Maxon GPT Series Installation Manual Download Page 2

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TABLE OF CONTENTS

WARNINGS ......................................................................................................................... 3

STANDARD LIFTGATE COMPONENTS .............................................................................. 4

GPT-SERIES INSTALLATION PARTS BAGS ........................................................................ 5

STEP 1 - PREPARE VEHICLE ............................................................................................. 6

STEP 2 - WELD EXTENSION PLATE TO VEHICLE ............................................................. 8

STEP 3 - WELD LIFTGATE TO VEHICLE .......................................................................... 10

STEP 4 - RUN POWER CABLE ......................................................................................... 14

STEP 5 - CONNECT POWER CABLE ............................................................................... 15

STEP 6 - INSTALL CONTROL SWITCH .............................................................................. 16

STEP 7 - CONNECT POWER CABLE TO BATTERY ......................................................... 19

STEP 8 - REMOVE LOCKING ANGLES & WELDS ........................................................... 20

STEP 9 - WELD PLATFORM OPENER TO LIFTGATE ....................................................... 21

STEP 10 - FINISH WELDING LIFTGATE TO VEHICLE ....................................................... 24

STEP 11 - INSTALL & ADJUST SADDLES ........................................................................ 25

STEP 12 - CHECK HYDRAULIC FLUID ............................................................................. 26

STEP 13 - WELD HOOK AND EYE TO LIFTGATE ............................................................. 27

STEP 14 - WELD DOCK BUMPERS TO LIFTGATE ........................................................... 28

STEP 15 - BOLT RUBBER BUMPERS TO LIFTGATE ........................................................ 29

STEP 16 - PLACE DECALS .............................................................................................. 30

STEP 17 - VEHICLE TAILLIGHT POSITIONING .................................................................. 32

HYDRAULIC SYSTEM SCHEMATIC ................................................................................ 33

ELECTRICAL SYSTEM SCHEMATIC .............................................................................. 34

OPTIONS ........................................................................................................................... 35

OPTIONAL LIFTGATE COMPONENTS............................................................................... 35

RECOMMENDED LIFTGATE POWER CONFIGURATION ................................................. 36

Summary of Contents for GPT Series

Page 1: ...M 99 49 REV K OCTOBER 2005 MAXON Lift Corp 2005 ...

Page 2: ...STEP 8 REMOVE LOCKING ANGLES WELDS 20 STEP 9 WELD PLATFORM OPENER TO LIFTGATE 21 STEP 10 FINISH WELDING LIFTGATE TO VEHICLE 24 STEP 11 INSTALL ADJUST SADDLES 25 STEP 12 CHECK HYDRAULIC FLUID 26 STEP 13 WELD HOOK AND EYE TO LIFTGATE 27 STEP 14 WELD DOCK BUMPERS TO LIFTGATE 28 STEP 15 BOLT RUBBER BUMPERS TO LIFTGATE 29 STEP 16 PLACE DECALS 30 STEP 17 VEHICLE TAILLIGHT POSITIONING 32 HYDRAULIC SYSTEM...

Page 3: ...e terminals together If battery acid gets in your eyes immediately seek first aid If acid gets on your skin immediately wash it off with soap and water If an emergency situation arises vehicle or Liftgate while operating the Liftgate release the control Toggle Switch and the Liftgate will stop Comply with the following WARNINGS while installing Liftgates See Operation Manual M 97 16 for operating ...

Page 4: ...acking list enclosed in each box If parts and components are missingor incorrect call Maxon Customer Service Call 800 227 4116 or Send e mail to customersupport maxonlift com Prevent injuries and equipment damage Before cutting the shipping straps from the Liftgate put Liftgate on level ground that will support at least 1500 pounds Be careful lifting and moving components such as Extension Plate a...

Page 5: ...X 4 3 1 X 2 1 3 M I H S 2 1 3 7 4 6 2 0 1 6 1 1 X 1 X 2 1 2 M I H S 2 2 3 7 4 6 2 1 1 8 3 X 4 X 5 T A L F 2 5 9 2 9 2 2 2 1 T I K S L A U N A M L A C E D 1 L A U N A M N O I T A R E P O A 1 6 1 7 9 M L A U N A M N O I T A L L A T S N I B 1 9 4 9 9 M L A U N A M E C N A N E T N I A M C 1 5 1 7 9 M D R A C Y T N A R R A W D 1 8 7 8 7 M M R O F Y E V R U S R E M O T S U C E 1 4 0 4 9 M S L A C E D F ...

Page 6: ... 19 REF 14 55 MAX BED HEIGHT 46 MIN BED HEIGHT APPROX 24 REF ONLY 12 21 REF 14 55 MAX BED HEIGHT 46 MIN BED HEIGHT NOTE BODY Maximum and Minimum Operating Bed Height For GPT 25 GPT 3 GPT 4 GPT 5 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 modified to install this Liftg...

Page 7: ... If installing Liftgate on a trailer skip frame cutting instructions in Item 2 CUTS FOR GPT 25 GPT 3 GPT 4 GPT 5 FIG 7 1 22 1 2 4 1 2 TRUCK FRAME 12 TOP OF TRUCK BODY FLOOR 2 11 16 20 To prevent Aluminum Platform from being damaged make sure Truck Frame is cut correctly as shown in the illustration below If the Frame is cut incorrectly Platform may hit the Truck Frame while stowing Liftgate CAUTIO...

Page 8: ... the Extension Plate to vehicle body sill as shown in FIG 8 1 and FIG 8 2 EXTENSION PLATE WELDS VIEWED FROM UNDERNEATH FIG 8 2 SILL PART OF VEHICLE BODY 2 PLACES MAKE 1 GAP WHERE SHOWN 1 4 2 LG 12 PLACES EQUAL SPACING TYP 1 4 1 4 5 PLACES MAKE 1 GAP WHERE SHOWN 1 GAP 1 GAP 4 LG LOCATED ABOVE EACH OF 3 RECTANGULAR TUBES TUBES SHOWN SHADED IN FIG 3 2 LG CENTERED BETWEEN 4 WELDS SHOWN 4 LG EXTENSION ...

Page 9: ...rom Parts Box between Platform and Extension Plate as shown in FIG 9 1B Spacers keep 1 8 between Platform and Extension Plate while welding liftgate to vehicle frame Weld the Straps and Spacers to Extension Plate FIG 9 1B STEP 2 WELD EXTENSION PLATE TO VEHICLE Continued 1 APPROX TYP STRAP OVERHANG 1 4 1 8 SPACER 1 2 APPROX TYP SPACER OVERHANG 17 1 2 1 4 LG TACK SUPPORT STRAP TO EXTENSION PLATE 1 W...

Page 10: ...rom Mounting Plates FIGS 10 1A 10 1B Split Looms will be reinstalled later after final welding 2 Unfold the Platform and Flipover FIG 10 2 PLATFORM FLIPOVER UNFOLDED FIG 10 2 PLATFORM UNFOLDED FLIPOVER UNFOLDED LOCKING ANGLES REF RH SIDE VIEW OF LIFTGATE FIG 10 1A SPLIT LOOMS MOUNTING PLATES MOUNTING PLATE FIG 10 1B MOUNTING PLATES ...

Page 11: ... UP VERTICAL HOIST CHAIN INCORRECT WAY TO HOIST LIFTGATE FIG 11 2 MAIN FRAME VEHICLE FLOOR HORIZONTAL MOUNTING PLATE To prevent damage to Aluminum Flip Over NEVER hoist the Liftgate by the Flipover as shown in the NO illustration Hoist the Liftgate by the Platform only as shown in the YES illustration FLIPOVER HOIST CHAIN CCORRECT WAY TO HOIST LIFTGATE FIG 11 1 YES NO CAUTION PLATFORM 4 Hoist the ...

Page 12: ...elding make sure cutout in vehicle frame does not block 2 slotted holes in Mounting Plate FIG 12 2 Weld the Mounting Plates to vehicle frame as shown in FIG 12 2 Next weld both Mounting Plates to Main Frame FIG 12 2 Remove clamps ORIGINAL TACK WELDS REMOVE TO REPOSITION MOUNTING PLATE 5 16 TACK TYPICAL RH LH MOUNTING PLATES REPOSITIONING MOUNTING PLATE RH SIDE SHOWN FIG 12 1 MAIN FRAME CUT AWAYVIE...

Page 13: ...EL LINE TIP OF FLIPOVER 1 MAX 7 At the tip of the Flipover measure distance Flipover is raised above bed level Tip of Flipover should be above level line shown in FIG 13 1 and up to 1 maximum FIG 13 1 If measure ment is correct Liftgate is mounted correctly If measurement is incorrect check the measurements used for preparing vehicle in STEP 1 and if needed repeat this entire step STEP 3 ...

Page 14: ...CABLE FIG 14 1 FUSE SHORTEST CABLEEND TERMINAL LUG VEHICLE BATTERY END VEHICLE FRAME TRUCK FRAME SHOWN 18 24 SPACING BARE WIRE END TO PUMP BOX FRONT OF VEHICLE REAR OF VEHICLE CABLE CLIPS 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 Attac...

Page 15: ...sed Power Cable and shrink the Heatshrink Tubing FIG 15 1C STEP 5 CONNECT POWER CABLE TYPICAL FUSED POWER CABLE ROUTING POWER DOWN PUMP BOX SHOWN FIG 15 1A FIG 15 1B 2 Remove hex nut and lock washer from battery power post on the RAISE Motor Solenoid Connect the Fused Power Cable to the RAISE Motor Solenoid as shown in FIG 15 2 Re install and tighten lock washer and hex nut COPPER TERMINAL LUG FUS...

Page 16: ...3 16 18 1 Drill one 3 4 hole and two 21 size holes in the vertical post on curb side of vehicle body as shown in FIG 16 1A Use template shown in FIG 16 1B VEHICLE BODY VERTICAL POST CURB SIDE STEP 6 INSTALL CONTROL SWITCH FIG 16 1A HOLE DRILLING TEMPLATE FIG 16 1B 1 3 4 7 8 ...

Page 17: ...ITCH Continued PLATFORM OPEN AND RAISED 3 4 HOLE VEHICLE BODY VERTICAL POST CONTROL SWITCH CABLE GROMMET PUMP BOX ROUTING CONTROL SWITCH WIRING FIG 17 1A 2 Route the Control Switch cable through the hole in the Vertical Post FIGS 17 1B and down the Vertical Post as shown in see dashed line in FIG 17 1A When the Control Switch is close to the Post attach Control Switch to Vertical Post with 2 self ...

Page 18: ...shown in FIG 18 1 CONNECTING CONTROL SWITCH CABLE TO PUMP WIRING FIG 18 1 WHITE WIRE GREEN WIRE BLACK WIRE RED WIRE CRIMP TERMINALS A VALVE A VALVE WIRE E VALVE E VALVE WIRE NOTE MAXON recommends using dielectric grease on all electrical connections NOTE An extra crimp on connector is supplied with the RED wire and BLACK wire on the Control Switch cable Crimp each of the extra connectors to the co...

Page 19: ... battery terminal connector Connect Power Cable to the positive battery terminal connector FIG 19 1 Re install and tighten nut FIG 19 1 POSITIVE BATTERY TERMINAL FUSED POWER CABLE BOLT NUT STEP 7 CONNECT POWER CABLE TO BATTERY NOTE MAXON recommends using dielectric grease on all electrical connections ...

Page 20: ...fluid stops release Control Switch Hydraulic System is ready 2 Remove Locking Angles from Hydraulic Cylinders FIG 20 1A NOTE To operate Liftgate Locking Angles must be removed from the Hydraulic Cylin ders and welds must be removed from Lifting Arm Knuckles 3 With Platform open FIG 20 1A grind off each weld as shown in FIG 20 1B 20 1C Make sure block remains on correct side of each Knuckle Joint a...

Page 21: ... LIFTGATE FIG 21 1 FLOOR JACK SUPPORT STRAPS SPACERS BOTH SIDES 1 Remove Floor Jack and Hoist supporting Liftgate FIG 21 1 PLATFORM 2 LOWER the Platform to the ground Remove both support straps and both spacers from Extension Plate FIG 21 2 FIG 21 2 3 Fold flipover FIG 21 3 FOLDING FLIPOVER FIG 21 3 FLIPOVER ...

Page 22: ... and TABLE 21 1 NOTE Platform Opener may only be installed on Right Hand side of Main Frame see the illustrations on this page STEP 9 WELD PLATFORM OPENER TO LIFTGATE Continued CENTERING OPENER ON PLATE FIG 22 2B 5 Fold the Platform against Opener FIG 22 2A Make sure Opener is entered on Protective Plate as shown in FIG 22 2B Reposition the Opener if necessary Clamp Opener to Main Frame OPENER MAI...

Page 23: ... interference with the Platform while stowing Liftgate check for dam age on bottom of Platform Flip Over and the hinge in between A damaged Platform or Flip Over may result in personal injury and more damage to Liftgate CAUTION 7 If the Platform lowered with a jerk ing motion bleed air from the Hydraulic System by doing the following Push the Control Switch to the LOWER position until you hear air...

Page 24: ...E TYPICAL TRUCK FRAME SHOWN VEHICLE FRAME CUTOUT DASHED LINES Prevent damaged hydraulic hoses Before welding next to hydraulic hoses protect the hoses with a heat resistant cover such as a welding blanket CAUTION 2 After welding is done and Mounting Plates are cool remove the 4 Fiber glass Sleeves shown in FIG 24 1B Then reinstall the Split Looms re moved in STEP 3 FIG 24 1B REINSTALLING SPLIT LOO...

Page 25: ...ck posi tioned at center of Platform near hinge to raise Platform 1 8 above Roller FIG 25 1B Install Saddle Bolts and Lock Nuts on RH side Mounting Plate FIG 25 1A Repeat for Saddle on LH side Butt each Saddle against Platform and tighten lock nuts 2 Install Saddle Bolts and Lock Nuts on RH side Mounting Plate FIG 25 1A Repeat for Saddle on LH side Butt each Saddle against Platform and tighten loc...

Page 26: ... L U A R D Y H 6 0 6 5 H L I M R O 0 1 O S I S D N A R B D E D N E M M O C E R R E B M U N T R A P L I O S M A A N N O R V E H C G D I U L F A D I U L F L L A D N E K U L B L A I C A L G L L E H S 1 4 D I U L F L L E H S O R E A N O X X E 3 1 I V H S I V I N U L I B O M A F H O R E A TABLE 26 3 70 to 140 Degrees F Grade ISO 32 40 to 105 Degrees F Grade ISO 15 Below 70 Degrees F Grade ISO 10 or MIL...

Page 27: ...Bag to Knuckle as shown in FIG 27 1 3 Insert the Safety Hook through the Pad Eye FIG 27 1 Next position the Safety Hook Chain on the Extension Plate as shown in FIG 27 1 Leave enough slack in the Chain to hook and unhook the Pad Eye Then weld the free end of Chain to the inboard side of the tubing on Extension Plate 3 16 INBOARD SIDE OF TUBING ONLY EXTENSION PLATE HOOK WITH CHAIN KNUCKLE RH SIDE V...

Page 28: ...d of Brace to Dock Bumper as shown in FIG 28 1A Clamp closed end of Brace to Main Frame FIG 28 1A Weld the Brace to Dock Bumper FIG 28 1A and Main Frame FIG 28 1C Repeat step for Brace and Dock Bumper on RH side of Extension Plate 4 Raise and lower Platform then stow Liftgate Operation Manual M 97 16 Make sure Dock Bumper does not interfere with Liftgate DOCK BUMPER BRACE 2 PLACES LH RH BRACES 3 1...

Page 29: ... The Rubber Dock Bumpers Kit P N 203410 contains 2 Rubber Bumpers and 2 sets of fasteners CAP SCREW 1 2 20 x 2 BOLTING RUBBER BUMPER TO DOCK BUMPER RIGHT HAND SIDE DOCK BUMPER SHOWN FIG 29 1 RUBBER BUMPER HEX NUT 1 2 20 LOCK WASHER 1 2 Bolt a Rubber Bumper to each of the 2 Dock Bumpers FIG 29 1 DOCK BUMPER FLAT WASHER 1 2 ...

Page 30: ...uson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 30 STEP 16 PLACE DECALS WARNING DECAL P N 264081 CAUTION DECAL P N 263998 INSTRUCTION DECAL P N 251838 REFERENCE CAPACITYDECAL REFERENCE FIG 30 1 ...

Page 31: ...CAL P N 264507 INSTRUCTION DECAL P N 251838 CAPACITY DECAL SEE TABLE 31 1 TABLE31 1 CAPACITYDECALS PART NO 2500 LBS 3000 LBS 4000 LBS 5000 LBS 220382 220388 220389 220390 CAPACITY WARNING DECAL P N 264081 REFERENCE CAUTION DECAL P N 263998 REFERENCE STEP 16 PLACE DECALS Continued FIG 31 1 ...

Page 32: ...ATE FIG 32 1 24 24 30 14 TAILLIGHTS ANGLE STEEL NOT SUPPLIED PLATFORM OPENER REFERENCE EXTENSION PLATE REFERENCE MAIN FRAME GROUND LEVEL TAILLIGHT ANGLE STEEL NOT SUPPLIED TAILLIGHTS PLATFORM OPENER REFERENCE TAILLIGHT OPTIONAL UNDERRIDE REFERENCE OPTIONAL UNDERRIDE REFERENCE IF REQUIRED NOTE Positions are based on using taillights of 6 3 4 height by 5 3 4 width Larger taillights may interfere wit...

Page 33: ...ULIC SYSTEM SCHEMATIC PORT B LOWER PWR DN PORT A RAISE M DRAIN HOLE PLUGGED VALVE A VALVE E RESERVOIR RELIEF VALVE SET AT 2200 PSI FILTER CHECK VALVE PUMP HYDRAULICCYLINDERS 4 GPM FLOW CONTROL VALVE ADJUSTABLE NEEDLEVALVE FILTER HAND PUMP PORT HAND PUMP PORT FILL HOLE PLUGGED MOTOR REFERENCE ...

Page 34: ... Springs CA 90670 800 227 4116 FAX 888 771 7713 34 CONTROL SWITCH BLACK GREEN WHITE SOLENOID VALVE E RED BATTERY MOTOR CABLE WITH 200 AMP FUSE CABLE ASSEMBLY SOLENOID VALVE A STARTER SOLENOID ELECTRICAL SYSTEM SCHEMATIC FIG 34 1 ...

Page 35: ... E T T A B Y R E T T A B O C L E D O W 5 0 4 5 1 1 5 2 K C U R T R O F X O B Y R E T T A B Y R E T T A B H T I W 1 0 4 5 1 1 5 2 K C U R T R O F X O B Y R E T T A B Y R E T T A B O W 3 0 4 5 1 1 5 2 T I K E N I L E G R A H C R E L I A R T E L O P E L G N I S 1 0 5 7 2 0 8 2 R E L I A R T T I K E N I L E G R A H C E L O P L A U D 2 0 5 7 2 0 8 2 T I K E N I L E G R A H C R O T C A R T E L O P E L G...

Page 36: ...TERY BOX INSTALLATION ON TRAILER FIG 36 1 TRAILER MOUNTED CIRCUITBREAKER SECONDARYLOCATION CIRCUIT BREAKER POWERCABLE 200 AMP IN LINE FUSE SHOWN CHARGELINE RECOMMENDED LIFTGATE POWER CONFIGURATION OPTIONS TRACTORBATTERY CIRCUITBREAKER PRIMARYLOCATION LIFTGATE ADDITIONALBATTERYBOX TYPICALLOCATION PUMP BOX LIFTGATEPOWERUNIT RECOMMENDED LIFTGATE BATTERY BOX INSTALLATION ON TRAILER FIG 36 2 CIRCUIT BR...

Page 37: ...along vehicle body crossmembers use 200 Amp Fused Power Cable from Liftgate Parts Box Always connect fused end of Cable to Battery CHARGE LINE TO TRUCK OR TRACTOR BATTERY BATTERY CABLE 6 VOLT BATTERY CONNECTIONS FIG 37 1 150 AMP CIRCUIT BREAKER BATTERY CABLES POWER CABLE TO PUMP BOX 200 AMP FUSED POWER CABLE ONLY IF REQUIRED SEE NOTE 2 Recommended Battery Box setup for 6 volt batteries is shown in...

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