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Summary of Contents for Maxon 11 Series
- Page 1 GPC X1-LDF liftgate in series 11 Installation Manual for Ford Transit from the year of production 2014 LIFT CORP. 11921 Slauson Avenue Santa Fe Springs, CA 90670-2221 P 800.227.4116 / 562.464.0099 Date 10.2021 F 888.771.7713 Part. No. 20 912 755...
- Page 2 Contact information 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...
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Page 3: Table Of Contents
Contents Contents Contact information ....................II Contents ........................III Safety ........................1 Intended use ....................1 Requirements for personnel ................1 Requirements for installation and commissioning .......... 2 Fundamental hazards ..................2 ... -
Page 4: Contents
Contents Securing the axle assemblies ............... 30 Connecting the cables to the lifting gear ............31 4.5.1 Installing and connecting theService switch extern box ..... 31 4.5.2 Installing and connecting the Control panel ........32 ... - Page 5 Contents Recommendations and instructions regarding the liftgate ......65 Hydraulic oil recommendations ..............65 Painting the lifting gear ................. 65 Rating plate ....................65 Useful information ....................66 About the service switches ................66 ...
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Page 6: Safety
Safety Safety 1.1 Intended use This liftgate was specially developed for cargo vans. It may be used only on the vehicles for which it was designed. To determine whether the liftgate may be installed on a specific vehicle, please contact ... -
Page 7: Requirements For Installation And Commissioning
Safety 1.3 Requirements for installation and commissioning Follow the vehicle manufacturer’s current installation guidelines for the relevant vehicle. Pay particular attention to safety instructions and warnings. Changes to the liftgate’s axle assemblies and to the necessary installation adapters are prohibited and invalidate approval by the German Federal Motor Transport Authority. -
Page 8: Presentation Of Warning Notices
Safety 1.6 Presentation of warning notices The following types of notices are used in this manual to identify hazards and complications: WARNING Failure to heed this notice can result in death or serious injury. CAUTION Failure to heed this notice can result in minor or moderate injury. -
Page 9: Introduction
Introduction Introduction 2.1 Scope of delivery IMPORTANT: All illustrations of the lifting gear are shown without factory-installed cables and hydraulic hoses. 2.1.1 Lifting gear Fig. 1 2.1.2 Platform Fig. 2... -
Page 10: Accessories Kit
Introduction 2.1.3 Accessories kit Fig. 3 Fig. 4... - Page 11 Introduction Parts list – accessories kit Item Part No. Description Standard Qty. 80 000 046 Hexagon nut DIN 934 - M5 - A2 20 908 251 Hexagon flange bolt DIN 6921 - M10x15 - 10.9 - ZN 20 907 616 Ground roller 20 907 615 Bushing...
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Page 12: Installation Adapter Kit 22 911 235 For Ford Transit With Front-Wheel Drive
Introduction 2.1.4 Installation adapter kit 22 911 235 for Ford Transit with front-wheel drive Fig. 5... - Page 13 Introduction Parts list – installation adapter kit Part No. 22 911 235 for Ford Transit with front- wheel drive Item Part No. Description Standard Qty. Cheese-head screw DIN 912 - M10x90 - 8.8 - 20909327 with hexagon socket ZN - PRE80 Cheese-head screw DIN 912 - M8x25 - 8.8 - 20907042...
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Page 14: Installation Adapter Kit 22 911 217 For Ford Transit With Rear-Wheel Drive
Introduction 2.1.5 Installation adapter kit 22 911 217 for Ford Transit with rear-wheel drive Fig. 6... -
Page 15: Damage During Transport
Introduction Parts list – installation adapter kit Part No. 22 911 217 for Ford Transit with rear-wheel drive Item Part No. Description Standard Qty. Cheese-head screw DIN 912 - M10x90 - 8.8 - 20909327 with hexagon socket ZN - PRE80 Cheese-head screw DIN 912 - M8x25 - 8.8 - 20907042... -
Page 16: Preparing For Installation
Preparing for installation Preparing for installation 3.1 Requirements for installation The vehicle exhaust must not be located at the rear of the vehicle. Line the vehicle floor with wood panels. For other types of flooring, verify whether installation is possible. ... -
Page 17: Remove Spare Tire
Preparing for installation 3.3.1 Remove spare tire If the vehicle has a spare tire between the rear axle and the rear bumper, remove the tire (see Fig. 7). Fig. 7 3.3.2 Move exhaust pipe If the exhaust pipe is at the rear, move it to the side. -
Page 18: Deactivate Parking Sensors
Preparing for installation 3.3.5 Deactivate parking sensors For vehicles with rear parking sensors, the sensors will no longer function correctly once the platform is installed, because the lifting gear interferes with the sensors (see Fig. 10). Fig. 10 3.3.6 Remove trailer hitch or step ... -
Page 19: Pre-Installing The Installation Adapters
Preparing for installation 3.5 Pre-installing the installation adapters Required material for Ford Transit with front-wheel drive from installation adapter kit (Part No. 22 911 235) Item Part No. Description Standard Qty. Cheese-head screw DIN 912 - M10x90 - 8.8 - 20909327 with hexagon socket ZN - PRE80... - Page 20 Preparing for installation Required material for Ford Transit with rear-wheel drive from the installation adapter kit (Part No. 22 911 217) Item Part No. Description Standard Qty. Cheese-head screw DIN 912 - M10x90 - 8.8 - 20909327 with hexagon socket ZN - PRE80 50141904 Hexagon head screw DIN 933 - M8x25 - ZN...
- Page 21 Preparing for installation Representation of vehicle with front-wheel drive and rear-wheel drive IMPORTANT: Figure shows the installation adapters for a vehicle with front-wheel drive. The installation adapters for a vehicle with rear-wheel drive are visually different. Installation is the same for both vehicle types and Fig. 12 applies to both. Fig.
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Page 22: Securing Angle Brackets To The Front Installation Adapters
Preparing for installation 3.6 Securing angle brackets to the front installation adapters Secure the two angle brackets (10) to the installation adapters (12 and 13) using the hexagon head screws (4), washers (6), and lock nuts (8) and tighten to a torque of 23 Nm (see Fig. -
Page 23: Installing The Cables/Preparation
Preparing for installation 3.7 Installing the cables/preparation IMPORTANT: Excess cable must not be wound up in a coil but must be placed in slings (Fig. 14). Fig. 14 3.7.1 Cable to the platform Route the Control Unit cable for platform connection (white plastic cover) to the swing-arm assembly in the center of the vehicle (Fig. -
Page 24: Routing The Cables To The Front Of The Vehicle
Preparing for installation 3.7.3 Routing the cables to the front of the vehicle For more information, look online at http://www.taillift.org/en/electrical-vehicle-interface IMPORTANT: Follow the vehicle manufacturer’s installation guidelines. NOTICE When installing cables, make sure they are safe from chafing. Do not install cables near heat-dissipating components. Install power cable ... - Page 25 Preparing for installation Cable for cabin switch unit Route the cabin switch cable from the accessories kit (Item No. 11) to the driver’s cabin (see Fig. 19). Connect the cabin switch cable to the 7-pin connector (DIN 72585) from the Control Unit click Fig.
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Page 26: Control Panel Cable On The Control Unit
Preparing for installation 3.7.4 Control panel cable on the Control Unit Route the Control Unit cable for Control panel connection to the right as viewed in the forward direction of travel (see Fig. 20). Fig. 20 3.7.5 Handheld control cable on the Control Unit ... - Page 27 Preparing for installation Disconnect the wires on the Control Unit (in the Power pack) as follows (see Fig. 22) Fig. 22 Route the cable 20 911 494 from the cargo area, to outside of the vehicle, to the Control Unit (in the Power pack).
- Page 28 Preparing for installation 3.7.6 Mounting the bracket for the 3- or 2-button Handheld control (optional) Mount the bracket (1) for the Handheld control (2) on the vehicle wall (3) using, for example, 2 screws or adhesive (see Fig. 24). Fig.
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Page 29: Aligning The Lifting Gear
Preparing for installation 3.8 Aligning the lifting gear Align the lifting gear under the vehicle on a mounting tool or pallet (see Fig. 25). Fig. 25... -
Page 30: Mounting Holes On The Vehicle
Preparing for installation Line up the installation adapters on the lifting gear with the manufacturer’s holes in the vehicle chassis (see Fig. 26). Fig. 26 3.9 Mounting holes on the vehicle IMPORTANT: Follow the vehicle manufacturer’s installation guidelines. Find the mounting holes on the vehicle. ... -
Page 31: Installation
Installation Installation 4.1 Positioning the lifting gear Place the prepared lifting gear (on a pallet) under the vehicle using a suitable means of transport, e.g. pallet truck, forklift, etc. (see Fig. 27). Fig. 27... -
Page 32: Tightening The Lifting Gear Fittings Until Hand-Tight
Installation 4.2 Tightening the lifting gear fittings until hand-tight WARNING Installation at crushing and shearing points Fingers are at risk of being crushed or sheared when the lifting gear is installed on the vehicle. Be careful at the connecting points between the lifting gear and vehicle. ... - Page 33 Installation Insert the front bolts (installation adapter kit – Part No. 22 911 217 or 22 911 235) as viewed in the forward direction of travel and tighten until hand-tight as shown in Fig. 29. NOTICE Do not damage cables. Fig.
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Page 34: Securing The Lifting Gear To The Vehicle
Installation 4.3 Securing the lifting gear to the vehicle Secure the lifting gear (with adapters) to the vehicle and tighten to a torque of 115 Nm in the rear and 23 Nm in front (see Fig. 30). On both sides of the liftgate Fig. -
Page 35: Securing The Axle Assemblies
Installation 4.4 Securing the axle assemblies Secure the installation adapters to the lifting gear and tighten to the specified torque of 53 Nm (see Fig. 31). Fig. 31... -
Page 36: Connecting The Cables To The Lifting Gear
Installation 4.5 Connecting the cables to the lifting gear 4.5.1 Installing and connecting the Service switch extern box Disconnect the Service switch extern box from the cable by loosening the screw terminals in the housing (see Fig. 32). Funktion KM + Y3 + Si Down: YA + Y3 + Si... -
Page 37: Installing And Connecting The Control Panel
Installation 4.5.2 Installing and connecting the Control panel WARNING Penetration of water Over the long term, the improper installation of cables can result in water penetrating the Control panel and causing it to malfunction. Risk of serious injury in subsequent operation. - Page 38 Installation Disassemble the Control panel SUPERSEAL connector and, if appropriate, the Control Unit SUPERSEAL connector so that the Control panel cable can be routed to the Control Unit cable via openings. IMPORTANT: A release tool is required for disassembling the SUPERSEAL connector. IMPORTANT: When reassembling, pay...
- Page 39 Installation For the pin housing, first use the release tool to pry out the safety guard (see Fig. 40). Fig. 40 For the pin housing, release the latches on the contact pins and pull the wires out of the back of the housing (Fig.
- Page 40 Installation Connect the connector (1) to the Control Unit connector (2) (see Fig. 43). Legend Item 1 Connector from Control panel for connection to Control Unit Item 2 Connector from Control Unit for connection to Control panel click! Fig. 43 ...
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Page 41: Connecting The Cables (Front Of Vehicle)
Installation 4.5.3 Connecting the cables (front of vehicle) WARNING Vehicle battery short-circuit Improper connection of the device to the vehicle battery can cause a short-circuit and explosion of the battery. Risk of damage to property, fire, and injury. Follow the vehicle manufacturer’s instructions for correctly handling the battery. NOTICE ... -
Page 42: Unpacking The Platform
Installation 4.6 Unpacking the platform Check the scope of delivery for completeness (see pages 4–10). IMPORTANT: Dispose of all packing materials in accordance with environmental regulations. 4.7 Raising the platform Lift the platform using suitable means, e.g. crane, assembly table, or pallet truck and pallet (see Fig. -
Page 43: Installing The Platform
Installation 4.8 Installing the platform WARNING Installation at crushing and shearing points Fingers are at risk of being crushed or sheared when the platform is installed on the lifting gear. Be careful at the connecting points between the platform and lifting gear. ... - Page 44 Installation Loosen the platform stop (1) and push it toward the vehicle (see Fig. 50). Fig. 50 Legend Item 1 Platform stop Thoroughly grease the bearing bushes with the special assembly grease (accessories kit parts list – Item No. 13) (see Fig. 51). Fig.
- Page 45 Installation Align the top bearing points of the platform (platform attachment points) with the swing- arm bearing points (top attachment points of the lifting gear) (see Fig. 52). Fig. 52 Insert the two pins (a, b) through the top attachment points of the platform and the attachment points of the swing-arm assembly.
- Page 46 Installation Lift the tip of the platform until the closing-rod bearing point (attachment point for the closing rod) is aligned with the swing-arm bearing point (bottom attachment point on the platform) (see Fig. 54). IMPORTANT: If necessary, slightly retract or extend the closing rod. Fig.
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Page 47: Mounting The Platform Lock On The Closing Arm
Installation Move the 6 pre-fitted O-rings (accessories kit parts list – Item No. 10) into their correct positions (see Fig. 56). IMPORTANT: All bearing points are sealed with O-rings. Fig. 56 Excerpt from parts list: accessories kit Item No. Part No. Description Standard Qty. -
Page 48: Mounting The Ground Rollers
Installation Mount the screw (1) for the platform lock, including the spring washer (2), washers (3), and sleeve (4), on the platform bearing (see Fig. 58). Legend Item 1 Hexagon head screw Item 2 Spring washer Item 3 Washer Item 4 Sleeve Fig. -
Page 49: Installing Supports (Vehicle-Dependent)
Installation 4.11 Installing supports (vehicle-dependent) With some vehicle types and installation versions, maximum loading of the platform can cause the front of the vehicle to lift up. WARNING Shift in center of gravity and lifting up of front end of the vehicle Unexpected movements of the vehicle can result in the severe injury or death of bystanders. -
Page 50: Connecting The License Plate Light
Installation 4.12.2 Connecting the license plate light Find the cable connection point for the license plate light in the C column (a) on the Ford Transit (see Fig. 61). Fig. 61 Route the license plate light cable (2) (cable outlet from platform’s aluminum torsion box) along the closing arm (see Fig. -
Page 51: Mounting The License Plate Holder
Installation 4.13 Mounting the license plate holder Mount the license plate holder below the license plate light. IMPORTANT: When positioning the holder, make sure the license plate is sufficiently illuminated. 4.14 Mounting the bridge plates set 20 910 374 ... - Page 52 Installation Close the liftgate (place in driving position). Align the warning flag holder (14c). IMPORTANT: Comply with the mounting specifications. Transfer the existing holes in the warning flag holder to the platform and pre-drill holes for the 2 blind rivets. ...
- Page 53 Installation Move the liftgate to the horizontal position. Fold out (open) the liftgate. Bring the open liftgate as far as necessary into the vertical position to comfortably mount the right warning flag. CAUTION Not a normal operating position Risk of injuring yourself or damaging the vehicle or liftgate.
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Page 54: Affixing The Danger Notice Sticker
Installation 4.16 Affixing the danger notice sticker Affix the danger notice sticker “Safe handling of the liftgate.” IMPORTANT: This sticker is supplied with all new liftgates. The installing company must place it in an easily visible location on the inside of the vehicle cargo area. The danger notice sticker uses pictograms to indicate potential incorrect and correct use of the liftgate. -
Page 55: Adjusting The Liftgate
Adjusting the liftgate Adjusting the liftgate 5.1 Adjusting the lift height to vehicle floor with lifting cylinder Adjust the platform to the desired position in relation to the vehicle floor by turning the lifting cylinder piston head (pos. 1) to the left, (platform rises) or to the right (platform lowers) see Fig. -
Page 56: Plattform In Fahrstellung Vertikal Zum Fahrzeugaufbau Einstellen Am Schließzylinderkopf
Adjusting the liftgate 5.2 Adjusting the platform vertically to the vehicle body with the tilting cylinder head (Driving position) Once the platform was adjusted in height, it may be adjusted vertically in closed (driving) position, in relation to the vehicle’s body (see Fig. 68) This adjustment is performed by turning the head of the tilting cylinder (pos. -
Page 57: Aligning The Platform Parallel To The Vehicle Floor
Adjusting the liftgate 5.3 Aligning the platform parallel to the vehicle floor NOTICE If no readjustment is necessary, make sure that the screws (1 and 3) are securely tightened. To align the platform parallel to the vehicle floor, adjust the lifting gear using the left- hand adjustment fork (adjustment screw accessible from above) (see Fig. - Page 58 Adjusting the liftgate Loosen the hex bolt (3). Rotate the adjustment screw (1) to the left or right. Rotating the adjustment screw (1) to the right moves the right side of the platform closer to the vehicle chassis. This slightly lifts the platform on the right side of the vehicle (see Fig.
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Page 59: Aligning The Platform (Foldover Section) Parallel To The Vehicle Floor
Adjusting the liftgate 5.4 Aligning the platform (foldover section) parallel to the vehicle floor If necessary, adjust the height of the foldover section on the right side of the platform using the right-hand adjustment fork (2) (adjustment screw accessible from below) (see Fig. 72). Fig. -
Page 60: Checking The Stop On The Foldover Section Of The Platform
Adjusting the liftgate 5.5 Checking the stop on the foldover section of the platform Check the stop on the foldover section of the platform. IMPORTANT: The roller (1) on the support arm (2) must remain against the stop (3) throughout the entire lifting process. -
Page 61: Setting The End Stop For The Closed Platform
Adjusting the liftgate 5.6 Setting the end stop for the closed platform The end stop for the platform in the closed position is mounted on the closing arm. The platform requires no additional stops on the vehicle. IMPORTANT: Adjust the platform so that it stands vertically behind the vehicle when closed and in the driving position. - Page 62 Adjusting the liftgate Retighten the 2 screws (1) on the clamping plate (2) on the platform stop to a torque of 195 Nm (see Fig. 77). Fig. 77 When you reclose the platform, it will stand vertically behind the vehicle (see Fig. 78). Fig.
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Page 63: Adjusting The Stopper For Fastening The Platform
Adjusting the liftgate 5.7 Adjusting the stopper for fastening the platform The stopper fastens the right-hand foldover section of the closed platform and keeps the platform from hitting the vehicle while driving. IMPORTANT: Make the adjustment with the platform folded and closed (driving position). ... -
Page 64: Adjusting The Support Arm For The Driving Position Using The Bowden Cable
Adjusting the liftgate 5.8 Adjusting the support arm for the driving position using the Bowden cable Adjust the support arm (1) so that it can be pulled as close to the vehicle as desired when the platform is closed. The adjustment is made outside at the Bowden cable (2) and, if applicable, also at the screw on the lever (3). -
Page 65: Programming The Tilt Sensor
Adjusting the liftgate 5.9 Programming the tilt sensor Platform tilt is adjusted by programming the tilt sensor. The tilt sensor is programmed by pressing a combination of buttons on the Control panel (a) (see Fig. 82). Using the manual control, move the platform to a horizontal position. Fig. -
Page 66: Testing The Liftgate
Testing the liftgate Testing the liftgate 6.1 Function test Test: opening, lifting, lowering, tilting down, tilting up, closing CAUTION Platform at ground level In the fully lowered position, the platform is easily overlooked and may cause people to trip, resulting in injury. ... -
Page 67: Load Tests
Testing the liftgate 6.3 Load tests WARNING High loading of components Incorrect installation or defective components may cause components to fail and break. Risk of injury when operating the liftgate. Perform all the load tests specified here. 6.3.1 Static test ... -
Page 68: Explanation Of Diagnostic Led On The Control Unit
Testing the liftgate 6.4 Explanation of diagnostic LED on the Control Unit Cabin switch in LED monitoring function driver’s cabin or fast flashing key switch flashing Platform closed (90°) Platform closed Platform open (90° to 60°) Platform open (60° to 0°) Platform tilted down (0°... -
Page 69: Checking Tilt Sensors S1 And S2 In The Platform
Testing the liftgate 6.4.1 Checking tilt sensors S1 and S2 in the platform Platform closed and liftgate switched on: LED on. Power supply is functioning correctly. Platform position 0° to approx. 60°: LED off Tilt sensor S1 in switching position is functioning correctly. Corner lights are activated. -
Page 70: Recommendations And Instructions Regarding The Liftgate
Recommendations and instructions regarding the liftgate Recommendations and instructions regarding the liftgate IMPORTANT: To ensure safe operation of the liftgate read the safety instructions and warnings in the accompanying user manual. 7.1 Hydraulic oil recommendations 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. -
Page 71: Useful Information
Useful information Useful information 8.1 About the service switches The service switch mounted in a housing (Box) enables trained service personnel to control and test Service switch extern box the functioning of the liftgate directly (see Fig. 86). If the liftgate’s Handheld control malfunctions, a trained person can operate the liftgate to any position using one of the service switch (emergency function). -
Page 72: Electrical Circuit Diagram Series 11
Useful information 8.2 Electrical circuit diagram series 11... -
Page 73: Hydraulic Circuit Diagram
Useful information 8.3 Hydraulic circuit diagram... -
Page 74: Torque Table
Useful information 8.4 Torque table Valid torque table for all the bolts and screws supplied and installed on our liftgates Screw size Tightening torque Thread sizes DIN Tightening torque in Nm 3852 in Nm 2.7 ± 0.1 G1/4“ 40 ± 1.2 9.5 ±... -
Page 75: Activating The Liftgate
Useful information 8.5 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. 8.6 Operation using the Control panel From the Control panel, all functions are initiated by pressing two different pushbuttons simultaneously.
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