Maxon GPC X1-LDF Installation Manual
GPC X1-LDF liftgate
Installation Manual
for
Mercedes Benz Sprinter
LIFT CORP.
11921 Slauson Avenue
Santa Fe Springs, CA 90670-2221
P 800.227.4116 / 562.464.0099
Date 07.2019
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
Contents
IV
Contents
Contact information ................................................................................................ III
Contents ................................................................................................................... IV
1 Safety .................................................................................................................. 1
1.1 Intended use ................................................................................................ 1
1.2 Requirements for personnel ......................................................................... 1
1.3 Requirements for installation and commissioning ........................................ 2
1.4 Fundamental hazards................................................................................... 2
1.5 Emergency procedure .................................................................................. 2
1.6 Presentation of warning notices ................................................................... 3
2 Introduction ....................................................................................................... 4
2.1 Scope of delivery .......................................................................................... 4
2.1.1 Lifting gear ........................................................................................ 4
2.1.2 Platform ............................................................................................. 4
2.1.3 Bridge plates (20 909 431) ................................................................ 4
2.1.4 Accessories kit .................................................................................. 5
2.1.5 Installation adapter kit (22 911 216) .................................................. 7
2.2 Damage during transport.............................................................................. 8
3 Preparing for installation .................................................................................. 9
3.1 Requirements for installation ........................................................................ 9
3.2 Lifting the vehicle ......................................................................................... 9
3.3 Preparing the vehicle ................................................................................... 9
3.3.1 Remove spare tire ........................................................................... 10
3.3.2 Move exhaust pipe ................................................................ .......... 10
3.3.3 Mount supplementary battery .......................................................... 10
3.3.4 Install standard bumper on Mercedes Sprinter ................................ 10
3.3.5 Deactivate parking sensors ............................................................. 10
3.3.6 Remove trailer hitch or step ............................................................ 11
3.4 Unpacking the lifting gear, installation adapters, and accessories kit ......... 11
3.5 Pre-installing the installation adapters ........................................................ 11
3.6 Installing the cables/preparation ................................................................. 15
3.6.1 Cable to the platform ....................................................................... 15
3.6.2 Cable for the service switch ............................................................ 15
3.6.3 Routing the cables to the front of the vehicle .................................. 16
3.6.4 Control panel cable on the control unit ............................................ 18
3.6.5 Handheld control (optional) ............................................................. 18
3.7 Aligning the lifting gear ............................................................................... 20
3.8 Mounting holes on the vehicle .................................................................... 21
4 Installation ....................................................................................................... 22
4.1 Positioning the lifting gear .......................................................................... 22
4.2 Tightening the lifting gear fittings until hand-tight ....................................... 23
4.3 Securing the lifting gear to the vehicle........................................................ 26
4.4 Laterally aligning the lifting gear ................................................................. 27
Contents
V
4.5 Securing the axle assemblies ..................................................................... 27
4.6 Securing the installation adapters .............................................................. 27
4.7 Connecting the cables to the lifting gear .................................................... 28
4.7.1 Installing and connecting the service switch .................................... 28
4.7.3 Installing and connecting the control panel ..................................... 29
4.7.4 Connecting the handheld control (optional) ..................................... 33
4.7.5 Mounting the bracket for the handheld control (optional) ................ 33
4.7.6 Connecting the cables (front of vehicle) .......................................... 33
4.8 Unpacking the platform .............................................................................. 36
4.9 Raising the platform ................................................................................... 36
4.10 Installing the platform ................................................................................. 37
4.11 Mounting the platform lock on the closing arm ........................................... 41
4.12 Mounting the ground rollers ........................................................................ 42
4.13 Installing supports (vehicle-dependent) ...................................................... 43
4.14 Connecting the platform to the electrical system ........................................ 43
4.14.1 Connecting the platform cable to the electrical system ................... 43
4.14.2 Connecting the license plate light .................................................... 44
4.15 Mounting the license plate holder ............................................................... 45
4.16 Mounting the bridge plates (20 909 431) .................................................... 45
4.17 Mounting the warning flags ........................................................................ 45
4.18 Affixing the danger notice sticker ............................................................... 48
5 Adjusting the liftgate ....................................................................................... 49
5.1 Setting the lift height to the vehicle floor level using the adjustable stop on
the axle assembly .............................................................................................. 49
5.2 Aligning the platform parallel to the vehicle floor ........................................ 49
5.3 Aligning the platform (foldover section) parallel to the vehicle floor ............ 50
5.4 Checking the stop on the foldover section of the platform .......................... 52
5.5 Setting the end stop for the closed platform ............................................... 53
5.6 Adjusting the stopper for fastening the platform ......................................... 55
5.7 Adjusting the support arm for the driving position using the Bowden cable 55
5.8 Programming the tilt sensor ....................................................................... 56
6 Testing the liftgate........................................................................................... 58
6.1 Function test ............................................................................................... 58
6.2 Testing the operating speed ....................................................................... 58
6.2.1 Vertical speed ................................................................................. 58
6.2.2 Closing and opening speed (90° to 10°) .......................................... 58
6.2.3 Tilting speed (10° to -10°)................................................................ 58
6.3 Load tests ................................................................................................... 59
6.3.1 Static test ........................................................................................ 59
6.3.2 Dynamic test ................................................................................... 59
6.3.3 Testing against lifting an overload ................................................... 59
6.3.4 Testing the safety devices ............................................................... 59
6.4 Explanation of diagnostic LED on the control unit ...................................... 60
6.4.1 Checking tilt sensors S1 and S2 in the platform .............................. 61
6.4.2 Checking pressure switch S4 .......................................................... 61
Contents
VI
6.5 Entry in inspection record book .................................................................. 61
7 Recommendations and instructions regarding the liftgate ......................... 62
7.1 Hydraulic oil recommendations .................................................................. 62
7.2 Painting the lifting gear ................................................................ ............... 62
7.3 Rating plate ................................................................................................ 62
8 Useful information ........................................................................................... 63
8.1 About the service switch............................................................................. 63
8.2 Assembly drawings of installation adapters ................................................ 65
8.3 Electrical circuit diagram ............................................................................ 66
8.4 Hydraulic circuit diagram ............................................................................ 67
8.5 Torque table ............................................................................................... 68
8.6 Activating the liftgate .................................................................................. 69
8.7 Operation using the control panel .............................................................. 69
8.8 Operation using the optional handheld control ........................................... 70
Safety
1
1 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 the manufacturer or customer service.
The liftgate is used for loading and unloading the vehicle and for transferring loads.
Any other use is prohibited.
Do not exceed the maximum load carrying capacity (see rating plate). Be sure to
correctly position the load on the platform.
Do not operate the liftgate with the vehicle in motion.
Do not use the liftgate to lift any person other than the operator.
This manual is intended for the manufacturer who installs the liftgate on the vehicle. It
contains information on transport, installation, and commissioning.
Read this manual before working on or operating the liftgate.
Do not deviate from the instructions contained in this manual. By doing so, you
risk injury, damage to property, and voiding of the warranty.
Make sure that this manual always remains with the liftgate or vehicle.
IMPORTANT: For information on operation, cleaning, maintenance,
decommissioning, disassembly, and disposal, refer to the accompanying user
manual.
1.2 Requirements for personnel
The tasks described in this manual may be performed only by qualified and
trained personnel.
Use personal safety gear when performing these tasks: protective goggles, work
gloves, and protective footwear.
Perform these tasks at an appropriate working height with the body in an
appropriate position. Avoid unusual positions.
Comply with valid legal and operational guidelines, such as occupational safety
regulations and environmental regulations.
Safety
2
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.
Do not modify or remove safety equipment (pressure limiting valves, non-return
valves, electrical fuses, and software control routines). By doing so, you risk
serious injury.
Do not modify, cover, or remove product labels (warning labels, instructions,
rating plates).
1.4 Fundamental hazards
Electrical system with on-board voltage:
The liftgate receives electrical power from the vehicle’s on-board power supply (max.
48 V DC). The electrical system is designed using state-of-the-art technology.
Do not damage or modify electrical components or wiring.
High-pressure hydraulic system:
The liftgate’s hydraulic system operates at high pressure (max. 220 bar). The
hydraulic system is designed using state-of-the-art technology.
Do not damage or modify hydraulic components or hoses.
Moving parts with crushing points:
All parts that move in close proximity to one another can potentially crush fingers.
Watch out for the unexpected movement of moving parts.
Hinges with crushing points (on liftgate with platform foldover section):
Fingers are at risk of being crushed in the hinge area when the platform is folded and
unfolded.
Be careful when folding and unfolding the platform.
1.5 Emergency procedure
If you or another person working on or operating the liftgate experience a dangerous
situation:
Immediately stop what you’re doing and seek expert help.
Safety
3
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.
NOTICE
Failure to heed this notice can result in damage to property
or the environment.
1.6 Presentation of warning notices
The following types of notices are used in this manual to identify hazards and
complications:
And:
IMPORTANT
Important information or useful tip for correct use.
Introduction
4
Fig. 3
Fig. 1
Fig. 2
2 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
2.1.2 Platform
2.1.3 Bridge plates (20 909 431)
Introduction
5
Fig. 4
2.1.4 Accessories kit
Introduction
6
Item
No.
Part No.
Description
Standard
Qty.
1
80 000 046
Hexagon nut
DIN 934 - M5 - A2
4
2
20 908 251
Hexagon flange bolt
DIN 6921 - M10x15 - 10.9 - ZN
2
3
20 907 616
Ground roller
2 4
20 907 615
Bushing
d20/16x32
2
5
20 907 200
Handheld control
3-button
1
6
20 904 647
Countersunk screw with
hexagon socket
ISO 10642 - M5x16 - A2
4
7
20 904 600
Flange screw
W 0263 - M16x40 - 10.9 - GEO
2
8
20 901 791
Countersunk screw with
hexagon socket
DIN 7991 - M10x12 - A2
1
9
20 850 543
Washer
DIN 9021 - D5,3 - A2
4
10
20 840 117
O-ring
40.65x5.33
6
11
20 906 975
12 m cable with VEHH
connector
1
12
20 906 974
Cabin switch
1
13
20 840 405
Lubricating grease
1 14
60 710 330
Warning flag
Kit
1
15
-------------
Accompanying
documentation
6
Parts list – accessories kit
Accompanying documents:
Inspection booklet Part No. 60 700 495
Installation manual Part No. 20 912 027
User manual Part No. 20 908 422
Oil-level sticker Part No. 20 911 907
Electrical circuit diagram Part No. 20 910 824
Hydraulic circuit diagram Part No. 20 908 421
IMPORTANT: As a general rule, only existing mounting points (holes in the vehicle
chassis) may be used for installation. Different installation adapters are available for
each vehicle type as described below.
Introduction
7
Fig. 5
2.1.5 Installation adapter kit (22 911 216)
Introduction
8
Item
No.
Part No.
Description
Standard
Qty.
1
20 908 103
Bracket
4
2
20 908 322
Installation adapter
2
3
20 908 395
Spacer ring
2
4
20 908 398
Installation adapter
2
5
20 908 639
Installation adapter
1
6
20 908 640
Installation adapter
1
7
20 909 327
Cheese-head screw
with hexagon socket
DIN 912 - M10x90 - 8.8 - ZN - PRE80
8
8
20 911 796
Hexagon flange bolt
MBN 10105 - M12x1.5x100 - 10.9 DBL
8
9
20 911 797
Hexagon nut with
flange and clamping
piece
MBN 13023 - M12x1.5 - 10 - DBL
8
10
20 911 864
Hexagon nut with
flange and clamping
piece
MBN 13023 - M10 - 10 - DBL
4
11
22 902 352
Cheese-head screw
with hexagon socket
ISO 4762 - M10x25 - 10.9 - ZFSHL
4
12
80 000 029
Hexagon head screw
ISO 4017 - M12x25 - 8.8 - ZFSHL
2
13
80 000 032
Hexagon head screw
DIN 933 - M12x40 - 8.8 - A2K
2
14
80 000 050
Hexagon nut
DIN 934 - M12 - 8 - A2K
2
15
80 000 061
Spring washer
DIN 127 – A – 10 - ZN
8
16
80 000 072
Washer
ISO 7089 - A - D10 - ZFSH
4
17
80 000 253
Lock washer
VS - D12 - Gal.ZN8
2
18
20 912 022
Cheese-head screw
with hexagon socket
MBN 10105 - M10x100 - 10.9 - DBL
4
Parts list – installation adapter kit (Part No. 22 911 216)
2.2 Damage during transport
After unloading, inspect the liftgate for damage. If any damage is found, record it in
writing on the shipper’s waybill so that claims can be asserted.
Preparing for installation
9
CAUTION
Unsuitable transport equipment
When transporting and lifting heavy parts, use transport equipment (e.g. cranes,
pallet trucks, or other lifting gear) with a sufficient load carrying capacity.
Verify the correct and reliable functioning of the transport equipment.
3 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.
The rear doors must open to a minimum angle of 180°.
A spare tire must not be located between the rear axle and rear bumper.
The liftgate cannot be installed if the rear bumper has an integrated step. In this
case, the vehicle must be fitted with a standard bumper.
A step must not be installed behind the bumper.
A supplementary battery and switching strip must be present.
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.
3.2 Lifting the vehicle
Lift the vehicle using a lifting platform.
IMPORTANT: Installation over a pit is also possible, in which case the vehicle must
also be raised (using winches or wedges) so that the liftgate and pallet can be
inserted under the vehicle.
3.3 Preparing the vehicle
Secure the vehicle in place to prevent unintentional movement.
Disconnect the vehicle battery. Follow the vehicle manufacturer’s instructions for
correctly handling the battery.
Be careful not to damage the vehicle. We recommend using appropriate
coverings.
Preparing for installation
10
NOTICE
Be sure to maintain a sufficient
distance from heat-sensitive
parts. The minimum distance
from plastics and cables is
300 mm (see Fig. 7).
Fig. 6
Fig. 7
Fig. 8
Fig. 9
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. 6).
3.3.2 Move exhaust pipe
If the exhaust pipe is at the rear,
move it to the side.
IMPORTANT: Changes to the exhaust
system must be carried out by qualified
personnel and according to the vehicle
manufacturer’s guidelines.
3.3.3 Mount supplementary battery
If applicable, mount a supplementary battery to supply power to the liftgate.
3.3.4 Install standard bumper
on Mercedes Sprinter
If the vehicle has a bumper
with an integrated step,
replace it with a standard
bumper (see Fig. 8).
3.3.5 Deactivate parking
sensors
For vehicles with rear parking sensors,
the sensors will no longer function
correctly once the platform is installed,
Preparing for installation
11
CAUTION
Unsecured, heavy parts
When transport locks are removed, parts may fall or tip over and the platform may tip
over. Risk of injury.
Secure loose parts. Remove transport locks carefully.
After disposing of packing materials, store all parts in a secured manner.
NOTICE
Oil leakage
Incorrect positioning of the lifting gear can result in oil leakage. Risk of environmental
damage.
Always transport the lifting gear in an upright position using suitable lifting points.
Item
No.
Part No.
Description
Standard
Qty.
1
20 908 103
Bracket
4
2
20 908 322
Installation adapter
2
Fig. 10
because the lifting gear interferes with the sensors (see Fig. 9).
3.3.6 Remove trailer hitch or step
If a trailer hitch or step is mounted
on the vehicle, remove it
(see Fig. 10).
3.4 Unpacking the lifting
gear, installation adapters, and accessories kit
Check the scope of delivery for completeness (see pages 4 – 8).
IMPORTANT: Dispose of all packing materials in accordance with environmental
regulations.
3.5 Pre-installing the installation adapters
Required material from installation adapter kit (Part No. 22 911 216)
Preparing for installation
12
3
20 908 395
Spacer ring
2
4
20 908 398
Installation adapter
2
5
20 908 639
Installation adapter
1
6
20 908 640
Installation adapter
1
7
20 909 327
Cheese-head screw
with hexagon socket
DIN 912 - M10x90 - 8.8 - ZN PRE80
8
12
80 000 029
Hexagon head screw
ISO 4017 - M12x25 - 8.8 ZFSHL
2
13
80 000 032
Hexagon head screw
DIN 933 - M12x40 - 8.8 - A2K
2
14
80 000 050
Hexagon nut
DIN 934 - M12 - 8 - A2K
2
15
80 000 061
Spring washer
DIN 127 - A - 10 - ZN
8
Fig. 11
Pre-install the installation adapters on the liftgate’s lifting gear as shown in Fig. 11
or Fig. 13, tightening the fittings until hand-tight.
IMPORTANT: Depending on the vehicle, choose either the 3.5 ton (see Fig. 11) or 5
ton (see Fig. 13) installation version.
Vehicle with maximum authorized mass of 3.5 tons
(for 5 ton vehicles, see next page)
Preparing for installation
13
Fig. 12
Depending on requirements, different installation options are available for the front
installation adapters (2 and 4) in the installation adapter kit (Part No. 22 911 216)
(see Fig. 12).
Preparing for installation
14
Fig. 13
Fig. 14
Vehicle with maximum authorized mass of 5 tons
(for 3.5 ton vehicles, see previous page)
Depending on requirements, different installation options are available for the front
installation adapters (2 and 4) in the installation adapter kit (Part No. 22 911 216)
(see Fig. 14).
Preparing for installation
15
Fig. 16
Fig. 17
Fig. 15
3.6 Installing the cables/preparation
IMPORTANT: Excess cable must not be wound up
in a coil but must be placed in slings.
(Fig. 15).
3.6.1 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. 16).
3.6.2 Cable for the service
switch
Route the control unit cable for
service switch connection to the
vehicle cargo area (Fig. 17).
Preparing for installation
16
NOTICE
When installing cables, make sure they are safe from chafing.
Do not install cables near heat-dissipating components.
Fig. 18
3.6.3 Routing the cables to the front of the vehicle
For more information, look online under
http://www.taillift.org/en/electrical-vehicle-interface
IMPORTANT: Follow the vehicle manufacturer’s installation guidelines.
With preparation according to ETMA Code A and Code B
Route the power cable and the cable for the cabin switch unit to the junction box
provided (Fig. 18).
Legen
d:
Item 1 Connector for cabin switch unit Part No. 20 910 754
Item 2 Connector for positive cable (red) Part No. 20 907 673
Item 3 Connector for negative cable (blue) Part No. 20 907 673
Preparing for installation
17
NOTICE
Do not yet connect the cables.
Fig. 19
Fig. 20
No preparation according to ETMA Code A and Code B
Power cable
Insert the positive cable (25 mm² red) (“power unit cable”) for the power supply
into a length of slit corrugated tubing (see Fig. 19).
Route the positive cable
(red) and negative cable
(blue) to the terminals but
do not yet connect them
(see Fig. 20).
Legend:
Item 1 Positive cable (red) Part No. 20 907 673
Item 2 Negative cable (blue) Part No. 20 907 673
Item 3 Connector for cabin switch unit Part No. 20 910 754
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