Maxon GPTWR-25 Installation Manuals Download Page 70

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Summary of Contents for GPTWR-25

Page 1: ...maintenance parts information for your GPTWR Liftgate go to www maxonlift com Click the PRODUCTS TUK A WAY GPTWR buttons Open the Maintenance Manual in the PRODUCT DOCUMENTATION window For parts clic...

Page 2: ...PPED 24 STEP 4 RUN POWER CABLE 32 STEP 5 CONNECT POWER CABLE 34 STEP 6 CONNECT GROUND CABLE RECOMMENDED 36 STEP 7 INSTALL CONTROL SWITCH 37 STEP 8 CHECKING HYDRAULIC FLUID 39 STEP 9 CONNECT POWER CABL...

Page 3: ...TOUCH UP PAINTED OR GALVANIZED FINISH 63 SYSTEM DIAGRAMS 64 PUMP MOTOR SOLENOID OPERATION 64 HYDRAULIC SCHEMATIC POWER DOWN 65 ELECTRICAL SCHEMATIC POWER DOWN 66 GPTWR ELECTRICAL VALUES 67 OPTIONS 68...

Page 4: ...mounting plates are not welded to main frame With bolt on mounting plates it s not necessary to remove split loom 23 Added electrical welder Caution for connecting welder 27 Removed instruction and i...

Page 5: ...objects clear of the inboard edge of the platform Your feet or objects on the platform can become trapped between the platform and the Liftgate extension plate Never perform unauthorized modifications...

Page 6: ...o not allow untrained persons to operate the Liftgate Be careful working by an automotive type battery Make sure the work area is well ventilated and there are no flames or sparks near the battery Nev...

Page 7: ...vice Call 800 227 4116 or Send e mail to cservice maxonlift com Unpacking the Liftgate on unlevel surface may allow heavy components to slide off when shipping bands are cut Injury and equipment damag...

Page 8: ...Y PART NUMBER REF PARTS BOX C 1 297502 02 1 SPRING CLIP 20 050079 2 PLASTIC TIE 4 206864 3 GROMMET 1 DIA 2 HOLES 1 266428 09 4 CABLE ASSY 175 AMP 38 FT LG 1 264422 5 GROUND CABLE ASSY 2 GA X 38FT LG 1...

Page 9: ...3 GPTWR 4 297225 14 GPTWR 5 1 INSTALLATION MANUAL GPTWR 1 M 17 06 2 OPERATION MANUAL GPT GPTWR 1 M 17 07 3 DECALS SEE DECAL PAGES IN THIS MANUAL 1 ALL GPTWR S TABLE 9 1 NOTE To find maintenance inform...

Page 10: ...rd platform are as follows Maximum height is 55 Unloaded Loaded height is 49 On vehicle bodies equipped with swing open doors extension plate and vehicle body must be modified to install this Liftgate...

Page 11: ...extension plate FIGS 11 1A and 11 1B to prevent interference VEHICLE REQUIREMENTS Continued GPTWR LIFTGATE WITH WALK RAMP BOX FIG 11 1A 1 1 2 WALK RAMP PAD 2 PLACES WALK RAMP LATCH NOTCH 4 PLACES 2 1...

Page 12: ...for Liftgate To prevent aluminum platform from being damaged make sure vehicle frame is cut correctly and rear sills are modified if over 4 1 8 in height If the cutouts are incorrect platform may hit...

Page 13: ...CA 90670 800 227 4116 FAX 888 771 7713 13 CENTER OF MASS GPTWR 25 GPTWR 3 CENTER OF MASS STOWED POSITION FIG 13 2 GPTWR 25 GPTWR 3 CENTER OF MASS PLATFORM AT BED HEIGHT FIG 13 1 11 1 2 CENTER OF MASS...

Page 14: ...670 800 227 4116 FAX 888 771 7713 14 CENTER OF MASS Continued GPTWR 4 GPTWR 5 CENTER OF MASS STOWED POSITION FIG 14 2 GPTWR 4 GPTWR 5 CENTER OF MASS PLATFORM AT BED HEIGHT FIG 14 1 11 3 16 CENTER OF M...

Page 15: ...st be drilled according to instructions Extension plate may also be welded to vehicle body Do the following bolting or welding instructions for the extension plate CAUTION To preserve the corrosion re...

Page 16: ...7 4116 FAX 888 771 7713 16 REAR SILL HOLE LOCATIONS FOR 102 WIDE VEHICLE FIG 16 1 STEP 1 ATTACH EXTENSION PLATE TO VEHICLE Continued 1 1 4 1 1 2 27 37 44 51 58 65 75 80 85 95 1 2 100 1 2 102 22 17 REA...

Page 17: ...of extension plate when all the bolts are tightened Distorted extension plate can also make the dual steps difficult to install correctly Remove interference or shim rear sill to eliminate or reduce t...

Page 18: ...ension plate is flush with the top of sill on vehicle body Top surface of extension plate is level with the ground 1 Center the extension plate on vehicle body Weld the extension plate to vehicle body...

Page 19: ...ighten hex nuts securely EXTENSION PLATE WELDS VIEWED FROM UNDERNEATH FIG 19 1 EXTENSION PLATE 3 16 WELD LENGTH SPACE 2 11 3 4 96 W VEHICLE 2 12 1 2 102 W VEHICLE VEHICLE BODY NOTE During installation...

Page 20: ...t s necessary to unbolt mounting plates from main frame FIG 20 1 torque mounting plate nuts and bolts 220 240 lb ft GPTWR 25 GPTWR 3 or 350 375 lb ft GPTWR 4 GPTWR 5 RH PLATE LH PLATE D INSIDE D OUTSI...

Page 21: ...d the platform and flipover FIG 21 1 PLATFORM FLIPOVER UNFOLDED FIG 21 1 FLIPOVER PLATFORM MOUNTING PLATES LOCKING ANGLES REF 2 Unbolt opener from mounting bracket shipping position and save to reinst...

Page 22: ...GPTWR 4 5 4 Hoist the Liftgate Then place floor jack under center of main frame FIG 22 1 Jack the Liftgate into position Make sure vehicle floor is horizontal Maintain distance between floor and top o...

Page 23: ...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 CAUTION CAUTION W...

Page 24: ...RECOMMENDED LIFTGATE OPTIONAL BATTERY BOX INSTALLATION ON TRAILER FIG 24 1 CIRCUIT BREAKER 175 AMP FUSED CABLE TRACTOR BATTERIES TYPICAL LOCATION LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE BATT...

Page 25: ...BATTERY BOX FRAME MOUNTING BRACKETS MOUNTING BRACKETS BOLTING BRACKETS 8 PLACES FIG 25 1C FLUSH BRACKETS FOR TRAILERS 8 PLACES FIG 25 1B FLUSH BRACKETS FOR TRUCKS 8 PLACES FIG 25 2 ALIGNING BATTERY BO...

Page 26: ...ckets as a tem plate mark and drill holes through cross members FIG 26 1 Bolt mounting brackets to cross mem bers as shown in FIGS 26 2A and 26 2B Torque bolts and lock nuts to 85 128 lb ft CROSS MEMB...

Page 27: ...ctices 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 we...

Page 28: ...d end of power cable to battery positive terminal NOTE To connect charge lines refer to instructions provided with each charge line kit Remove all rings watches and jewelry before doing any electrical...

Page 29: ...TO VEHICLE IF EQUIPPED Continued FUSED CABLE SEE NOTE BATTERY CABLE TO COMMON GROUND FUSED CABLE TO PUMP BOX 42 LG BATTERY BOX KIT ITEM 150 AMP CIRCUIT BREAKER CABLE 12 LG CABLE 10 LG GROUND CABLE TO...

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: ...common chassis ground RECOMMENDED CONFIGURATION 1 Liftgate powered from truck batteries is typically installed on trailers as shown in FIG 32 1 and on trucks as shown in FIG 32 2 See the fol lowing p...

Page 33: ...FIG 33 1 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...

Page 34: ...ss cable from bare wire end of cable Put heat shrink tubing parts bag item FIG 34 2B on the end of the cable and leave room for terminal lug Crimp copper terminal lug parts bag item on the fused power...

Page 35: ...rom the battery power terminal STEP 5 CONNECT POWER CABLE Continued 3 Remove hex nut and lock washer from battery power terminal on the solenoid switch Remove fuse holder assembly Connect the power ca...

Page 36: ...L GROUND EXTERNAL GROUND CABLE CABLE NOTE If there is a grounding point on the frame use it to connect ground cable Then skip the step for drilling a hole 2 Extend the ground cable to reach vehicle fr...

Page 37: ...00 227 4116 FAX 888 771 7713 37 STEP 7 INSTALL CONTROL SWITCH DRILLING MOUNTING HOLES FIG 37 1 1 Drill one 3 4 hole and two 21 size holes in the vertical post on curb side of vehicle body as shown in...

Page 38: ...ble back into the hole in the vertical post until con trol switch cover touches the post FIG 38 1 Attach control switch to vertical post with 2 self tapping screws FIG 38 1 ROUTING CONTROL SWITCH WIR...

Page 39: ...add fluid to the reservoir as follows Pull out no threads filler cap FIG 39 1 Fill the reservoir with hydraulic fluid to level shown in FIG 39 1 Reinstall filler cap FIG 39 1 3 Bolt on the pump cover...

Page 40: ...DRAULIC OIL RECOMMENDED BRANDS PART NUMBER CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 EXXON UNIVIS N 32 MOBIL DTE 13M DTE 24 HYDRAULIC OIL 13 ISO 15 OR MIL H 5606 HYDRAULIC OIL RECOMM...

Page 41: ...ERY CABLES FIG 41 3 POSITIVE BATTERY TERMINAL POSITIVE BATTERY CABLE NUT NUT 2 Remove nut from positive battery terminal FIG 41 1 3 Connect fused positive cable to positive battery terminal FIG 41 2 T...

Page 42: ...arms FIG 42 1A NOTE To operate Liftgate locking angles must be removed from the lift arms and shipping bolt must be removed from both knuckles 3 With platform open FIG 42 1A unbolt each knuckle as sho...

Page 43: ...bleed air from the hydraulic system by doing the fol lowing Push the control switch to the DOWN position until you hear air escaping into the hydraulic fluid reservoir Then raise the platform FIG 43...

Page 44: ...form to the ground FIG 44 1 STEP 10 REMOVE LOCKING ANGLES KNUCKLE BOLTS CHECK FOR INTERFERENCE Continued REMOVING INSTALLATION BRACKETS FIG 44 2 7 Unbolt the 2 installation brackets from extension pla...

Page 45: ...GAP BETWEEN PLATFORM AND EXTENSION PLATE FIG 45 1 PLATFORM EXTENSION PLATE 5 8 5 8 8 Raise the platform to vehicle floor level FIG 45 1 Refer to GPT 25 GPT 3 GPT 4 GPT 5 GPTWR 25 GPTWR 3 GPTWR 4 GPTWR...

Page 46: ...s 1 8 maximum as shown SURFACES FLUSH PLATFORM DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM EXTENSION PLATE RH VIEW FIG 46 1 DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM EXTENSION PLATE LH VIEW FIG 46 2 NOTE...

Page 47: ...al injury and equipment damage disconnect battery cable and cable from battery 2 Disconnect power to the pump by disconnecting negative and positive cables from battery FIG 47 2 Reinstall nuts on nega...

Page 48: ...S FLAT WASHER 4 PLACES 3 Bolt ICC bumper opener parts bag items and license plate bracket to main frame as shown in FIG 48 1 Then torque bolts and lock nuts to 105 lb ft 4 Reconnect power to the pump...

Page 49: ...RNING To prevent accidental personal injury and equipment damage disconnect battery cable and cable from battery INSTALLATION WITH UNDERRIDE 1 Lower platform to ground level Refer to operating instruc...

Page 50: ...POST BATTERY POWER RECONNECTED FIG 50 1 NEGATIVE BATTERY CABLE NEGATIVE BATTERY POST NUT POSITIVE BATTERY CABLE 6 Put license plate bracket in desired position on top of underride FIG 50 2 Next use b...

Page 51: ...6 If outboard edge is higher than 1 do instructions 4 through 6 3 Weld shims parts bag item on both platform stops FIG 51 3 to raise outboard edge of platform to correct position PLATFORM EDGE BELOW B...

Page 52: ...depths in TABLE 52 1 For example If measurement B FIG 52 1 is 3 above bed level and you want to lower the outboard edge of platform to 1 above bed level grind 1 8 from each platform stop TABLE 52 1 5...

Page 53: ...ers and electrical parts 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 MOUNTING PLATE WELDING...

Page 54: ...VE BATTERY POST NEGATIVE BATTERY CABLE NEGATIVE BATTERY POST NUT POSITIVE BATTERY CABLE WARNING To prevent accidental personal injury and equipment damage disconnect battery cable and cable from batte...

Page 55: ...e damage maintain 90 angle between steps and extension plate Tighten bolts only in the order shown in illustration CAUTION 3 Line up the LH step Kit item on LH side of the extension plate Bolt step to...

Page 56: ...ehicle rear sill and I beams Then butt the support against back of the step FIG 56 1 STEP 14 BOLT STEPS TO EXTENSION PLATE Continued I BEAM VEHICLE BODY LH STEP STEP SUPPORT MOUNTING CHANNEL LOCK NUT...

Page 57: ...mounting channel to vehicle body ensure step is straight and steps are in vertical position STEP 14 BOLT STEPS TO EXTENSION PLATE Continued 3 16 WELD TO AS MUCH I BEAM FLANGE REAR SILL AS POSSIBLE I B...

Page 58: ...FIG 58 1B Slide the pads toward the outside of the walk ramp box FIG 58 1B 3 Install the walk ramp not shown according to manufacturer s in structions WALK RAMP INSERTED HERE WALK RAMP BOX EXTENSION P...

Page 59: ...and arms until grease starts oozing from ends of the bearings Then wipe off excess grease with a clean lint free cloth STEP 16 LUBE GREASE FITTINGS AS NEEDED LUBRICATION DIAGRAM FIG 59 1 NOTE Lube fi...

Page 60: ...urface 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...

Page 61: ...116 FAX 888 771 7713 61 APPLY DECALS Continued CAPACITY DECAL TABLE 61 1 MODEL DECAL P N CAPACITY DECAL GPTWR 25 220382 2500 POUNDS GPTWR 3 220388 3000 POUNDS GPTWR 4 296274 01 4000 POUNDS GPTWR 5 296...

Page 62: ...771 7713 62 FIG 62 1 PLATFORM LOADING DECAL P N 281326 01 2 PLACES SERIAL PLATE REF MAXON NAME PLATE P N 280004 01 DECALS PLATES NOTE Preferred decal layout is shown Decals on the Liftgate are attach...

Page 63: ...hile painting CAUTION TOUCH UP PAINTED OR GALVANIZED FINISH If bare metal or primer is exposed on the painted portions of the Liftgate touch up the paint To maintain the protection provided by the ori...

Page 64: ...draulic lock valve is on the RH cylinder POWER UNIT FIG 64 1 POWER UNIT MOTOR SOLENOID OPERATION LIFTGATE FUNCTION PORT SOLENOID OPERATION MEANS ENERGIZED MOTOR VALVE S2 VALVE S1 LOCK VALVE POWER DOWN...

Page 65: ...C POWER DOWN FIG 65 1 PORT B LOWER POWER DOWN PORT A RAISE RELIEF VALVE 2 SET AT 1100 PSI PUMP AUX HAND PUMP PORT PLUGGED VALVE S2 VALVE S1 HYDRAULIC CYLINDERS 4 GPM FLOW CONTROL VALVE RESERVOIR DRAIN...

Page 66: ...11921 Slauson Ave Santa Fe Springs CA 90670 800 227 4116 FAX 888 771 7713 66 ELECTRICAL SCHEMATIC POWER DOWN FIG 66 1...

Page 67: ...Contact 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...

Page 68: ...NIZED NOTE COMPLIES WITH CANADIAN MVS REGULATIONS FMVSS REAR IMPACT GUARD REQUIREMENTS 287050 01G UNDERRIDE 95 GPT 4 GPT 5 GALVANIZED NOTE COMPLIES WITH CANADIAN MVS REGULATIONS FMVSS REAR IMPACT GUAR...

Page 69: ...5 33G DUAL STEP W LIGHT GALVANIZED CURB SIDE 13 5 LG RUBBER BUMPERS 288705 34G DUAL STEP DOCK BUMPER KITS WITHOUT BUMPERS DUAL STEP GALVANIZED NO BUMPERS 288705 05G DUAL STEP GALVANIZED STREET SIDE NO...

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