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Maxon Tuk-A-Way GPT Series Installation Manual

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M-17-05
REV. E
NOVEMBER 2021
To fi nd maintenance & parts information for your GPT Liftgate, go to www.maxonlift.
com. Click the PRODUCTS, TUK-A-WAY & GPT buttons. Open the Maintenance Manual in
the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL,
TUK-A-WAY & GPT buttons.
© MAXON Lift Corp. 2021

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Summary of Contents for Maxon Tuk-A-Way GPT Series

  • Page 1 To fi nd maintenance & parts information for your GPT Liftgate, go to www.maxonlift. com. Click the PRODUCTS, TUK-A-WAY & GPT buttons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A-WAY & GPT buttons. © MAXON Lift Corp. 2021...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SUMMARY OF CHANGES: M-17-05 REVISION E .............. 4 WARNINGS ........................... 5 SAFETY INSTRUCTIONS ....................6 NOTICE ..........................6 STANDARD LIFTGATE COMPONENTS ................7 GPT INSTALLATION PARTS BOXES ................... 8 GPT-SERIES MANUALS & DECALS ..................9 VEHICLE REQUIREMENTS ....................10 CENTER OF MASS ......................
  • Page 3 ATTACH DECALS ......................61 DECALS & PLATES ......................63 TOUCH-UP PAINTED OR GALVANIZED FINISH .............. 64 SYSTEM DIAGRAMS ......................65 PUMP MOTOR & SOLENOID SWITCH OPERATION - SINGLE PUMP ......65 PUMP MOTOR & SOLENOID SWITCH OPERATION - DUAL PUMPS ......66 HYDRAULIC SCHEMATIC (POWER DOWN) ..............

  • Page 4: Summary Of Changes: M-17-05 Revision E

    SUMMARY OF CHANGES: M-17-05 REVISION E PAGE DESCRIPTION OF CHANGE COVER Updated REV and date of release. Updated ground cable to 57.75” long cable in Parts Box A. Added new cap screw, fl at washer and lock nut to Parts Boxes A and C. Removed plastic ties (items for packaging) from Parts Boxes A and C.

  • 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: 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 cservice@maxonlift.com...

  • Page 8: Gpt Installation Parts Boxes

    GPT INSTALLATION PARTS BOXES ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER PARTS BOX A 297502-01 SPRING CLIP, 1/2” x 1-3/8” 050079 #10 RUBBER LOOM CLAMP 801681 CABLE ASSEMBLY, 175 AMPS, 38 FT LG. 264422 SELF-TAPPING SCREW, 10 X 1/2” LG. 030458 CABLE ASSEMBLY, 2 GA, BLACK, 57-3/4”...

  • Page 9: Gpt-Series Manuals & Decals

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

  • Page 10: Vehicle Requirements

    VEHICLE REQUIREMENTS NOTE: BODY maximum and minimum operating bed height: For all GPT models 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 modifi ed to install this Liftgate. NOTE: Make sure vehicle is parked on level ground while preparing vehicle and installing Liftgate.
  • Page 11 VEHICLE REQUIREMENTS - Continued WARNING Incorrect modifi cation of vehicle frame and/or body could contribute to serious mechanical failure of the vehicle. Serious injury to operator, motorists, and bystanders could result. Installer is responsible for ensuring vehicle body and frame modifi cation do not adversely affect the integrity of the body and frame. If unsure about modifying vehicle, installer should consult truck/trailer body manufacturer.
  • Page 12 VEHICLE REQUIREMENTS - Continued WARNING Incorrect modifi cation of vehicle frame and/or body could contribute to serious mechanical failure of the vehicle. Serious injury to operator, motorists, and bystanders could result. Installer is responsible for ensuring vehicle body and frame modifi cation do not adversely affect the integrity of the body and frame. If unsure about modifying vehicle, installer should consult truck/trailer body manufacturer.

  • Page 13: Center Of Mass

    CENTER OF MASS CENTER OF MASS 19-3/16” 13-11/16” GPT-25 & GPT-3 CENTER OF MASS (STOWED POSITION) FIG. 13-1 20-5/16” CENTER OF MASS 13-11/16” GPT-4 & GPT-5 CENTER OF MASS (STOWED POSITION) FIG. 13-2...

  • Page 14: Step 1 - Attach Extension Plate To Vehicle

    MAXON recommends bolting the galvanized extension plate to vehicle. NOTE: GPT 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 recommends getting the optional extension plate hardware kit listed in OPTIONS section.
  • Page 15 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” 6-1/2” USE 9/16” DRILL REAR (19 PLACES) SILL 3-1/8” REAR SILL - HOLE LOCATIONS FOR 102” WIDE VEHICLE FIG.
  • Page 16 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 17: Weld Extension Plate (Alternate Method)

    WELD EXTENSION PLATE (ALTERNATE METHOD) CAUTION To preserve the corrosion-resistant properties of the galvanized fi nish, MAXON recommends bolting the galvanized extension plate to vehicle. 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 18 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued EXTENSION PLATE VEHICLE BODY 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. 18-1 NOTE: During installation of liftgate, installation brackets keep the heel of the plat- form level with extension plate and maintain a ¾”...

  • Page 19: Step 2 - Weld Liftgate To Vehicle

    STEP 2 - WELD LIFTGATE TO VEHICLE NOTE: GPT 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 20 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued 1. Unfold the platform and fl ipover (FIG. 20-1). LOCKING ANGLES (REF) PLATFORM MOUNTING PLATES FLIPOVER STOP (2 PLACES) OPENER FLIPOVER PLATFORM & FLIPOVER UNFOLDED FIG. 20-1 2. Unbolt opener from mounting bracket (shipping position) and save to reinstall (FIG.
  • Page 21 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 Correct fl...
  • Page 22 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 23: 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 24 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 to WASHER CROSS FIGS. 24-1 & 24-1A for trailers and MEMBER FIG.
  • Page 25 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued NOTE: The hanger brackets for the battery box frame can either be bolted or welded to the cross members of the vehicle body. If welding mounting brackets to cross members, skip instruction 3.
  • Page 26 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 27 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 28 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued NOTE: Always connect fused end of power cable to battery positive (+) terminal. GROUND CABLE TO PUMP BOX OR COMMON CHASSIS GROUND, 74” LG. (BATTERY BOX KIT ITEM) (-) BATTERY CABLE TO COMMON GROUND...
  • Page 29 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 30 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued BATTERY BOX ASSEMBLY LOCK NUT, 1/4”-20 175 AMP FUSED GROUND CABLE (2 PLACES) FLAT WASHER CABLE TO FROM VEHICLE PAN HEAD SCREW 1/4” PUMP BOX BATTERY 1/4”-20 X 1”...

  • Page 31: Step 4 - Run Power & Ground Cables

    STEP 4 - RUN POWER & GROUND CABLES 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 32 STEP 4 - RUN POWER & GROUND CABLES - 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. Keep adequate distance between (+) and (-) cables that connect to battery.

  • Page 33: Step 5 - Connect Power Cable

    STEP 5 - CONNECT POWER CABLE Unbolt and remove pump cover (FIG. 33-1). UNBOLTING PUMP COVER FIG. 33-1 2. On the bare wire end of fused power cable, keep enough length to attach copper ter- minal lug and reach motor solenoid switch (single pump) or pump selector switch (dual pumps) without putting tension on cable (after connection) (FIG.
  • Page 34 STEP 5 - CONNECT POWER CABLE - Continued CAUTION Do not over-tighten the terminal nuts on solenoid switch. For the load terminals, torque nuts to 35 lb-in max. Torque the nuts on #10-32 control terminals to 15 lb-in. NOTE: Form a drip loop in the fused power cable where it enters the power unit on the outside of the pump mounting plate.
  • Page 35 STEP 5 - CONNECT POWER CABLE - Continued 4. Remove hex nut and lock washer PUMP SELECTOR from OUTPUT terminal on pump SWITCH selector switch. Connect fused OUTPUT TERMINAL power cable to OUTPUT terminal on pump selector switch as shown FUSED in FIG.

  • Page 36: Step 6 - Connect Ground Cable

    STEP 6 - CONNECT GROUND CABLE NOTE: To ensure power unit is correctly grounded, connect 2 gauge ground cable from grounding connection on pump mounting plate to a grounding point on the frame, or negative battery terminal in the optional battery box. Refer to STEP 9 to connect a dedicated 38 foot long ground cable to vehicle battery.
  • 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. Drill one 3/4“ hole and two #21 (.159) size holes in the vertical post on curb side of vehicle body as shown in FIG. 38-1. VEHICLE BODY VERTICAL POST (CURB SIDE) DRILLING MOUNTING HOLES FIG.
  • Page 39 STEP 7 - INSTALL CONTROL SWITCH - Continued NOTE: Form a drip loop in the control switch cable where it enters the power unit on the outside of the pump mounting plate. 2. Insert control switch cable into the 3/4” hole on the SELF-TAPPING SCREW, 1-1/2”...

  • 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 BRANDS PART NUMBER ROSEMEAD ROSEMEAD MV150 EXXONMOBIL MOBIL DTE 10 EXCEL 32 EXXONMOBIL UNIVIS N-32, DTE-24 CHEVRON CHEVRON AV MV32 CHEVRON HIPERSYN 32 U.S. PRESTIGE PRESTIGE AW HVI 32 KENDALL GOLDEN MV SHELL...

  • Page 42: Step 9 - Connect Power & Ground Cables To Battery

    STEP 9 - CONNECT POWER & GROUND CABLES TO BATTERY POSITIVE (+) 1. Remove nut from negative (-) 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 Angles & Knuckle Bolts, Check For Interference

    STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR INTERFERENCE CAUTION Check for leaking hydraulic fl uid as the system is being pressurized. If there is leakage, stop & correct the problem before fully pressurizing the system. 1. Push control switch to UP position to pressurize hydraulic system. Listen for hydraulic fl...
  • Page 44 STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR INTERFERENCE - Continued 4. Remove fl oor jack and hoist supporting Liftgate (FIG. 44-1). FLOOR JACK REMOVING JACK 5. Lower platform to the ground (FIG. 44-2). FIG. 44-1 Look for any interference between liftgate and vehicle as platform is lowered.
  • Page 45 STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR INTERFERENCE - Continued 6. Lower platform to the ground (FIG. 45-1). LOWERING PLATFORM FIG. 45-1 EXTENSION PLATE 7. Unbolt the 2 installation brackets BRACKET & NUT from extension plate (FIG. 45-2). (2 PLACES) BOLT (2 PLACES)
  • Page 46 STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, 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. 46-1). (Refer to GPT Series OPERATION MANUAL.) Check for 5/8”...
  • Page 47 STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR INTERFERENCE - Continued NOTE: Correct any fi t and interference problems before continuing with installation. 9. Ensure top surface of platform SURFACES FLUSH and extension plate are fl ush at the RH &...

  • Page 48: Step 11 - Install Opener & License Plate Bracket With Icc Bumper Or Underride

    STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER OR UNDERRIDE NOTE: If Liftgate is equipped with underride, skip these instructions for installation with ICC bumper. Go to the instructions for INSTALLATION WITH UNDERRIDE. INSTALLATION WITH ICC BUMPER 1.
  • Page 49 STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d NOTE: License plate bracket can be bolted in 4 positions on the ICC bumper brackets. License plate bracket can be bolted on the inside or outside of the LH bumper bracket or RH bumper bracket.

  • Page 50: Installation With Underride

    STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d INSTALLATION WITH UNDERRIDE 1. Lower platform to ground level. Refer to operating instructions in Operation Manual. WARNING To prevent accidental personal injury POSITIVE (+) and equipment damage, disconnect POWER CABLE (-) battery cable and (+) cable from...
  • Page 51 STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d INSTALLATION WITH UNDERRIDE - Continued 4. Reconnect negative (-) battery cable to negative (-) battery terminal (FIG. 51-1). If dedicated NEGATIVE (-) ground cable was installed, con- DEDICATED (-) BATTERY TERMINAL nect ground (-) cable to negative...

  • Page 52: Step 12 - Adjust Platform (If Required)

    STEP 12 - ADJUST PLATFORM (IF REQUIRED) NOTE: Before doing the following procedure, make sure vehicle is parked on level ground. 1. Lower platform to the ground. With the EXTENSION platform and fl ipover unfolded, raise plat- PLATE (REF) OUTBOARD EDGE form to bed level (FIG.
  • Page 53 STEP 12 - ADJUST PLATFORM - Continued EXTENSION 4. Compare measurement “B” (FIG. 53-1) PLATE (REF) VEHICLE with distances and grinding depths in “B” FLOOR (REF) TABLE 53-1. For example: If measure- ment “B” (FIG. 53-1) is 3” above bed level and you want to lower the out- board edge of platform to 1”...

  • Page 54: Step 13 - Finish Welding Liftgate To Vehicle

    STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE CAUTION Prevent damage to hydraulic hoses. Before welding next to hydraulic hoses, protect the hoses with a heat-resistant cover such as a welding blanket. CAUTION To protect the original paint system, a 3” wide area of paint must be removed from all sides of the weld area before welding.

  • Page 55: Step 14 - Bolt Steps To Extension Plate

    STEP 14 - BOLT STEPS TO EXTENSION PLATE 1. Lower platform to the ground (FIG. 55-1). PLATFORM LOWERED TO GROUND FIG. 55-1 WARNING To prevent accidental personal injury and equipment damage, disconnect (-) battery cable and (+) cable from battery. 2.
  • Page 56 STEP 14 - BOLT STEPS TO EXTENSION PLATE - Cont’d CAUTION To prevent interference with Liftgate and possible damage, maintain 90º angle between steps and extension plate. Tighten bolts only in the order shown in illustration. NOTE: If 102” extension kit is to be installed for 102” wide vehicle, install the exten- sion kit before installing the steps.
  • Page 57 STEP 14 - BOLT STEPS TO EXTENSION PLATE - Cont’d 4. Bolt the step support (Kit item) to mounting channel (Kit item) (FIG. 57-1). REAR SILL I-BEAM (VEHICLE BODY) LOCK NUT (3 PLACES) FLAT WASHER (3 PLACES) MOUNTING 1/2” X 3-1/2” LG. CHANNEL LH STEP FRAME BOLT...
  • Page 58 STEP 14 - BOLT STEPS TO EXTENSION PLATE - Cont’d NOTE: Before welding mounting channel to vehicle body, ensure step is straight WELD TO AS MUCH 3/16” and steps are in vertical position. I-BEAM FLANGE & 3/16” REAR SILL AS POSSIBLE 7.

  • Page 59: Step 15 - Vehicle Taillight Positioning

    STEP 15 - VEHICLE TAILLIGHT POSITIONING 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 60: Step 16 - Lube Grease Fittings (As Needed)

    STEP 16 - LUBE GREASE FITTINGS (AS NEEDED) 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 lubrication diagram (FIG.

  • Page 61: Attach Decals

    ATTACH DECALS NOTE: Ensure there is no residue, dirt or corrosion where decals are attached. If necessary, clean surface before attaching 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 62 ATTACH DECALS - Continued DECAL SHEET P/N 297205-01 FIG. 62-1 CAPACITY MODEL DECAL P/N DECAL GPT-25 220382 2500 POUNDS GPT-3 220388 3000 POUNDS GPT-4 296274-01 4000 POUNDS GPT-5 296274-02 5000 POUNDS CAPACITY DECAL TABLE 62-1...

  • Page 63: Decals & Plates

    DECALS & PLATES NOTE: Preferred decal layout is shown. Decals on the Liftgate are attached at the factory. MAXON NAME PLATE MAXON 24/7 P/N 280004-01 SUPPORT DECAL P/N 298634-01 PARTS QR CODE DECAL P/N 299348-05 SERIAL PLATE (REF) PLATFORM WARNING DECAL...

  • Page 64: Touch-Up Painted Or Galvanized Finish

    To maintain the protection provided by the original paint system, MAXON recommends aluminum primer touchup paint. • 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 65: System Diagrams

    SYSTEM DIAGRAMS PUMP MOTOR & SOLENOID SWITCH OPERATION - SINGLE PUMP POWER DOWN MODULE PORT A MOTOR “S2” VALVE “S1” VALVE SOLENOID SWITCH PORT B POWER UNIT FIG. 65-1 NOTE: Hydraulic lock valve is on the RH cylinder. PUMP MOTOR & SOLENOID SWITCH OPERATION SOLENOID SWITCH OPERATION MEANS ENERGIZED) LIFTGATE...

  • Page 66: Pump Motor & Solenoid Switch Operation - Dual Pumps

    PUMP MOTOR & SOLENOID SWITCH OPERATION - DUAL PUMPS PUMP SOLENOID MOUNTING SWITCH PLATE PUMP #2 MOTOR PORT C2 PORT C1 “S1” VALVE MOTOR DUAL PUMP POWER UNIT - REAR VIEW SOLENOID FIG. 66-2 SWITCH PUMP #1 DUAL PUMP POWER UNIT FIG.

  • Page 67: Hydraulic Schematic (Power Down)

    HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDERS HYDRAULIC LOCK VALVE PORT B - LOWER (POWER DOWN) PORT A - RAISE VALVE S2 4 GPM FLOW CONTROL RELIEF VALVE 2 VALVE (SET AT 1100 PSI) VALVE S1 RELIEF VALVE 1 (SET AT 2750 PSI) AUX.

  • Page 68: Hydraulic Schematic (Power Down) - Dual Pumps

    HYDRAULIC SCHEMATIC (POWER DOWN) - DUAL PUMPS LH HYDRAULIC HYDRAULIC RH HYDRAULIC CYLINDER LOCK VALVE CYLINDER HYDRAULIC LOCK VALVE 3 GPM FLOW CONTROL VALVE VENT PORT C2 - DOWN PORT C1 - RAISE VENT GAUGE PORT RELIEF VALVE 2 (PLUGGED) (SET AT 1800 PSI) VALVE S1 RELIEF VALVE 1...

  • Page 69: 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. 69-1...

  • Page 70: Electrical Schematic (Power Down) - Dual Pumps

    ELECTRICAL SCHEMATIC (POWER DOWN) - DUAL PUMPS BLACK NOTE: One cycle is counted when BLACK the down switch is activated for 5-7 continuous seconds. FIG. 70-1...

  • Page 71: Gpt Electrical Values & Torque Specifications

    SYSTEM DIAGRAMS GPT 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 (S1 & S2) 4.0Ω @ 70ºF. ±15% 26.7Ω...

  • Page 72: Options

    OPTIONS OPTIONAL LIFTGATE COMPONENTS MISCELLANEOUS KITS PART NO. FRAMELESS TRAILER BRACKET, MOUNTING, 102” WIDE 282970-01 FRAMELESS TRAILER BRACKET, MOUNTING, 102” WIDE (GALVANIZED) 282970-01G FRAMELESS TRAILER BRACKET, MOUNTING, 96” WIDE 282970-02 FRAMELESS TRAILER BRACKET, MOUNTING, 96” WIDE (GALVANIZED) 282970-02G FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS (GALVANIZED) 282372-01G FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS, NO FINISH (HAS RUST PREVENTIVE COAT) 282372-03...
  • Page 73 OPTIONAL LIFTGATE COMPONENTS - Continued DUAL STEP DOCK BUMPER KITS WITH BUMPERS - CONTINUED DUAL FLEX STEP (GALVANIZED), STREET SIDE, NO STEPS, 14” LG. RUBBER BUMPERS 288705-23G DUAL FLEX STEP (PAINTED), STREET SIDE, NO STEPS, 13.5” LG. RUBBER BUMPERS 288705-24G DUAL STEP W/LIGHT, (GALVANIZED) CURB SIDE, 14”...

  • Page 74: 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:

Tuk-a-way gpt-25Tuk-a-way gpt-3Tuk-a-way gpt-4Tuk-a-way gpt-5

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