDERRIDE - Continued 53”- 54” 55” 51”- 52” 48”-50” 47” 44” UNDERRIDE GPTLR-25 & GPTLR-33 FMVSS UNDERRIDE BRACKET SETTINGS GPTLR-25 & GPTLR-33 BASED ON BED HEIGHT (RH BRACKET SHOWN) OPTIONAL FMVSS UNDERRIDE FIG. 64-1B FIG. 64-1A 53”- 54”...
  • Page 65 STEP 15 - ADJUST UNDERRIDE - Continued 53” 54” 55” 52” 51” 50” 49” UNDERRIDE GPTLR-44 & GPTLR-55 CMVSS UNDERRIDE BRACKET SETTINGS BASED ON BED HEIGHT (RH BRACKET SHOWN) FIG. 65-1B GPTLR-44 & GPTLR-55 OPTIONAL CMVSS UNDERRIDE FIG. 65-1A...
  • Page 66 STEP 15 - ADJUST UNDERRIDE - Continued NOTE: If your underride is not in the correct position for bed height of vehicle, per- form the following procedure. ADJUSTING UNDERRIDE ASSEMBLY NOTE: Platform seats must be removed from lift arms to adjust position of underride assembly.
  • Page 67 STEP 15 - ADJUST UNDERRIDE - Continued NOTE: At the lowest bed heights, underride may have too little ground clearance for a jack. If necessary, raise the platform up to 6” to get a jack in position to support the underride. 6.
  • Page 68 STEP 15 - ADJUST UNDERRIDE - Continued NOTE: The only models with an adjustable underride tube are • Optional FMVSS underride (GPTLR-25 & GPTLR-33) • Standard FMVSS underride (GPTLR-44 & GPTLR-55). ADJUSTING UNDERRIDE TUBE EXTENSION PLATE (REF) 9. Stow the platform. Refer to FIG. 68-1. Loosen bolt and lock nut, at each end of tube, just enough to move underride tube (FIG.
  • Page 69 STEP 15 - ADJUST UNDERRIDE - Continued CAUTION When using an electric welder, connect the welder to one of the parts being welded, as close to the weld as possible. Failure to comply could result in damage to cylinders and electrical parts. CAUTION To protect the original paint system, a 3”...
  • Page 70 STEP 15 - ADJUST UNDERRIDE - Continued 11. With platform stowed, measure and record ground clearance “H” (FIG. 70-1). Then, lower the platform to the ground to measure ground clearance “H1” (FIG. 70-2). Compare measurements with TABLES 71-1, 72-1 and 72-2. 11”...
  • Page 71 STEP 15 - ADJUST UNDERRIDE - Continued NOTE: The bed height dimensions, for each underride hole shown below, apply to an unloaded vehicle. RECOMMENDED BOLTED HOLE POSITIONS FOR OPTIONAL FMVSS UNDERRIDE INSTALLED ON GPTLR-25 & GPTLR-33 “H” “H1” UNDER- EXPECTED UN- EXPECTED UNDERRIDE GROUND CLEAR- RIDE DERRIDE GROUND...
  • Page 72 STEP 15 - ADJUST UNDERRIDE - Continued NOTE: The bed height dimensions, for each underride hole shown below, apply to an unloaded vehicle. RECOMMENDED BOLTED HOLE POSITIONS FOR STANDARD FMVSS UNDERRIDE INSTALLED ON GPTLR-44 & GPTLR-55 “H” “H1” UNDER- EXPECTED UN- EXPECTED UNDERRIDE GROUND CLEAR- DERRIDE GROUND ANCE &...
  • Page 73 STEP 15 - ADJUST UNDERRIDE - Continued CAUTION When using an electric welder, connect the welder to one of the parts being welded, as close to the weld as possible. Failure to comply could result in damage to cylinders and electrical parts. CAUTION To protect the original paint system, a 3”...
  • Page 74 STEP 15 - ADJUST UNDERRIDE - Continued NOTE: For some bed heights, platform seat may be bolted against the underride bracket. 13. Lower platform to the ground (FIG. 74-1A). Then, bolt the LH platform seat (FIG. 74-1B) and the RH platform seat in position. Torque the cap screws and lock nuts to 42 lb-ft.
  • Page 75 STEP 15 - ADJUST UNDERRIDE - Continued 14. Stow platform (FIG. 75-1). Next, center conspi- cuity (refl ective) tape on the underride tube as shown in FIG. 75-1. Remove backing from tape. Then, attach tape to underride (FIG. 75-1). UNDERRIDE CENTER OF CONSPICUITY TUBE...

  • Page 76: Step 16 - Vehicle Taillight Positioning (If Required)

    STEP 16 - VEHICLE TAILLIGHT POSITIONING (IF REQUIRED) NOTE: Taillights may interfere with Liftgate. Taillights and attaching hardware are not provided with the Liftgate. If needed, install vehicle taillights to comply with state and federal vehicle lighting requirements, such as FMVSS 108.

  • Page 77: Attach Decals

    ATTACH 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 78: Decals & Plates

    MAXON PLATE P/N 280004-01 PARTS QR CODE DECAL P/N 299348-08 SERIAL PLATE (REF) CAUTION DECAL WARNING DECAL (FLIPOVER EQUIPPED WITH LATCH ONLY) P/N 265736-02 P/N 267694-01 NOTE: MAXON 24/7 LIFTGATE SUPPORT service is only available in the Continental U.S. FIG. 78-1...

  • Page 79: Attach Nonskid & Safety Striping

    ATTACH 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. 79-1...

  • Page 80: Touchup 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 81: System Diagrams

    SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) STARTER SOLENOID “A” VALVE MOTOR DIRECTION OF CONTROLLED FLOW GRAVITY DOWN POWER UNIT FIG. 81-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE LOCK MOTOR “A”...

  • Page 82: 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. 82-1 POWER UNIT MOTOR & SOLENOID OPERATION SOLENOID OPERATION MEANS ENERGIZED) LIFTGATE PORT FUNCTION VALVE VALVE LOCK MOTOR “S2”...

  • Page 83: 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 84: 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 85: Electrical Schematic (Gravity Down)

    ELECTRICAL SCHEMATIC (GRAVITY DOWN) CONTROL SWITCH (UP) (DOWN) GREEN BLACK JUNCTION BLOCK WHITE CYCLE COUNTER SOLENOID LOCK VALVE “A” VALVE EQUIPPED) FUSE HOLDER WITH 10 AMP FUSE CABLE WITH 175 AMP FUSE STARTER SOLENOID MOTOR BATTERY FIG. 85-1...

  • Page 86: Electrical Schematic (Power Down)

    ELECTRICAL SCHEMATIC (POWER DOWN) FIG. 86-1...

  • Page 87: Gptlr Electrical Values & Torque Specifications

    SYSTEM DIAGRAMS GPTLR ELECTRICAL VALUES & TORQUE SPECIFICATIONS 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 88: Options

    OPTIONS OPTIONAL LIFTGATE COMPONENTS MISCELLANEOUS KITS PART NO. IN CAB ON-OFF SWITCH 250477 FRAMELESS TRAILER, GPTLR, 102” WIDE 282562-01 FRAMELESS TRAILER, GPTLR, 102” WIDE, GALVANIZED 282562-01G FRAMELESS TRAILER, GPTLR, 96” WIDE 282562-02 FRAMELESS TRAILER, GPTLR, 96” WIDE, GALVANIZED 282562-02G CIRCUIT BREAKER (150 AMP) 251576 TRAFFIC CONES 268893-01...

  • Page 89: 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:

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

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