Maxon GPT, GPT-25, GPT-3, GPT-4, GPT-5 Installation Manual

M-99-49
REV. K
OCTOBER 2005

© MAXON Lift Corp. 2005

TABLE OF CONTENTS

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

ST ANDARD LIFTGA TE COMPONENTS .............................................................................. 4

GPT-SERIES INST ALLA TION P ARTS BAGS........................................................................ 5

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

STEP 2 - WELD EXTENSION PLA TE TO VEHICLE............................................................. 8

STEP 3 - WELD LIFTGA TE T O VEHICLE .......................................................................... 10

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

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

STEP 6 - INST ALL CONTROL SWITCH .............................................................................. 16

STEP 7 - CONNECT POWER CABLE T O BA TTERY......................................................... 19

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

STEP 9 - WELD PLA TFORM OPENER TO LIFTGA TE....................................................... 21

STEP 10 - FINISH WELDING LIFTGA TE TO VEHICLE....................................................... 24

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

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

STEP 13 - WELD HOOK AND EYE TO LIFTGA TE ............................................................. 27

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

STEP 15 - BOL T RUBBER BUMPERS TO LIFTGA TE........................................................ 29

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

STEP 17 - VEHICLE T AILLIGHT POSITIONING .................................................................. 32

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

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

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

OPTIONAL LIFTGA TE COMPONENTS............................................................................... 35

RECOMMENDED LIFTGA TE POWER CONFIGURA TION ................................................. 36

Comply with the following WARNINGS while installing Liftgates. See Operation Manual
M-97-16 for operating safety requirements.

!

WARNINGS

• Read and understand the instructions in this Installation Manual before installing Liftgate.

• Before operating the Liftgate, read and understand the operating instructions in Operation Manual
M-97-16.

• Comply with all WARNING and instruction decals attached to the Liftgate.

• Keep decals clean and legible. If decals are defaced or missing, replace them. Free replacement
decals are available from Maxon Customer Service.

• Consider the safety and location of bystanders and location of nearby objects when operating the

Liftgate. St and to one side of the platform while operating the Lif tgate

• Do not allow untrained persons to operate the Liftgate.

• Do not stand under, or allow obstructions under the platform when lowering the Liftgate. Be sure
your feet are clear of the Liftgate.

• Keep fingers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when operating the Liftgate.

• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.

• Make sure vehicle battery power is disconnected while installing Liftgate. Connect vehicle

battery power to the Liftgate only when installation is complete or as required in the installation
instructions.

• Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while
performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact
with battery acid may injure unprotected eyes and skin.

• 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. Never lay objects on the battery that can short the
terminals together. If battery acid get s 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.

• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise
during operation comes from the pump unit while the platform is raised and lowered. Listen for
scraping, grating and binding noises and correct the problem before continuing to operate Liftgate.

• If it is necessary to stand on the platform while operating the Liftgate, keep your feet and any
objects clear of the inboard edge of the platform. Your feet or objects on the plat form could be
trapped between the platform and the Liftgate extension plate.

• Never perform unauthorized modifications on the Liftgate. Modifications may result in early failure of
the Liftgate and may create hazards for Liftgate operators and maintainers.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

3

STANDARD LIFTGATE COMPONENTS

!

CAUTION

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) after shipping
straps are removed.

NOTE: Make sure you have all components and parts before you start installing Liftgate.

Compare parts in the Part Box and each Kit Box with packing list enclosed in each
box. If parts and components are missingor incorrect call:

Maxon Customer Service

Call [phone] or

Send e-mail to [e-mail]

DOCK BUMPER

BRACES

P ARTS BAGS

(SEE TABLE 5-1)

OPENER ASSEMBL Y

ANGLES

PUMP BOX

(SEE T ABLE 5-1)

MAIN

ASSEMBL Y

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

EXTENSION

PLATE

TYPICAL LIFTGATE PACKAGED FOR SHIPMENT

FIG. 4-1

4

GPT-SERIES INSTALLATION PARTS BAGS

STNETNOCXOBSTRAP.YTQREBMUNTRAP

.1"8/1X"1X"2/1-2,TALF2999102
.2REPMUBKCODREBBUR,TIK1014302
.3)AG2#(GULREPPOC1877622

F1224462

.4.GL'83,PMA002,ELBACREWOPDESU
.5"2/1-1X"4/3,DAPDEGROFPORD,EYE1839622
.6.GL"2/1-1X.D.I"8/5,GNIBUTKNIRHSTAEH140-613352
.7YSSAKOOH1007722
.8Y
.9"4/1X"4/3-1X"2/1-3,MIHS2137462

.01"61/1X"1X"2/1-2,MIHS2237462
.11"8/3X"4X"5,TALF2592922
.21TIKSLAUNAM&LACED1-

RAW.D187-87-M

SLACED.F-

.31MOOLREBBUR01#,PMALC2186108
.41"1X42-01WERCSGNIPPAT-FLES45-750009
.51"8/3-1X"2/1,PILCEMARF7970050

SSAHCTIWSDEDLOM110-159462

LAUNAMNOITAREPO.A161-79-M

LAUNAMNOITALLATSNI.B194-99-M

LAUNAMECNANETNIAM.C151-79-M

DRACYTNAR

MROFYEVRUSREMOTSUC.E140-49-M

SEGAPLACEDOTREFER

.LAUNAMSIHTNI

.61ELIFORPWOL,ELDDAS210-948562
.7131-"2/1,DE
.818EDARG,GL"4/1-2,31-"2/1,EMARF,TLOBXEH43-420109

GNALF,TUNKCOL4320109

TABLE 5-1

5

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

STEP 1 - PREPARE VEHICLE

NOTE: BODY Maximum and Minimum Operating Bed Height:

For GPT-25, GPT-3, GPT-4, & GPT -5 With St andard Plat form -

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 inst all this Liftgate.

NOTE: Make sure vehicle is parked on level ground while preparing V ehicle and installing

Liftgate.

1. Check for correct clearances (FIG. 6-1 and FIG. 6-2) on vehicle to prevent interference

between vehicle and Liftgate.

APPROX. 20”

(REF . ONL Y)

14”

55” MAX. BED HEIGHT
46” MIN. BED HEIGHT

55” MAX. BED HEIGHT
46” MIN. BED HEIGHT

10”-19”

REF .

GPT-25 & GPT-3 CLEARANCES

FIG. 6-1

APPROX. 24”

(REF . ONL Y)

14”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

GPT-4 & GPT-5 CLEARANCES

FIG. 6-2

6

12”-21”

REF.

STEP 1 PREPARE VEHICLE - Continued

CAUTION

T o prevent Aluminum Plat form from being damaged, make sure T ruck Frame is cut
correctly as shown in the illustration below. If the Frame is cut incorrectly, Platform
may hit the Truck Frame while stowing Lif tgate.

NOTE: If installing Liftgate on a trailer , skip frame cutting instructions in Item 2.

2. Fit Liftgate to a truck body by cutting the truck frame members as shown in FIG. 7-1.

TOP OF TRUCK

22-1/2”

4-1/2”

12”

BODY FLOOR

20”

TRUCK
FRAME

2-11/16”

CUTS FOR GPT-25, GPT-3, GPT-4 & GPT -5

FIG. 7-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

7

STEP 2 - WELD EXTENSION PLATE TO VEHICLE

1. Center the Extension Plate on vehicle body . Before welding Extension Plate to vehicle

body , make sure top surface of Extension Plate is flush with floor of vehicle body . Weld the
Extension Plate to vehicle body sill as shown in FIG. 8-1 and FIG. 8-2.

4” LG.

4” WELDS SHOWN

1/4”

2” LG . CENTERED

BETWEEN

4” LG . LOCA TED ABOVE EACH OF
3 RECT ANGULAR TUBES (TUBES
SHOWN SHADED IN FIG . 3)

(P ART OF VEHICLE BODY)

1/4”

4” LG.

1/4”

1/4”

EXTENSION PLATE WELDS - VIEWED FROM ABOVE

FIG. 8-1

SILL

2 PLACES, MAKE 1”

2” LG , 12 PLACES

EQUAL SP ACING

(TYP.)

1/4”

1/4”

1” GAP

GAP WHERE SHOWN

(P ART OF

VEHICLE BODY)

1/4”

1” GAP

SILL

5 PLACES, MAKE 1”
GAP WHERE SHOWN

EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH

FIG. 8-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

1” GAP

8

STEP 2 - WELD EXTENSION PLATE TO VEHICLE -

Continued

2. Place 2 temporary Support Straps (5” x 4” x 3/8”

flats from Parts Box) on the Extension Plate as
shown in FIG . 9-1A. Also, put 2 temporary
spacers (2” x 1” x 1/8” flats from Parts Box)
between Platform and Extension Plate as shown
in FIG . 9-1B. (Sp acers keep 1/8” between
Platform and Extension Plate while welding
liftgate to vehicle frame.) Weld the S traps and
Spacers to Extension Plate (FIG. 9-1B).

1” (APPROX. - TYP.
STRAP OVERHANG)

1/8” SP ACER

EXTENSION

PLATE

1/4” LG . TACK, SUPPORT

1/4”

4”

17-1/2”

STRAP TO EXTENSION
PLA TE (1 WELD ONL Y),
SP ACER & SUPPORT
STRAP TO EXTENSION
PLA TE (1 WELD ONL Y)

1/2” (APPROX.-

TYP . SP ACER

OVERHANG)

STRAP & SPACER WELDS

(TYPICAL - BOTH ENDS OF

EXTENSION PLATE)

FIG. 9-1B

SUPPORT

STRAPS

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 9-1A

9

STEP 3 - WELD LIFTGATE TO VEHICLE

1. Remove Split Looms from Mounting Plates

(FIGS. 10-1A & 10-1B). (S plit Looms will be

reinstalled later after final welding).

MOUNTING

PLA TE

SPLIT LOOMS

MOUNTING PLA TES

FIG. 10-1B

RH SIDE VIEW OF LIFTGATE

FIG. 10-1A

2. Unfold the Platform and Flipover (FIG. 10-2).

LOCKING ANGLES

PLA TFORM

(UNFOLDED)

(REF)

MOUNTING

PLATES

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FLIPOVER

(UNFOLDED)

PLATFORM & FLIPOVER UNFOLDED

FIG. 10-2

10

STEP 3 - WELD LIFTGATE TO VEHICLE - Continued

!

CAUTION

T o 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.

3. Make sure Hoist will not

be set up the incorrect
way (FIG. 1 1-2). Place a
“C”-Clamp on each side
of Platform as shown in
FIG. 11-1. (Clamps
prevent Hoist Chain
from slipping off Plat­form.) Place chain all
around Platform

(FIG. 11-1).

HOIST CHAIN

FLIPOVER

PLA TFORM

FLOOR JACK

VEHICLE FLOOR

(HORIZONT AL)

PINS
(LINED UP­VERTICAL)

MOUNTING

PLATE

YES

4. Hoist the Liftgate. Then place

floor jack under Main Frame
(FIG. 11-1). Jack the Liftgate
in position. Make sure V ehicle
Floor is horizontal and Pins are
lined up (FIG. 11-1).

FLIPOVER

MAIN FRAME

CCORRECT WAY TO HOIST LIFTGATE

FIG. 11-1

HOIST CHAIN

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

NO

INCORRECT WAY TO HOIST LIFTGATE

FIG. 11-2

11

STEP 3 - WELD LIFTGATE TO VEHICLE - Continued

!

WARNING

Liftgate is shipped from factory with Mounting Plates that are only Tack Welded to
Main Frame. Weld as shown in illustration before operating Liftgate.

CAUTION

Prevent damaged hydraulic hoses. If welding next to hydraulic hoses, use
a protective cover such as a welding blanket to cover the hoses.

5. Check if both Mounting

Plates line up with the
vehicle frame. If the
Mounting Plates do not
line up, remove the tack
welds from one Mounting
Plate (FIG. 12-1). Make

ORIGINAL T ACK WELDS
(REMOVE TO REPOSITION
MOUNTING PLA TE)

sure Liftgate stays cen­tered on vehicle. Reposi­tion the Mounting Plate
against vehicle frame.
T ack weld as shown in
FIG. 12-1. Repeat for
second Mounting Plate
(reposition and tack
weld).

NOTE: Weld both Mounting Plates to
vehicle frame before welding Mounting
Plates to Main Frame.

T ACK

(TYPICAL - RH & LH

MOUNTING PLA TES)

MAIN FRAME
(CUT-A WA Y VIEW)

REPOSITIONING MOUNTING PLA TE

VEHICLE FRAME CUTOUT

(TYPICAL TRUCK FRAME SHOWN)

5/16”

MOUNTING
PLATE

(RH SIDE SHOWN)

FIG. 12-1

VEHICLE FRAME CUTOUT

(TYPICAL TRUCK FRAME SHOWN)

6. Clamp both Mounting

Plates to vehicle frame.
Before welding, 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.

2” LG. 4 PLACES

(TYPICAL - RH & LH

MOUNTING PLA TES)

WELD TO VEHICLE FRAME AND MAIN FRAME

12

5/16”

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

MOUNTING
PLATE

MAIN FRAME
(CUT-A WAY VIEW)

5/16”

(RH SIDE SHOWN)

FIG. 12-2

STEP 3 - WELD LIFTGATE TO VEHICLE - Continued

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 measure­ment 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).

TIP OF

FLIPOVER

1” MAX.

LEVEL LINE

MEASURING DISTANCE ABOVE BED

LEVEL AT THE TIP OF FLIPOVER

FIG. 13-1

13

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

STEP 4 - RUN POWER CABLE

CAUTION

!

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. A void making sharp bends in wiring. Attach securely. If drilling is
necessary , first check behind the drilling surface so you do not damage any fuel
lines, vent lines, brake lines or wires.

Clip Fused Power Cable to vehicle chassis, with fuse nearest the vehicle battery , as shown in
FIG. 14-1. Keep enough cable near the battery to reach the positive terminal without putting
tension on cable (after connection). Run bare wire end of cable to Liftgate.

VEHICLE FRAME

(TRUCK FRAME SHOWN)

FUSE

SHORTEST

CABLE END

18” - 24”

SP ACING

CABLE

CLIPS

BARE WIRE END

(TO PUMP BOX)

FRONT OF VEHICLE

REAR OF VEHICLE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

TERMINAL LUG

(VEHICLE BA TTERY

END)

FIG. 14-1

14

STEP 5 - CONNECT POWER CABLE

1. On the bare wire end of Fused Power Cable, keep enough length to attach copper terminal
lug and reach Motor Solenoid without putting tension on cable (after connection) (FIG. 15­1A). Measure (if needed) and then cut excess cable from bare wire end of cable. Put

heatshrink tubing (Parts Box) (FIG. 15-1B) on the end of the cable (leave room for terminal
lug). Crimp copper terminal lug (from Parts Box) on the Fused Power Cable and shrink the
Heatshrink Tubing (FIG. 15-1C).

FUSED

POWER CABLE

HEA TSHRINK TUBING

COPPER TERMINAL LUG

FIG. 15-1B

FIG. 15-1C

TYPICAL FUSED POWER CABLE ROUTING

(POWER DOWN PUMP BOX SHOWN)

FIG. 15-1A

NOTE: MAXON recommends using dielectric

grease on all electrical connections.

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.

FUSED

POWER CABLE

MOTOR SOLENOID

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

HEX NUT

LOCK

WASHER

BA TTER Y

POWER POST

TYPICAL FUSED POWER CABLE ELECTRICAL CONNECTION

(POWER DOWN PUMP BOX SHOWN)

FIG. 15-2

15

STEP 6 - INSTALL CONTROL SWITCH

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.

7/8”

VEHICLE BODY

VERTICAL POST

(CURB SIDE)

18”

FIG. 16-1A

1-3/4”

HOLE DRILLING TEMPLATE

FIG. 16-1B

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

16

STEP 6 - INSTALL CONTROL SWITCH - Continued

2. Route the Control Switch cable through the

¾” hole in the Vertical Post (FIGS. 17-1B)
and down the V ertical Post as shown in
(see dashed line in FIG. 17-1A). When
the Control Switch is close to the Post,
attach Control Switch to V ertical Post with
2 self-tapping screws (FIG. 17-1B).

(SEE DECALS P AGE)

SELF-T APPING

SCREW

3. Run Control Switch cable under Vehicle Body
(see dashed line in FIG. 17-1A) and through

the Grommet on the Pump Box. Use 2 loom
clamps and 2 self-tapping screws (Parts Box)
to secure the Control Switch cable to vehicle
frame.

CONTROL SWITCH

DECAL

ATTACHING CONTROL SWITCH

FIG. 17-1B

3/4” HOLE

PLA TFORM

(OPEN AND RAISED)

PUMP BOX

3/4” HOLE

CONTROL SWITCH

CABLE

VEHICLE BODY

VERTICAL POST

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

GROMMET

ROUTING CONTROL SWITCH WIRING

FIG. 17-1A

17

STEP 6 - INSTALL CONTROL SWITCH - Continued

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 correct
wires shown in the illustration.

4. Open the Pump Box Cover.
Connect the RED, BLACK,
GREEN, and WHITE wires
from the Control Switch cable
to Pump Wiring as shown in

FIG. 18-1.

CRIMP

TERMINALS

BLACK WIRE

RED WIRE

“A” V AL VE

WIRE

“A” V AL VE

“E” V ALV E

WIRE

“E” VAL VE

WHITE WIRE GREEN WIRE

CONNECTING CONTROL SWITCH

CABLE TO PUMP WIRING

FIG. 18-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

18

STEP 7 - CONNECT POWER CABLE TO BATTERY

NOTE: MAXON recommends using dielectric

grease on all electrical connections.

Remove nut from positive (+) battery terminal connector. Connect Power Cable to the positive

(+) battery terminal connector (FIG. 19-1). Re-install and tighten nut.

POSITIVE (+)

BA TTERY TERMINAL

BOL T

NUT

FUSED

POWER CABLE

FIG. 19-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

19

STEP 8 - REMOVE LOCKING ANGLES & WELDS

1. Push Control Switch to RAISE position to pressurize Hydraulic System. Listen for

Hydraulic Fluid flowing through the system. Check for fluid leaks. (If there are leaks, release
the Control Switch and correct the leaks before fully pressurizing system.) When the sound
of flowing fluid stops, release Control Switch. Hydraulic System is ready .

NOTE: T o operate Liftgate, Locking Angles must be removed from the Hydraulic Cylin-

ders and welds must be removed from Lifting Arm Knuckles.

2. Remove Locking Angles from Hydraulic Cylinders (FIG. 20-1A).

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 as shown in FIG. 20-1D &
20-1E.

PLA TFORM

(UNFOLDED)

FLIPOVER

(UNFOLDED)

CUT WELD

BLOCK ST A YS

HERE

HERE

FIG. 20-1B

FIG. 20-1D

FIG. 20-1A

FIG. 20-1C

LOCKING

ANGLE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

CUT WELD

HERE

BLOCK ST A YS

HERE

FIG. 20-1E

20

STEP 9 - WELD PLATFORM OPENER TO LIFTGATE

1. Remove Floor Jack and Hoist

supporting Liftgate (FIG. 21-1).

FLOOR JACK

FIG. 21-1

SUPPORT STRAPS

& SP ACERS

2. LOWER the Platform to the ground.

Remove both support straps and
both spacers from Extension Plate

(FIG. 21-2).

PLA TFORM

(BOTH SIDES)

3. Fold flipover (FIG. 21-3).

FIG. 21-2

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FLIPOVER

FOLDING FLIPOVER

FIG. 21-3

21

STEP 9 - WELD PLATFORM OPENER TO LIFTGATE

- Continued

NOTE: Platform Opener may only be installed on Right Hand side of Main Frame

(see the illustrations on this page).

4. Position the Opener on Main Frame as
shown in FIG . 22-1 and TABLE 21-1.

ETAGTFIL"L"
3-/52-TPG

5-/4-TPG

"61
"31

OPENER

“L”

(T ABLE 2)

TABLE 22-1

POSITIONING OPENER

FIG. 22-1

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.

PROTECTIVE

PLATE

MAIN

FRAME

OPENER

PLA TFORM

OPENER

FIG. 22-2A

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

MAIN

FRAME

CENTERING OPENER ON PLATE

FIG. 22-2B

22

STEP 9 - WELD PLATFORM OPENER TO LIFTGATE

- Continued

CAUTION

!

If there is any interference with the Platform while stowing Liftgate, check for dam­age on bottom of Platform, Flip Over , and the hinge in between. A damaged Plat form
or Flip Over may result in personal injury and more damage to Liftgate.

6. Stow and unfold Liftgate several

times to verify there is no interfer­ence. If there is no interference,
weld Opener to Main Frame

(FIG. 23-1).

OPENER

3/16”

MAIN

FRAME

1” LG.
4 PLACES

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 escaping into the Hydraulic Fluid
Reservoir. RAISE the Platform and
then repeat this step until there is no
air left in the system and Platform
lowers smoothly .

WELDING OPENER TO MAIN FRAME

FIG. 23-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

23

STEP 10 - FINISH WELDING LIFTGATE TO VEHICLE

CAUTION

Prevent damaged hydraulic hoses. Before welding next to hydraulic hoses, protect
the hoses with a heat-resistant cover such as a welding blanket.

1. Weld each of the two Mounting

Plates to V ehicle Frame

(FIG. 24-1A).

(TYPICAL TRUCK FRAME

VEHICLE FRAME

SHOWN)

WELDING MOUNTING PLATE

FIG. 24-1A

VEHICLE FRAME CUTOUT

(DASHED LINES)

MOUNTING PLA TE

TYPICAL -

5/16”

BOTH
MOUNTING
PLA TES

FIBERGLASS

SLEEVES

2. Af ter welding is done and Mounting

Plates are cool, remove the 4 Fiber­glass Sleeves shown in FIG. 24-1B.
Then reinstall the S plit Looms re­moved in STEP 3 (FIG. 24-1B).

SPLIT LOOMS

MOUNTING

FIBERGLASS

SLEEVES

PLA TES (REF)

REINSTALLING SPLIT LOOMS

FIG. 24-1B

24

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

STEP 11 - INSTALL & ADJUST SADDLES

CAUTION

!

Make sure Mounting Plates are cooled before installing Saddles. Hot surface could
result in personal injury and damaged Saddles.

1. Stow the Plat form as shown in
FIG. 25-1A. Use floor jack 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.

HINGE

MOUNTING

PLA TE

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 lock nuts.

SADDLE

STOWED LIFTGATE - SIDE VIEW

LIFTING FRAME

BRACKET

(RH SIDE SHOWN)

FIG. 25-1A

ROLLER

PLA TFORM

BOL TS &

LOCK NUTS

1/8”

GAP

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

GAP BETWEEN PLATFORM & ROLLER

FIG. 25-1B

25

STEP 12 - CHECK HYDRAULIC FLUID

NOTE: Use correct grade of hydraulic fluid for your location.

+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-H-5606

See TABLES 26-1, 26-2, & 26-3 for recommended brands.

1. Remove the Filler Cap (FIG. 26-1).

PUMP

RESERVOIR

FILLER

DECAL

(FLUID LEVEL)

CHECKING HYDRAULIC

FLUID LEVEL

FIG. 26-1

2. Check the Hydraulic Fluid level in the

Pump Reservoir (FIG. 26-1). If fluid is
below FILL LEVEL shown on Decal
on the Pump Reservoir (FIG. 26-1),
add fluid to the FILL LEVEL.

CAP

SDNARBDEDNEMMOCERREBMUNTRAP

LIOSMA50-HWA

NORVEHC23NYSREPIH

LLADNEKVMNEDLOG

LLEHS23-TSULLET

NOXXE23-NSIVINU

LIBOM

TABLE 26-1

SDNARBDEDNEMMOCERREBMUNTRAP

LIOSMA50-FWA

NORVEHC51-VM-WA,ADIULF

LLADNEKULBLAICALG

LLEHS51-TSULLET

NOXXE31-IVHSIVINU

LIBOMM11-ETD

TABLE 26-2

LIOCILUARDYH23OSI

,42-ETD,M31-ETD

DYH

31-LIOCILUAR

LIOCILUARDYH51OSI

3. Reinstall the Filler Cap (FIG. 26-1).

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

DIULFCILUARDYH6065-H-LIMRO01-OSI

SDNARBDEDNEMMOCERREBMUNTRAP

LIOSMAA/N

NORVEHCGDIULF,ADIULF

LLADNEKULBLAICALG

LLEHS14-DIULFLLEHSOREA

NOXXE31-IVHSIVINU

LIBOMAFHOREA

TABLE 26-3

26

STEP 13 - WELD HOOK AND EYE TO LIFTGATE

1. Stow the Liftgate under hydraulic pressure

(FIG. 27-1).

INBOARD SIDE OF

TUBING , ONL Y

HOOK

(WITH CHAIN)

KNUCKLE

BASE OF

P AD EYE, ONL Y

3/16”

1/4”

2. Weld the Pad Eye (from Installation

Parts Bag) to Knuckle as shown in

FIG. 27-1.

EXTENSION PLA TE

P AD EYE

RH SIDE VIEW OF STOWED LIFTGATE

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.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

27

STEP 14 - WELD DOCK BUMPERS TO LIFTGATE

1. Lower the Platform to the ground (Operation Manual M-97-16).

2. Clamp a Dock Bumper to Left Hand (LH) side of Extension Plate as shown in FIG. 28-1A.

Weld the Dock Bumper to Extension plate as shown in FIG. 28-1B. Make sure bolt holes in
the Dock Bumper are visible from the rear of the vehicle. Repeat step for Dock Bumper on
Right Hand (RH) side of Extension Plate.

2 PLACES

LH & RH DOCK

BUMPER

EXTENSION

PLA TE

3/16”

GRIND OFF

SHARP

CORNERS

DOCK BUMPER

BRACE

LINE UP BOTTOM EDGES A T

MAIN FRAME

TYPICAL DOCK BUMPER & BRACE

POSITIONING (LH SIDE SHOWN)

FIG. 28-1A

WELDING ANGLE TO EXTENSION PLATE

THIS POINT.

BRACE

(CENTERED

BETWEEN 2 PINS)

PINS

FIG. 28-1B

3/16”

(P ART OF BRACE)

2 PLACES
LH & RH BRACES

FLAT

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

3. Clamp open end of Brace to Dock Bumper as shown in FIG. 28-1A.

FIG. 28-1C

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.

28

STEP 15 - BOLT RUBBER BUMPERS TO LIFTGATE

NOTE: The Rubber Dock Bumpers Kit P/N 203410 contains 2 Rubber Bumpers

and 2 sets of fasteners.

Bolt a Rubber Bumper to each of the 2 Dock Bumpers (FIG. 29-1).

FLA T WASHER

(1/2”)

HEX NUT

(1/2”- 20)

CAP SCREW

(1/2”- 20 x 2”)

DOCK

BUMPER

RUBBER
BUMPER

BOLTING RUBBER BUMPER TO DOCK BUMPER

(RIGHT HAND SIDE DOCK BUMPER SHOWN)

FIG. 29-1

LOCK WASHER

(1/2”)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

29

STEP 16 - PLACE DECALS

INSTRUCTION DECAL

P/N 251838

(REFERENCE)

CAP ACITY DECAL

(REFERENCE)

CAUTION DECAL

P/N 263998

WARNING DECAL

P/N 264081

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 30-1

30

STEP 16 - PLACE DECALS - Continued

UP/DOWN DECAL

P/N 264507

WARNING DECAL

P/N 264081

(REFERENCE)

CAUTION DECAL

P/N 263998

(REFERENCE)

CAPACITY DECAL (SEE TABLE 31-1)

CAP ACITY

2500 LBS.
3000 LBS.

4000 LBS.

CAP ACITY DECALS

P ART NO.

220382
220388
220389

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

INSTRUCTION DECAL

P/N 251838

5000 LBS.

TABLE 31-1

220390

FIG. 31-1

31

STEP 17 - VEHICLE TAILLIGHT POSITIONING

(IF REQUIRED)

NOTE: Positions are based on using taillights of 6-3/4” height by 5-3/4” width. Larger

taillights may interfere with Liftgate. Taillights and attaching hardware are not
provided with the Liftgate. Underride is optional equipment.

Install vehicle taillights (FIG. 32-

1) as shown in FIG. 32-2 and
FIG. 32-3.

T AILLIGHTS

VEHICLE TAILLIGHTS INSTALLED ON LIFTGATE

ANGLE STEEL

MAIN

FRAME

EXTENSION

PLATE

(REFERENCE)

(NOT SUPPLIED)

OPTIONAL

UNDERRIDE

(REFERENCE)

FIG. 32-1

PLA TFORM OPENER

(REFERENCE)

14”

T AILLIGHTS

(NOT SUPPLIED)

T AILLIGHT

T AILLIGHTS POSITION (TOP VIEW)

FIG. 32-2

ANGLE STEEL

24”

GROUND LEVEL

PLA TFORM OPENER

(REFERENCE)

24”

30”

OPTIONAL

UNDERRIDE

(REFERENCE)

T AILLIGHT

T AILLIGHTS HORIZONTAL SP ACING (FRONT VIEW)

FIG. 32-3

32

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

ADJUST ABLE

NEEDLE V ALVE

HYDRAULIC SYSTEM SCHEMATIC

HYDRAULIC CYLINDERS

4 GPM FLOW

CONTROL V AL VE

FILL HOLE

(PLUGGED)

PORT B-

LOWER

(PWR DN)

CHECK V ALVE

MOTOR

(REFERENCE)

M

FIL TER

PUMP

PORT A-

RAISE

RELIEF

VALVE

(SET A T

2200 PSI)

RESERVOIR

V AL VE “A”

FIL TER

V AL VE “E”

HAND PUMP

PORT

HAND PUMP

PORT

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

FIG. 33-1

33

DRAIN HOLE

(PLUGGED)

ELECTRICAL SYSTEM SCHEMATIC

CABLE

ASSEMBL Y

RED

CONTROL SWITCH

GREEN

BLACK

WHITE

SOLENOID,

V AL VE E

CABLE WITH

200 AMP FUSE

SOLENOID,

V ALVE A

MOTOR

ST ARTER

SOLENOID

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

BA TTERY

FIG. 34-1

34

OPTIONS

OPTIONAL LIFTGATE COMPONENTS

TNENOPMOCLANOITPOS

)SO( SIHTNIDEDULCNISNOITCURTSNI-

LAUNAM

*TIKEDIRREDNU

*TIKREPMUBETAGTFIL

ICPMA051

*)NDRWP(TIK)STVL(

*HCTIWSFFOTUCBAC

SELEMARF

TIKGNITNUOM

TIKRELIARTEDIW"201

KCURTROFXOBYRETTAB

)YRETTABOCLEDO/W(

XOBYRETTAB

)YRETTABHTIW(

KCURTROF

)SO(REKAERBTIUCR

HCTIWSLAMREHTEGATLOVWOL

EMARFBUSRELIARTS

3-TPG/52-TPG5-TPG/4-TPG

10-24066210-340662

SLEDOM

10-068562

675152

10-575082

774052

010082

255362

50-451152

10-451152

)YRETTABO/W(

S(

RELIARTTIKENILEGRAHC

(ELOPLAUD)

S(

*)DROC

)ELOPELGNI

)ELOPLAUD(

)ELOPELGNIS(

ROTCARTTIKEN

ROTCARTTIKENILEGRAHC

)RETPADAHTIW(

KCURTROFXOBYRETTAB

TIKENILEGRAHCRELIART

TIKENILEGRAHCROTCART

ILEGRAHC

30-451152

10-572082

20-572082

30-572082

40-572082

50-572082

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

TIKENILEGRAHCRELIART

)ELOPLAUD&ELGNI

DELIOC(LORTNOCDLEHDNAH

*TIKLORTNOCEDISTEERTS

*TIKLORTNOCHCTIWSLAUD

60-572082

10-075082

20-562082

8462

54

*TIKREPMUBKCODPETS-2

10-022662

TABLE 35-1

35

RECOMMENDED LIFTGATE POWER CONFIGURATION

1. Liftgate and additional

Battery Box are typically
installed on trailers as
shown in FIG. 36-1 and
on trucks as shown in
FIG. 36-2. See the follow­ing page for battery and
cable connections.

LIFTGA TE

OPTIONS

POWER CABLE

(200 AMP IN-LINE

FUSE SHOWN)

TRAILER-MOUNTED
CIRCUIT BREAKER -

SECONDARY LOCA TION

CIRCUIT

BREAKER

TRACTOR BA TTERY
CIRCUIT BREAKER -

PRIMARY LOCA TION

PUMP BOX

(LIFTGATE POWER UNIT)

RECOMMENDED LIFTGATE & BATTERY BOX

POWER CABLE

(200 AMP IN-LINE

FUSE SHOWN)

LIFTGATE

PUMP BOX

(LIFTGATE POWER UNIT)

ADDITIONAL BATTER Y BOX -

TYPICAL LOCA TION

CHARGE LINE

INSTALLATION ON TRAILER

FIG. 36-1

TRUCK BATTER Y

CIRCUIT BREAKER -

PRIMARY LOCA TION

CIRCUIT

BREAKER

ADDITIONAL BATTER Y BOX -

TYPICAL LOCA TION

CHARGE LINE

TRACTOR BA TTERIES -

TYPICAL LOCA TION

TRUCK BA TTERIES -

TYPICAL LOCA TION

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

RECOMMENDED LIFTGATE & BATTERY BOX

INSTALLATION ON TRAILER

FIG. 36-2

36

OPTIONS

RECOMMENDED LIFTGATE POWER CONFIGURATION - Continued

NOTE: If more than 10’ of cabling is required to connect Battery Box batteries to

Liftgate Power Unit, and/or if cable is run through/along vehicle body
crossmembers, use 200 Amp Fused Power Cable from Liftgate Part s Box.

Always connect fused end of Cable to Battery .

2. Recommended Battery Box
setup for 6 volt batteries is
shown in FIG. 37-1.

200 AMP FUSED POWER CABLE

(ONL Y IF REQUIRED - SEE NOTE)

POWER CABLE

TO PUMP BOX

(+)

BA TTER Y

CABLES

150 AMP CIRCUIT

BREAKER

150 AMP CIRCUIT BREAKER
(NEAR TRUCK OR TRACTOR

BA TTERY AND/OR

NOSE OF TRAILER)

CHARGE LINE TO

TRUCK OR TRACTOR

BA TTER Y

(-) BA TTERY

CABLE

6 VOLT BATTERY CONNECTIONS

FIG. 37-1

NOTE: If more than 10’ of cabling is required to connect Battery Box batteries to

Liftgate Power Unit, and/or if cable is run through/along vehicle body
crossmembers, use 200 Amp Fused Power Cable from Liftgate Part s Box.

Always connect fused end of Cable to Battery .

3. Recommended Battery Box
setup for 12 volt batteries is
shown in FIG. 37-2.

200 AMP FUSED POWER CABLE

(ONL Y IF REQUIRED - SEE NOTE)

POWER CABLE

TO PUMP BOX

(-) BA TTERY

CABLES

150 AMP CIRCUIT BREAKER

(+)

BA TTER Y

CABLES

150 AMP CIRCUIT

BREAKER

(NEAR TRUCK OR TRACTOR

12 VOLT BATTERY CONNECTIONS

FIG. 37-2

37

BA TTERY AND/OR

NOSE OF TRAILER)

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]

CHARGE LINE TO

TRUCK OR TRACTOR

BA TTER Y