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Maxon GPC 17 X-1 User & Maintenance Manual

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USER-, MAINTENANCE MANUAL
GPC 17 X-1, GPC 22 X-1,
GPC 33 X-4, GPC 44 X-4
LIFT CORP.
11921 Slauson Avenue
Date 12.2020
Santa Fe Springs, CA 90670-2221
Part-no. S 20 912 525
P 800.227.4116 / 562.464.0099
F 888.771.7713

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  • Page 1 USER-, MAINTENANCE MANUAL GPC 17 X-1, GPC 22 X-1, GPC 33 X-4, GPC 44 X-4 LIFT CORP. 11921 Slauson Avenue Date 12.2020 Santa Fe Springs, CA 90670-2221 Part-no. S 20 912 525 P 800.227.4116 / 562.464.0099 F 888.771.7713...
  • Page 2 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 3: Table Of Contents

      2.11 P ermissible loads ..................20     2.12 L oad diagram GPC 17 X-1, GPC 22 X-1, GPC 33 X-4, GPC 44 X-4 ..21     Operation of the liftgate .................. 22     Activating the liftgate .................. 22  ...
  • Page 4     Liability exclusions ..................43     Copyright ....................43     Notes ........................ 44     This user and maintenance manual applies to the following liftgates: GPC 17 X-1 GPC 22 X-1 GPC 33 X-4 GPC 44 X-4...

  • Page 5: General

    41 1.3 Description of the MAXON liftgate You have chosen a liftgate of the highest quality. MAXON liftgates comply with the EU Machinery Directive 2008/42/EG as well as DIN EN 1756 – 1. The MAXON liftgate is simple to use. It is equipped with maintenance-free bearings and requires no lubrication...

  • Page 6: Overview Of The Maxon Gpc 17 X-1 Liftgate

    1.4 Overview of the MAXON GPC 17 X-1 liftgate IMPORTANT: The illustration shows the liftgate in the driving position 1 Platform 2 Warning flags 3 Torsion box 4 Lifting arm 5 Lifting cylinder 6 Closing arm 7 Closing cylinder 8 Compact power unit...

  • Page 7: Overview Of The Maxon Gpc 22 X-1 Liftgate

    1.5 Overview of the MAXON GPC 22 X-1 liftgate IMPORTANT: The illustration shows the liftgate in the driving position 1 Platform 2 Warning flags 3 Torsion box 4 Lifting arm 5 Lifting cylinder 6 Closing arm 7 Closing cylinder 8 Compact power unit...

  • Page 8: Overview Of The Maxon Gpc 33 X-4 Liftgate

    1.6 Overview of the MAXON GPC 33 X-4 liftgate IMPORTANT: The illustration shows the liftgate in the driving position 1 Platform 2 Warning flags 3 Lifting gear, left 4 Lifting gear, right 5 Lifting cylinder 6 Closing cylinder 7 Compact power unit (integrated in axle...

  • Page 9: Overview Of The Maxon Gpc 44 X-4 Liftgate

    1.7 Overview of the MAXON GPC 44 X-4 liftgate IMPORTANT: The illustration shows the liftgate in the driving position 1 Platform (with intergrated Torsions box) 2 Warning flags 3 Lifting gear, left 4 Lifting gear, right 5 Lifting cylinder 6 Closing cylinder...

  • Page 10: Description Of The Maxon Liftgate Components

    1.8 Description of the MAXON liftgate components Electrical system/operating unit The individual functions are controlled via a very flat control panel with four membrane switches (see page 22). Optionally for some models, the functions are initiated via the 2-button control panel (see page 23) or the version with two lateral toggle switches (see page 24) or via a handheld control (see page 26).

  • Page 11: Information, Spare Parts Ordering, And Warranty Services Using The Liftgate Serial Number And Rating Plate

    1.9 Information, spare parts ordering, and warranty services using the liftgate serial number and rating plate You can order spare parts, submit warranty claims, and find technical information online at https://www.maxonlift.com/support or you can send an e-mail to: techservice@maxonlift.com, or contact our service personnel by calling 800-227-4116.

  • Page 12: Safety

    IMPORTANT  Important information or useful tip for correct use. 2.2 Safety The “Safety” section describes the safe operation of the MAXON liftgate. Correct operation of the liftgate will guard against misuse and prevent injury and damage to property. WARNING Do not deviate from the instructions contained in this manual for safely operating the liftgate.

  • Page 13: Fundamental Hazards (Hazards Caused By The Liftgate)

    2.3 Fundamental hazards (hazards caused by the liftgate) DANGER Electrical system with on-board voltage: The liftgate receives electrical power from the vehicle’s on-board power supply (max. 48 V DC). The electrical system is designed using state-of-the-art technology.  Do not damage or modify electrical components or wiring. Fire and explosion hazard.

  • Page 14: Emergency Procedure

    2.6 Intended use Depending on the type, the MAXON liftgate was developed for vehicles ranging from trucks to trailers, including semitrailers. The liftgate is used for both loading and unloading the vehicle and for transferring loads. Do not use the liftgate to lift any person other than the operator.

  • Page 15: Responsibilities Of Operating Company And Requirements For Operator

    2.7 Responsibilities of operating company and requirements for operator The operating company must comply with occupational safety regulations. The operating company is responsible for providing personal protective equipment such as protective footwear and protective clothing for operators and maintenance personnel. Valid accident prevention regulations, legal and operational guidelines, occupational safety regulations, and environmental regulations must be observed.

  • Page 16: Commissioning

    2.8 Commissioning (1) Do not use the liftgate before it is properly installed. (2) Never operate the liftgate with the vehicle in motion. (3) Operate the liftgate at your own risk. (4) When operating the liftgate, secure the vehicle against unexpected movement. (5) Portable lifting platforms such as liftgates must be stable to avoid creating crushing and shearing points between the liftgate and objects around it.
  • Page 17 WARNING Risk of the vehicle losing stability/tipping. The front end of the vehicle can potentially lift and create a risk of injury. Refer to the safety sticker for instructions on correct operation. (8) Keep people and objects way from all moving parts of the liftgate. WARNING Slipping, tripping, or falling hazard (involving the liftgate).
  • Page 18 (14) Do not modify, cover, or remove product labels (warning labels, instructions, rating plates). They must be undamaged and clearly visible. WARNING The absence of warning notice stickers on the vehicle or the absence of a load diagram (missing rating plate) may make it more difficult to recognize hazards and result in injuries.

  • Page 19: Handling And Behavior During Operation

    2.9 Handling and behavior during operation Secure the vehicle against unexpected movement when performing any kind of loading or unloading operation (use handbrake or chocks). Do not place loads on the liftgate that exceed the rated capacity (comply with loading distance and load, see load diagram). Never drive a forklift onto the liftgate platform! (Exception: the weight of the forklift plus the weight of the load being transported is less than the liftgate’s maximum carrying capacity).
  • Page 20 (11) Operating personnel must ensure that neither they nor any other person is endangered by any movement of the liftgate. WARNING Because the device cannot be seen from the control panel, there is a risk that the operator or a third party could be shut inside. Make sure that no one is in the cargo area when the liftgate is closed.
  • Page 21 Rolling and sliding loads must be secured to the platform. Rolling loads must not be transported on the platform without a cart stop. On request, MAXON liftgates come equipped cart stops that reliably secure rolling loads (wheels with max. 4 ″ diameter).
  • Page 22 (21) A moveable liftgate may be moved only when the lifting device is in the driving position (see pages: 2, 3, 4 and 5). The one exception is when the necessary stability is guaranteed and certified in the inspection record book.

  • Page 23: Danger Notice Sticker "Safe Handling Of The Liftgate

    2.10 Danger notice sticker “Safe handling of the liftgate” The danger notice sticker uses individual pictograms to indicate potential incorrect and correct usage of the liftgate. This sticker is supplied with all new liftgates. The installing company must place it in a clearly visible location on the inside of the vehicle cargo area.

  • Page 24: Permissible Loads

    2.11 Permissible loads IMPORTANT Do not allow any load to exceed the rated capacity for the liftgate. The load diagram on the rating plate must be observed. A one-sided load must not exceed 50% of the load- carrying capacity. The center of the load should be as centered as possible between the lifting arms.

  • Page 25: L Oad Diagram Gpc 17 X-1, Gpc 22 X-1, Gpc 33 X-4, Gpc 44 X-4

    2.12 Load diagram GPC 17 X-1, GPC 22 X-1, GPC 33 X-4, GPC 44 X-4 Depending on load-carrying capacity, load center distance = 24″, 30” or 40 IMPORTANT Do not exceed the maximum load-carrying capacity specified in the load diagram. When the platform is completely lowered, it may be traversed/loaded only with loads that do not exceed its rated capacity.

  • Page 26: Operation Of The Liftgate

    Operation of the liftgate 3.1 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. 3.2 Operation using the control panel (membrane switch) From the control panel, all functions are initiated by pressing two different pushbuttons simultaneously.

  • Page 27: Operation Using The Optional 2-Button Control Panel (Et Series 11)

    3.3 Operation using the optional 2-button control panel (et series 11) After the platform has been opened via the control panel (membrane switch), the 2-button control panel can be used to operate the lifting and lowering functions. Lift Lower WARNING Be careful not confuse the control elements for tilt up/tilt down and lift/lower.

  • Page 28: Optional Control Box (Toggle Switches)

    3.4 Optional control box (toggle switches) From the control box, all functions are activated by simultaneously operating the two toggle switches on the left-hand and right-hand sides of the control box using both hands. Heben Lift Senken Lower Öffnen / Abneigen Open/tilt down Anneigen / Schließen Tilt up/close...

  • Page 29: Operating Using The Optional Foot Controls

    3.5 Operating using the optional foot controls The foot controls are configured in such a way that the two foot controls must always be operated one after the other: To lift and tilt up 1. Activate Lower safety pushbutton 2. Initiate Lift function To lower and tilt down 1.

  • Page 30: Operation Using The Optional Handheld Control With Spiral Cable

    3.6 Operation using the optional handheld control with spiral cable After the platform has been opened via the control panel, the 2-button handheld control can be used to operate the lifting and lowering functions. When the platform is open the 3-button handheld control can also be used to operate the tilt up and tilt down functions.

  • Page 31: Operating Positions And Safety Distances When Using The Optional Handheld Control With Spiral Cable

    3.6.1 Operating positions and safety distances when using the optional handheld control with spiral cable IMPORTANT When using a handheld control with a spiral cable, the operator may initiate liftgate functions only while standing in the positions shown in the illustration. Operating position on the platform or vehicle floor The operator must stand a minimum of 10″...

  • Page 32: Maintenance

    Maintenance 4.1 Daily visual inspections Check functioning and completeness of the operating and safety devices. Check that all warning and instruction labels are legible. Check for damage and completeness of pins and check that pins are securely tightened. Check cylinders for damage to/tightness of hoses, screw connections, and valves.
  • Page 33 Hydraulic fluid recommendations Use 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. In colder regions, use HLPD 10 grade hydraulic fluid. OIL SPECIFICATIONS Grade ISO - (32) Gravity, API - 29.5 degrees Pour Point, F - (-54 degrees) VISCOSITY...
  • Page 34 IMPORTANT Do not make changes to the liftgate without written permission from MAXON construction management. Use only original spare parts for repairs. WARNING Do not modify, bypass, or remove safety devices. Removing, modifying, or bypassing safety devices can result in injury.
  • Page 35 IMPORTANT If you believe that the batteries are draining too quickly, have the batteries and the cables to the power pack inspected by a specialist. It may be necessary to repair or replace the cables, ground connection, or batteries. IMPORTANT Make sure that the battery charging intervals between individual loading and unloading operations are sufficient.

  • Page 36: Fault Diagnosis And Fault Elimination

    Fault diagnosis and fault elimination 5.1 Explanation of diagnostic LED in the control unit The control unit is the central control unit for the liftgate’s electrical system. An LED (monitoring and diagnostic LED) integrated in the control unit serves as an operating state and fault diagnosis indicator.

  • Page 37: Support For Fault Diagnostics And Elimination

    5.4 Support for fault diagnostics and elimination Problem Possible cause 1. Power pack’s electric Battery cable or ground cable is not connected or is defective motor does not work Cable to driver’s cabin is disconnected Main fuse is defective Fuse in power pack is defective Main battery switch is not switched on Switch in driver’s cabin is not switched on Power relay is defective and does not operate...
  • Page 38 6. Platform tilts down Solenoid valve from closing cylinder is defective independently without the function being activated 7. Platform does not tilt Cable feed to pressure switch is defective down when touching the Pressure switch is defective ground 8. Liftgate does not lift Power pack does not work Too little fluid in reservoir Voltage is too low...

  • Page 39: When Electric Motor Is Operated Continuously "Liftgate Cannot Be Switched Off

    5.5 When electric motor is operated continuously “liftgate cannot be switched off” Tip: Turn the nut on the battery’s positive terminal to the left until contact is interrupted or disconnect using battery main switch to stop the motor from running. Then take the liftgate to the nearest authorized repair shop or call our customer service so that the defect can be corrected.

  • Page 40: Emergency! Platform Moved By Mechanical Means

    5.6 Emergency! Platform moved by mechanical means In an emergency – for example, the liftgate breaks down while open – lifting and/or closing the liftgate by mechanical means instead of hydraulically causes the hydraulic cylinders to be filled with air. This means that the safety valves (solenoid valves) are out of order.

  • Page 41: Decommissioning, Disassembly, And Disposal

    Decommissioning, disassembly, and disposal After decommissioning, secure power-operated and power-assisted liftgates against unauthorized use (see Section 5.6 Emergency! Platform moved by mechanical means). Be particularly careful when removing the solenoid valves (safety valves). Before unscrewing the solenoid valves, make sure the platform is secured against sudden lowering and opening, e.g.
  • Page 42 Risk of injury during disassembly/assembly (particularly of safety devices, e.g. removing solenoid valves) due to improper or incorrect assembly/disassembly Use only trained and qualified maintenance personnel. MAXON offers training in assembly, maintenance, and accident prevention regulations (UVV). WARNING Risk of unexpected startup. If the priority circuit is defective, the liftgate can be unexpectedly activated from a second control point, resulting in injury.
  • Page 43 WARNING When transport locks are removed, parts may fall or the platform my tip over, resulting in injury. After disposing of packing materials, store all parts in a secured manner and carefully remove transport locks. WARNING When transport locks are removed, parts may fall. If parts fall, fluid can escape.

  • Page 44: Electrical Circuit Diagram

    Electrical circuit diagram IMPORTANT The electrical circuit diagram is supplied with the liftgate as a separate document and is part of this user manual. IMPORTANT The electrical circuit diagram must always remain with the liftgate. You can also get the circuit diagram from the Technical Service. For this you will need the liftgate serial number (see page 7) or the drawing number from the relevant circuit diagram.

  • Page 45: Hydraulic Circuit Diagram

    Hydraulic circuit diagram IMPORTANT The hydraulic circuit diagram is supplied with the liftgate as a separate document and is part of this user manual. IMPORTANT The hydraulic circuit diagram must always remain with the liftgate. You can also get the circuit diagram from the Technical Service. For this you will need the liftgate serial number (see page 7) or the drawing number from the relevant circuit diagram.

  • Page 46: Warranty, Liability Exclusions, Copyright

    Type of Warranty: Full Parts and Labor MAXON agrees to replace any components which are found to be defective during the first 2 years of service, and will reimburse for labor based on Maxon’s Liftgate Warranty Flat Rate Labor Schedule.

  • Page 47: Purchase Part Warranty

    R.G.A. (Returned Goods Authorization) number must be obtained from Maxon’s Warranty Department prior to the return of any defective part. Defective Parts must be returned within 60 days of the claim date for consideration Warranty Department, MAXON Lift Corp.

  • Page 48: Notes

    Notes...

This manual is also suitable for:

Gpc 22 x-1Gpc 33 x-4Gpc 44 x-4

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