Maxon GPTLR-25 Installation Manual Download

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© MAXON Lift Corp. 2019

M-18-14
JANUARY 2019

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.

Summary of Contents for GPTLR-25

Page 1: ...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 cl...

Page 2: ...HOD 19 STEP 2 WELD LIFTGATE TO VEHICLE 21 STEP 3 ATTACH OPTIONAL BATTERY BOX FRAME TO VEHICLE IF EQUIPPED 25 STEP 4 RUN POWER CABLE 32 STEP 5 CONNECT POWER CABLE 34 STEP 6 CONNECT GROUND CABLE 36 STEP...

Page 3: ...H 80 SYSTEM DIAGRAMS 81 PUMP MOTOR SOLENOID OPERATION GRAVITY DOWN 81 PUMP MOTOR SOLENOID OPERATION POWER DOWN 82 HYDRAULIC SCHEMATIC GRAVITY DOWN 83 HYDRAULIC SCHEMATIC POWER DOWN 84 ELECTRICAL SCHEM...

Page 4: ...o the Liftgate only when installation is complete or as required in the installation instructions If it is necessary to stand on the platform while operating the Liftgate keep your feet and any object...

Page 5: ...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...

Page 6: ...are missing or incorrect call Maxon Customer Service Call 800 227 4116 or Send e mail to cservice maxonlift com GPTLR COMPONENTS FIG 6 1 LIFTGATE CAUTION Unpacking the Liftgate on unlevel surface may...

Page 7: ...1 2 LG 2 900035 3 PARTS BOX A WITH POWER CABLE TABLE 7 1 PARTS BOX C WITH GROUND CABLE TABLE 7 3 ITEM NOMENCLATURE OR DESCRIPTION QTY PART NUMBER REF PARTS BOX C 1 297502 02 1 SPRING CLIP 20 050079 2...

Page 8: ...GPTLR 25 SWG EXT 299460 05 GPTLR 33 SWG EXT 299459 01 GPTLR 44 299459 02 GPTLR 55 1 INSTALLATION MANUAL 1 M 18 14 2 OPERATION MANUAL 1 M 18 15 3 DECALS SEE DECAL PAGES IN THIS MANUAL 1 ALL GPTLR S TA...

Page 9: ...rd 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 unde...

Page 10: ...Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 10 VEHICLE REQUIREMENTS Continued VEHICLE BODY CORNER POST CLEARANCE FOR REFERENCE FIG 10 1 BODY FLOOR REFERENCE 5 5 8 GPTLR 44 55 6 1 8 GPTLR 25 33 L...

Page 11: ...71 7713 11 VEHICLE REQUIREMENTS Continued GPTLR EXTENSION PLATE DIMENSIONS FOR 102 WIDE BODY FIG 11 2 102 85 1 2 1 2 GPTLR EXTENSION PLATE DIMENSIONS FOR 96 WIDE BODY FIG 11 1 96 79 4 7 16 GPTLR 25 33...

Page 12: ...ilers refer to FIG 14 1 for lift arm and platform clearances on the rear sill If necessary remove the interfering portions of the rear sill according to dimensions shown in FIG 14 1 To prevent aluminu...

Page 13: ...227 4116 FAX 888 771 7713 13 VEHICLE FRAME CUT FOR GPTLR 44 GPTLR 55 FIG 13 1 VEHICLE REQUIREMENTS Continued 5 1 2 13 24 TRUCK FRAME BODY FLOOR BODY CROSS MEMBERS REAR SILL WOODEN SPACER LONG SILL PLA...

Page 14: ...lauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 14 3 If necessary cut trailer rear sill as shown in FIG 14 1 VEHICLE REQUIREMENTS Continued REAR SILL CUTS FOR ALL GPTLR LIFTGATES FI...

Page 15: ...gs CA 90670 800 227 4116 FAX 888 771 7713 15 CENTER OF MASS GPTLR 25 GPTLR 33 CENTER OF MASS STOWED POSITION FIG 15 1 12 3 4 CENTER OF MASS 8 1 2 GPTLR 44 GPTLR 55 CENTER OF MASS STOWED POSITION FIG 1...

Page 16: ...tension 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...

Page 17: ...7 4116 FAX 888 771 7713 17 REAR SILL HOLE LOCATIONS FOR 102 WIDE VEHICLE FIG 17 1 1 1 4 1 1 2 27 37 44 51 58 65 75 80 85 95 1 2 100 1 2 102 22 17 STEP 1 ATTACH EXTENSION PLATE TO VEHICLE Continued REA...

Page 18: ...as possible Interference between the mating surfaces could result in a distorted top surface of extension plate when all the bolts are tightened Distorted extension plate can also make the dual steps...

Page 19: ...Center the extension plate on vehicle body Weld the extension plate to vehicle body sill as shown in FIGS 19 1 and 20 1 EXTENSION PLATE WELDS VIEWED FROM ABOVE FIG 19 1 3 16 3 16 EXTENSION PLATE VEHIC...

Page 20: ...ighten hex nuts securely EXTENSION PLATE WELDS VIEWED FROM UNDERNEATH FIG 20 1 3 16 EXTENSION PLATE VEHICLE BODY WELD LENGTH SPACE 2 11 3 4 96 W VEHICLE 2 12 1 2 102 W VEHICLE NOTE During installation...

Page 21: ...it s necessary to unbolt mounting plates from main frame FIG 21 1 torque mounting plate nuts and bolts 220 240 lb ft GPTLR 25 GPTLR 33 or 350 375 lb ft GPTLR 44 GPTLR 55 BOLT LOCK NUT 6 PLACES BOLT L...

Page 22: ...2 1 Unfold the platform and flipover FIG 22 1 PLATFORM FLIPOVER UNFOLDED FIG 22 1 FLIPOVER PLATFORM MOUNTING PLATES 2 Unbolt opener from mounting bracket shipping position and save to reinstall FIG 22...

Page 23: ...LD LIFTGATE TO VEHICLE Continued Maintain distance between vehicle floor and top of main frame at center of main frame as shown in the instructions Dimension tolerance is 1 4 Nev er apply force at the...

Page 24: ...16 6 Weld the mounting plates to vehicle frame as shown in FIG 24 1 Remove clamps TOLERANCE IS 1 4 Prevent damage to hydraulic hoses If welding next to hydraulic hoses use a protective cover such as...

Page 25: ...D LIFTGATE OPTIONAL BATTERY BOX INSTALLATION ON TRAILER FIG 25 1 150 AMP CIRCUIT BREAKER 175 AMP FUSED CABLE TRACTOR BATTERIES TYPICAL LOCATION LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE BATTER...

Page 26: ...LACES FIG 26 1C FLUSH BRACKETS FOR TRAILERS 8 PLACES FIG 26 1B FLUSH BRACKETS FOR TRUCKS 8 PLACES FIG 26 2 ALIGNING BATTERY BOX FRAME TRAILER SHOWN FIG 26 1A 2 Select holes on top of battery box frame...

Page 27: ...1 Bolt mounting brackets to cross mem bers as shown in FIGS 27 2A and 27 2B Torque bolts and lock nuts to 85 128 lb ft NOTE If welding mounting brackets to cross members skip instruction 3 CROSS MEMB...

Page 28: ...TTERY BOX FRAME FIG 28 1A CROSS MEMBERS CROSS MEMBERS BRACKET WELDING BRACKETS 8 PLACES FIG 28 1B 3 16 3 16 3 16 IF ACCESSIBLE STEP 3 ATTACH OPTIONAL BATTERY BOX FRAME TO VEHICLE IF EQUIPPED Continued...

Page 29: ...fused end of power cable to battery positive terminal NOTE To connect charge lines refer to instructions provided with each charge line kit FUSED CABLE SEE NOTE FUSED CABLE TO PUMP BOX IN PARTS BOX 8...

Page 30: ...es 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 WARNING BATTERY BOX ASSEM...

Page 31: ...20 2 PLACES HEX NUT 1 2 20 4 PLACES LOCK WASHER 9 16 4 PLACES FLAT WASHER 9 16 4 PLACES J BOLT ANCHOR PART OF BATTERY PLATE FLAT WASHER 1 4 4 PLACES PAN HEAD SCREW 1 4 20 X 1 LG 2 PLACES CAP SCREW 1...

Page 32: ...LIFTGATE RECOMMENDED LIFTGATE POWER CABLE INSTALLATION ON TRAILER FIG 32 1 175 AMP FUSED CABLE TRACTOR BATTERIES TYPICAL LOCATION LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE POWER CABLE INSTALLA...

Page 33: ...d 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...

Page 34: ...FAX 888 771 7713 34 1 Unbolt and remove pump cover as shown in FIG 34 1 STEP 5 CONNECT POWER CABLE UNBOLTING PUMP COVER FIG 34 1 CAP SCREW 5 16 18 2 PLACES HOLDER FLAT 2 PLACES FLAT WASHER 5 16 2 PLA...

Page 35: ...POWER CABLE WITH TERMINAL LUG INSTALLED FIG 35 2 4 Remove hex nut and lock wash er from battery terminal post on the starter solenoid Connect the fused power cable to the starter solenoid as shown in...

Page 36: ...unting plate FIGS 36 1 36 1A 2 Bolt ground cable to ground connection on pump using existing bolt FIGS 36 1 36 1B 3 Form a drip loop on the ground cable where it enters the grommet from outside the pu...

Page 37: ...tion Connect to an existing grounding point if available 7 Bolt the ground cable terminal lug to vehicle frame as shown in FIG 37 1 NOTE Clean the ground cable connection point on the frame down to ba...

Page 38: ...ir ing harness parts box into 3 4 hole on corner post and down the vertical post and under the vehicle body to the pump assembly See dashed line FIG 38 2 CONTROL SWITCH SELF TAPPING SCREW 2 PLACES ROU...

Page 39: ...e 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 met on pump mounting plate...

Page 40: ...r the long side of the holder flats must butt against pump cov er as shown in the illustration CAUTION Keep dirt water and other contaminants from entering the hydraulic system Before opening the hydr...

Page 41: ...32 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 EXXONMOBIL UNIVIS N 32 DTE 24 ISO 15 OR MIL H 5606 HYDRAULIC OIL RECOMMENDED BRANDS PART NU...

Page 42: ...ed positive cable to positive battery terminal FIG 42 2 Then reinstall nut on positive battery terminal FIG 42 2 4 Reconnect negative battery cable to negative battery ter minal FIG 42 3 Then reinstal...

Page 43: ...43 STEP 10 REMOVE LOCKING BRACKETS CHECK FOR INTERFERENCE 1 Remove floor jack and hoist supporting Liftgate FIG 43 1 REMOVING JACK FIG 43 1 FLOOR JACK 2 Lower platform to ground level FIG 43 2 Refer...

Page 44: ...the locking brackets from both cylinders FIG 44 1 To prevent damage to Liftgate the locking bracket on each cylinder must be removed before operating Liftgate CAUTION LOCKING BRACKET CAP NUT FLAT WASH...

Page 45: ...y interference between liftgate and vehicle as platform is lowered If the platform lowers with a jerking motion bleed air from the hydraulic system by doing the following Push the control switch to th...

Page 46: ...r platform to the ground FIG 46 1 REMOVING INSTALLATION BRACKETS FIG 46 2 7 Unbolt the 2 installation brackets from extension plate FIG 46 2 EXTENSION PLATE LOWERING PLATFORM FIG 46 1 STEP 10 REMOVE L...

Page 47: ...he platform to vehicle floor level FIG 47 1 Refer to operating instruc tions in Operation Manual Check for 5 8 gap between platform and edge of extension plate FIG 47 1 PLATFORM EXTENSION PLATE NOTE C...

Page 48: ...e off the ground or if there is too much gap between platform and extension plate continue doing this procedure PLATFORM SHACKLES TOUCH GROUND FIG 48 2 NOTE In most cases if Liftgate is installed acco...

Page 49: ...T TOUCH GROUND FIG 49 1 FIG 49 2A 3 Fold the flipover and platform Then raise the platform to position shown in FIG 49 2A 4 Use TABLE 49 1 to select the correct size shim from the parts box Weld shim...

Page 50: ...flipover RAISE the platform to bed height then LOWER it to the ground The tip of flipover and shackle should touch the ground as shown in FIG 50 1 Tip of flipover must not be higher than 1 4 above the...

Page 51: ...UIRED Continued 9 RAISE platform to position just below extension plate see FIG 51 2 Refer to operating instructions in Operation Manual FIG 51 2 8 Review the WARNING page at the front of this manual...

Page 52: ...te while installing parts 10 Disconnect power to the pump by disconnecting negative and positive cables from battery FIG 52 1 Reinstall nuts on negative and positive battery terminals POSITIVE BATTERY...

Page 53: ...sured 50 for C and 1 for B the calculat ed distance D for the platform adjustment is 49 14 Raise or lower the floor jack to adjust distance D between tip of flipover and ground level FIG 53 3 Use the...

Page 54: ...the original paint system a 3 wide area of paint must be removed from all sides of the weld area before welding 16 Reconnect power to the pump by reconnecting positive and negative cables to battery...

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 REMOVING INSTALLATION BRA...

Page 56: ...7713 56 REMOVING LOCKING BRACKETS FIG 56 1 LOCKING BRACKET CAP NUT FLAT WASHER BOLT LH CYLINDER RH CYLINDER LOCKING BRACKET 2 PLACES 19 Unbolt the locking brackets from both cylinders FIG 56 1 Re mov...

Page 57: ...g next to hydraulic hoses protect the hoses with a heat resistant cover CAUTION To protect the original paint system a 3 wide area of paint must be re moved from all sides of the weld area before weld...

Page 58: ...de of the truck body WELDING TRUCK BODY TO FRAME RH SIDE SHOWN FIG 58 1 TRUCK BODY C CHANNEL FLAT TRUCK FRAME CAUTION To protect the original paint sys tem a 3 wide area of paint must be removed from...

Page 59: ...latform FIG 59 2 UNFOLDING PLATFORM FIG 59 2 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...

Page 60: ...t not rub against bumper Ensure the 3 position roller remains in contact with ICC bumper at first contact and through the full range of motion to highest position Bolt roller in one of the 3 hole posi...

Page 61: ...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 po...

Page 62: ...icle 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 tubular underride...

Page 63: ...height FIG 63 2 NOTE If underride is already bolted in correct position for your bed height and if tube posi tion is adjustable go to the instructions for ADJUSTING UNDERRIDE TUBE MEASURING BED HEIGH...

Page 64: ...25 GPTLR 33 FMVSS UNDERRIDE BRACKET SETTINGS BASED ON BED HEIGHT RH BRACKET SHOWN FIG 64 1B GPTLR 25 GPTLR 33 OPTIONAL FMVSS UNDERRIDE FIG 64 1A UNDERRIDE GPTLR 44 GPTLR 55 STANDARD FMVSS UNDERRIDE F...

Page 65: ...16 FAX 888 771 7713 65 STEP 15 ADJUST UNDERRIDE Continued GPTLR 44 GPTLR 55 OPTIONAL CMVSS UNDERRIDE FIG 65 1A GPTLR 44 GPTLR 55 CMVSS UNDERRIDE BRACKET SETTINGS BASED ON BED HEIGHT RH BRACKET SHOWN F...

Page 66: ...ADJUSTING UNDERRIDE ASSEMBLY 4 Lower platform to the ground Then unfold platform and flipover FIG 66 1A LH SEAT RH SEAT UNBOLTING PLATFORM SEAT LH SEAT SHOWN FIG 66 1B PLATFORM SEAT LOCK NUT 2 PLACES...

Page 67: ...ittle ground clearance for a jack If necessary raise the platform up to 6 to get a jack in position to support the underride UNDERRIDE JACK UNDERRIDE SUPPORT 6 Adjust position of the underride assembl...

Page 68: ...e tube up or down and slide the tube outward or inward to the dimensions shown in FIG 68 1 Tighten bolts and lock nuts to secure tube in correct position UNDERRIDE TUBE ADJUSTMENT RH SIDE SHOWN FIG 68...

Page 69: ...welding underride support brackets STEP 15 ADJUST UNDERRIDE Continued 10 Tack weld flat on underride tube to RH support bracket FIG 69 1 Repeat for LH support bracket TACK WELDING FLATS TO SUPPORT BR...

Page 70: ...tinued 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 a...

Page 71: ...LTED HOLE POSITIONS FOR OPTIONAL FMVSS UNDERRIDE INSTALLED ON GPTLR 25 GPTLR 33 BED HEIGHT UNDER RIDE HOLE NO H EXPECTED UN DERRIDE GROUND CLEARANCE PLATFORM STOWED H1 EXPECTED UNDERRIDE GROUND CLEAR...

Page 72: ...51 5 21 41 1 75 50 6 21 42 1 44 49 7 21 42 1 24 TABLE 72 2 RECOMMENDED BOLTED HOLE POSITIONS FOR STANDARD FMVSS UNDERRIDE INSTALLED ON GPTLR 44 GPTLR 55 BED HEIGHT UNDER RIDE HOLE NO H EXPECTED UN DE...

Page 73: ...1 4 2 PLACES DATE OF MFR DECAL INBOARD OF BRACKET STEP 15 ADJUST UNDERRIDE Continued CAUTION Prevent the date of manufacture decal from being damaged Cover decal when welding underride support bracke...

Page 74: ...D STANDARD FMVSS UNDERRIDE SHOWN FIG 74 1A LH SEAT RH SEAT LIFTING ARM 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 th...

Page 75: ...5 ADJUST UNDERRIDE Continued 14 Stow platform FIG 75 1 Next center conspi cuity reflective tape on the underride tube as shown in FIG 75 1 Remove backing from tape Then attach tape to underride FIG 75...

Page 76: ...EP 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...

Page 77: ...2 4400 LBS 253155 5500 LBS 253161 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...

Page 78: ...36 02 CAUTION DECAL FLIPOVER EQUIPPED WITH LATCH ONLY P N 267694 01 WARNING DECAL P N 265736 03 DECALS PLATES PARTS QR CODE DECAL P N 299348 08 SERIAL PLATE REF MAXON 24 7 SUPPORT DECAL P N 298634 01...

Page 79: ...1 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 79 SAFETY STRIPE TAPE 2 PLACES P N 096018 10 NONSKID LH P N 281204 01 NONSKID RH P N 281204 02 ATTACH NONSKID SAFETY STRIPING FIG...

Page 80: ...t from apply ing cold galvanized finish to the polished portion of the cylinder rod To prevent damage protect the exposed polished portion of the cylinder rod while spraying If bare metal is exposed o...

Page 81: ...UNIT FIG 81 1 PUMP MOTOR SOLENOID OPERATION GRAVITY DOWN TABLE 81 1 POWER UNIT MOTOR SOLENOID OPERATION LIFTGATE FUNCTION PORT SOLENOID OPERATION MEANS ENERGIZED MOTOR VALVE A LOCK VALVE RAISE A LOWE...

Page 82: ...MP MOTOR SOLENOID OPERATION POWER DOWN TABLE 82 1 POWER UNIT MOTOR SOLENOID OPERATION LIFTGATE FUNCTION PORT SOLENOID OPERATION MEANS ENERGIZED MOTOR VALVE S2 VALVE S1 LOCK VALVE RAISE A LOWER B REFER...

Page 83: ...HEMATIC GRAVITY DOWN FIG 83 1 M 4 5 GPM FLOW CONTROL VALVE VALVE A RELIEF VALVE SET AT 3250 PSI PUMP MOTOR REF RESERVOIR CHECK VALVE FILTER DRAIN HOLE PLUGGED HYDRAULIC CYLINDERS FILL HOLE PLUGGED HYD...

Page 84: ...AULIC SCHEMATIC POWER DOWN HYDRAULIC CYLINDERS PORT B POWER DOWN PORT A RAISE RELIEF VALVE 2 SET AT 1100 PSI PUMP AUX HAND PUMP PORT PLUGGED VALVE S2 RESERVOIR DRAIN HOLE PLUGGED FILTER MOTOR REF RELI...

Page 85: ...888 771 7713 85 FIG 85 1 ELECTRICAL SCHEMATIC GRAVITY DOWN DOWN UP CONTROL SWITCH STARTER SOLENOID MOTOR FUSE HOLDER WITH 10 AMP FUSE JUNCTION BLOCK WHITE BLACK GREEN 1 1 2 2 CYCLE COUNTER IF EQUIPPED...

Page 86: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 86 FIG 86 1 ELECTRICAL SCHEMATIC POWER DOWN...

Page 87: ...t terminal torque 30 35 lb in max Solenoid Valves A S1 S2 Coil resistance 4 0 70 F 15 26 7 70 F 15 Ampere 3A 2 5A 10V Coil terminal torque 15 45 lb in max Valve cartridge torque 25 30 lb ft max Coil n...

Page 88: ...PUMP GPTLR GRAVITY DOWN 287369 01 HAND PUMP GPTLR POWER DOWN 287389 01 EXTRA CONTROLS CONTROL KITS PART NO HAND HELD CONTROL TUK A WAY 280570 07 HAND HELD CONTROL TUK A WAY 120 263260 13 HAND HELD CO...

Page 89: ...GPTLR 25 or GPTLR 33 only Unloaded platform lowers in 6 sec Unloaded platform raises in 15 sec GPTLR 44 or GPTLR 55 only Unloaded platform lowers in 10 sec Unloaded platform raises in 25 sec All GPTLR...

Page 90: ......

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