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

M-17-06

JULY 2017

To fi nd 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, click on the PARTS PORTAL,
TUK-A-WAY & GPTWR buttons.

© MAXON Lift Corp. 2017

TABLE OF CONTENTS

SUMMARY OF CHANGES: M-17-06 ................................................................................... 4

WARNINGS ........................................................................................................................... 5

SAFETY INSTRUCTIONS ....................................................................................................6

NOTICE .................................................................................................................................6

STANDARD LIFTGATE COMPONENTS .............................................................................. 7

GPTWR INSTALLATION PARTS BOX .................................................................................. 8

GPTWR-SERIES MANUALS & DECALS.............................................................................. 9

VEHICLE REQUIREMENTS ............................................................................................... 10

CENTER OF MASS ............................................................................................................. 13

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE ....................................................... 15

BOLT EXTENSION PLATE .................................................................................. 15

WELD EXTENSION PLATE (ALTERNATE METHOD) ........................................ 18

STEP 2 - WELD LIFTGATE TO VEHICLE .......................................................................... 20

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) . 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 CABLE TO BATTERY ......................................................... 41

STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR

INTERFERENCE ................................................................................................................. 42

STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH

ICC BUMPER OR UNDERRIDE ......................................................................................... 47

INSTALLATION WITH ICC BUMPER ................................................................ 47

INSTALLATION WITH UNDERRIDE ................................................................. 49

STEP 12 - ADJUST PLATFORM (IF REQUIRED) .............................................................. 51

STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE ..................................................... 53

STEP 14 - BOLT STEPS TO EXTENSION PLATE ............................................................ 54

STEP 15 - ADJUST WALK RAMP PADS ............................................................................ 58

STEP 16 - LUBE GREASE FITTINGS AS NEEDED ........................................................... 59

APPLY DECALS ................................................................................................................. 60

DECALS & PLATES ........................................................................................................... 62

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

OPTIONAL LIFTGATE COMPONENTS .............................................................................. 68

SUMMARY OF CHANGES: M-17-06

PAGE DESCRIPTION OF CHANGE

5 Changed WARNING for welding galvanized steel to reference AWS D19.0.

7 Main assembly shows new bolt-on mounting plates.

Added Installation Parts Box Tables A, B & C. Added new molded, toggle switch

8

9 Updated GPTWR series manuals and decals part numbers.

17 Added welding note and specifi cations for bolt-on extension plate.

18

20 Added illustration and table showing mounting plates for various frame widths.

20-23

assembly, Added new 1/2” X 5/16” fl at washer, 1-1/2” long self-tapping screws for
control switch assembly, and 1/2” long self-tapping screws for rubber loom clamp.
Added ground cable assembly, 2 GA X 48’ LG.

Removed WARNING for welding galvanized parts. Added note for recommended

practices for welding galvanized steel to refer to AWS (American Welding Soci-

ety) D19.0 Welding Zinc-Coated Steel.

Updated Step 2: Weld Liftgate to Vehicle instructions. Bolt-on 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 image regarding welding galvanized decal.

34, 35, 38, 65Updated power unit has no thermal switch. Fused power connection shows new 10

AMP fuse holder assembly.

36 Added new instructions to connect ground cable supplied with parts Box B.

38 Updated hydraulic fl uid reservoir fi ll level.

40, 47, 49,

10, 55

47-50 Made separate procedures for GPT’s equipped with ICC bumper or underride.

55 Added 1/2”-13 fl ange lock nuts for mounting steps to extension plate.

62 Removed galvanized warning decal.

63 Updated Platform Warning Decal, P/N 281189-02

66 Updated electrical schematic show cycle counter (if equipped).

67 Added GPTWR electical values.

68, 69

Added instructions for disconnecting and reconnecting both negative (-) and posi­tive (+) battery connections.

Updated hand-held, street side and dual control kits in the OPTIONS table. Re­moved cold galvanize spray (16 OZ) and bright zinc spray paint (16 OZ). Removed
painted step kit options.

Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.

WARNINGS

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

• Keep fi ngers, 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.

• 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 platform can become
trapped between the platform and the Liftgate extension plate.

• Never perform unauthorized modifi cations on the Liftgate. Modifi cations may result in early failure

of the Liftgate and may create hazards for Liftgate operators and maintainers.

• Recommended practices for welding on steel parts are contained in the current AWS (American
Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and

personal injury can result from welds that are done incorrectly.

!

WARNING

• Recommended practices for welding galvanized steel are contained in the current AWS (Ameri­can Welding Society) D19.0 Welding Zinc-Coated Steel. Damage to Liftgate and/or vehicle, and

personal injury can result from welds that are done incorrectly.

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

5

SAFETY INSTRUCTIONS

• 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.

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

• Keep decals clean and legible. If decals are illegible 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. Stand to one side of the platform while operating the Liftgate.

• Do not allow untrained persons to operate the Liftgate.

• 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 fl ames or sparks near the battery. Never lay objects on the battery that can short the
terminals together. If battery acid gets in your eyes, immediately seek fi rst 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 con-

trol switch to stop the Liftgate.

SAFETY INSTRUCTIONS

• A correctly installed Liftgate operates smoothly and reasonably quiet. The only noticeable noise

during operation comes from the power unit while the platform is raised and lowered. Listen for
scraping, grating and binding noises and correct the problem before continuing to operate Liftgate.

NOTICE

NOTICE

• Maxon Lift is responsible for the instructions to correctly install MAXON Liftgates on

trucks or trailers only.

• Liftgate installers, not Maxon Lift, are responsible for reviewing and complying with all

applicable Federal, State, and Local regulations pertaining to the trailer or truck.

• Installers of the liftgate should ensure that all trucks and trailers are equipped with grab

handles as needed. Refer to Technology Maintenance Council (TMC) RP 1428: Entry
And Egress Guidelines for Vehicles With Fold-Under Type Liftgates.

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

6

STANDARD LIFTGATE COMPONENTS

!

CAUTION

Unpacking the Liftgate on unlevel surface may allow heavy components to slide off
when shipping bands are cut. Injury and equipment damage could result. Before
the shipping bands are cut, put Liftgate on level surface that will support 1500 lbs.
When unpacking the Liftgate, remove heavy components carefully to avoid injury
and damage.

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 missing or incorrect, call:

Maxon Customer Service

Call [phone] or

Send e-mail to [e-mail]

STEP KIT

ASSEMBL Y

(DUAL STEPS

SHOWN)

EXTENSION PLATE

MAIN

ASSEMBLY

PARTS

BOXES

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

OPENER

TYPICAL LIFTGATE COMPONENTS FOR SHIPMENT

(OPTIONAL COMPONENTS NOT SHOWN)

FIG. 7-1

7

GPTWR INSTALLATION PARTS BOX

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX A 1 297502-01

1 SPRING CLIP, 1/2” x 1-3/8” 10 050079
2 PLASTIC TIE 2 206864
3 #10 RUBBER LOOM CLAMP 2 801681
4 CABLE ASSEMBLY, 175 AMPS, 38 FT LG. 1 264422

SELF-TAPPING SCREW, 10 X 1/2” LG. 2 030458

5

GROUND CABLE ASSEMBLY, 2 GA X 48” LG. 1 251871-26

6

PARTS BOX A WITH POWER CABLE

TABLE 8-1

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX B 1

1 SHIM, 2-1/2” X 1” X 16 GAUGE 2 264732
2 TOGGLE SWITCH ASSEMBLY 1 296855-01
3 FLAT WASHER, 1/2” X 5/16” THICK 2 902000-13
4 HEX NUT, 1/2”-13 2 901011-9
5 CAP SCREW, 1/2’’-13 X 1-1/2” LG. 2 900035-3
6 INSTALLATION BRACKET 2 269462-01
7 LUG, 2 GAUGE, COPPER, 5/16” 1 906497-02
8 SCREW, SELF TAPPING, #10-24 X 1-1/2” LG 2 900057-7

9 HEAT SHRINK TUBING, 3/4” X 1-1/12” LG. 1 253316-04
10 FLAT, 2-1/2” X 1” X 1/8” THICK 2 201999
11 LICENSE PLATE BRACKET KIT 1 287015-01

297049-02

PARTS BOX B WITHOUT POWER CABLE, GROUND CABLE, OR FRAME CLIPS

TABLE 8-2

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

REF PARTS BOX C 1 297502-02

1 SPRING CLIP 20 050079

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

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 269191-01

6 #10 LOOM CLAMP 2 801681

SELF-TAPPING SCREW, 10 X 1/2” LG. 2 030458

7

PARTS BOX C WITH GROUND CABLE

TABLE 8-3

8

GPTWR-SERIES MANUALS & DECALS

NOTE: To fi nd maintenance information for your GPTWR Liftgate, go to www.max-

onlift.com. Click the PRODUCTS, TUK-A-WAY & GPTWR buttons. Open

the Maintenance Manual in the PRODUCT DOCUMENTATION window. For
parts, click on the PARTS PORTAL, TUK-A-WAY & GPTWR buttons.

ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER

297225-11 (GPTWR-25)

REF

1
2
3

DECAL & MANUAL KIT 1

INSTALLATION MANUAL (GPTWR) 1 M-17-06

OPERATION MANUAL (GPT & GPTWR) 1 M-17-07

DECALS (SEE DECAL PAGES IN THIS MANUAL) 1

TABLE 9-1

297225-12 (GPTWR-3)

297225-13 (GPTWR-4)

297225-14 (GPTWR-5)

(ALL GPTWR’S)

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

9

VEHICLE REQUIREMENTS

NOTE: BODY maximum and minimum operating bed height, for GPTWR models

with standard 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
modifi ed to install this Liftgate.

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

installing Liftgate.

NOTE: Dimensions are provided as reference for fi tting Liftgate to vehicle body.

1. Check for correct clearances (FIG. 10-1 & 10-2) on

vehicle to prevent interference between vehicle
and Liftgate.

33”

29-5/8”

15”

23-7/8”

55” MAX. BED HEIGHT
49” LOADED BED HEIGHT

15-5/8” TO 21-5/8”

22”

GPTWR-25 & GPTWR-3 LIFTGATE CLEARANCE DIMENSIONS

FIG. 10-1

39-1/2”

35-5/16”

27-7/8”

15”

22”

12”

14-3/4”

13-5/16”

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

55” MAX. BED HEIGHT
49” LOADED BED HEIGHT

GPTWR-4 & GPTWR-5 LIFTGATE CLEARANCE DIMENSIONS

22-3/8”

12”

16-3/16” TO 22-3/16”

FIG. 10-2

10

VEHICLE REQUIREMENTS - Continued

2. Check for correct clearances between walk ramp, walk ramp box, and the extension
plate (FIGS. 11-1A and 11-1B) to prevent interference.

NOTCH

(4 PLACES)

27-1/2”

20-1/2”

1-1/2”

9-3/16”

2-1/4”

EXTENSION PLATE

8-3/8”

WALK RAMP

LATCH

25” MIN.
32-1/2” MAX.
(RAMP WIDTH)

WALK RAMP PAD

(2 PLACES)

WALK RAMP BOX

CLEARANCE DIMENSIONS

(FOR REFERENCE ONLY)

FIG. 11-1B

2-1/4”

1-1/2”

H

SILL

H

RAMP

H

= 8-3/8” - H

RAMP

H

is the height of the vehicle body sill.

SILL

H

is the height of the ramp (max).

RAMP

- 1/8” clearance

SILL

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

GPTWR LIFTGATE WITH WALK RAMP BOX

FIG. 11-1A

11

VEHICLE REQUIREMENTS - Continued

!

WARNING

Incorrect modifi cation of vehicle frame and/or body could contribute to serious
mechanical failure of the vehicle. Serious injury to operator, motorists, and
bystanders could result. Installer is responsible for ensuring vehicle body and
frame modifi cation do not adversely affect the integrity of the body and frame.
If unsure about modifying vehicle, installer should consult truck/trailer body
manufacturer.

CAUTION

To prevent aluminum platform from being damaged, make sure vehicle frame
is cut correctly and rear sills are modifi ed if over 4-1/8” in height. If the cutouts
are incorrect, platform may hit vehicle frame or underbody when stowing Lift­gate. If rear sill is over 4-1/8” in height, bottom of the platform may hit the sill.

NOTE: Dimensions, shown in illustration below, are maximums except as indicated.
NOTE: The platform cutout area for truck frame, shown below, is required to prevent

frame interference when platform is being stowed and unstowed. For trailers,
refer to instructions supplied with trailer mounting kit for Liftgate.

3. Fit the Liftgate to vehicle body by cutting vehicle frame as shown in FIG. 12-1.

TRUCK BODY

REAR SILL

10”

TRUCK
FRAME

PLATFORM CLEARANCE CUTOUT AREA

(WITHIN DASHED LINES)

BODY FLOOR

BODY CROSS-

MEMBERS

LONG SILL

WOODEN SPACER

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

VEHICLE FRAME CUTOUT FOR GPTWR PLATFORM CLEARANCE

22”

(TRUCK FRAME IS SHOWN)

FIG. 12-1

12

CENTER OF MASS

CENTER OF MASS

10-1/4”

11-1/2”

GPTWR-25 & GPTWR-3 CENTER OF MASS

(PLATFORM AT BED HEIGHT)

FIG. 13-1

16-1/8”

17-1/4” CENTER OF MASS

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

GPTWR-25 & GPTWR-3 CENTER OF MASS

(STOWED POSITION)

FIG. 13-2

13

CENTER OF MASS - Continued

CENTER OF MASS

11-3/8”

11-3/16”

GPTWR-4 & GPTWR-5 CENTER OF MASS

(PLATFORM AT BED HEIGHT)

FIG. 14-1

16-3/16”

22-3/4”

CENTER OF MASS

GPTWR-4 & GPTWR-5 CENTER OF MASS

(STOWED POSITION)

FIG. 14-2

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

14

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE

CAUTION

CAUTION

To preserve the corrosion-resistant properties of the galvanized fi nish,
MAXON recommends bolting the galvanized extension plate to vehicle.

NOTE: GPTWR Liftgate extension plate comes with bolt holes so it can be

bolted to vehicle body with optional bolt kit. GRADE 8 bolts are re­quired. MAXON recommends getting the optional extension plate
hardware kit listed in OPTIONS section. Vehicle body must 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.

BOLT EXTENSION PLATE

1. Mark and drill holes into rear sill as shown in FIGS. 15-1 and 16-1.

96”

94-1/2”

19”

14”

1-1/2”

24”

6-1/2”

34”

41”

REAR

SILL

48”

55

62”

72”

77”

82”

USE 9/16” DRILL

(19 PLACES)

1-1/4”

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

3-1/8”

6-1/2”

REAR SILL - HOLE LOCATIONS FOR 96” WIDE VEHICLE

FIG. 15-1

15

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -

Continued

102”

100-1/2”

95-1/2”

85”

80”

75”

65”

58”

51”

44”

37”

1-1/2”

27”

22”

17”

6-1/2”

REAR

SILL

USE 9/16” DRILL

(19 PLACES)

REAR SILL - HOLE LOCATIONS FOR 102” WIDE VEHICLE

FIG. 16-1

1-1/4”

6-1/2”

3-1/8”

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

16

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -

Continued

CAUTION

CAUTION

The mating surface between the bolt-on extension plate and vehicle rear sill
must be as fl at 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 diffi cult to
install correctly. Remove interference or shim rear sill to eliminate or reduce
the possibility of a distorted extension plate.

NOTE: Do not tighten extension plate bolts and lock nuts until:

• All the bolts and lock nuts are in place.

• Mating surfaces of extension plate and rear sill are made fl at as possible.

• Top of extension plate is fl ush with top of rear sill.

NOTE: Weld the LH and RH ends of the extension plate to vehicle body as shown

in FIG. 17-1 if any of the following conditions apply.

• Bolt holes are not accessible on the corner posts of the vehicle body.

• Liftgate will be used for dock loading applications.

• As required by body/trailer manufacturer

2. Bolt extension plate to vehicle as shown in FIG. 17-1. If necessary, reposition ex-

tension plate so top surface is fl ush with top surface of sill. Then, torque bolts and

lock nuts to 105 +/-20 lb-ft.

BOLTS

(KIT ITEM)

VEHICLE

BODY

TEARDROP

LOCK NUTS

(KIT ITEMS)

WELD VERT. EDGE

IF NOT BOLTING

3/16”

EXTENSION

PLATE

WELD VERT. EDGE
IF NOT BOLTING

IF NO CORNER POST ACCESS FOR

BOLT & NUT, WELD OUTSIDE EDGES AS SHOWN.

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

3/16”

BOLTING EXTENSION PLATE (96” WIDE EXTENSION PLATE SHOWN)

NOTE: An optional 102” wide extension kit is available for 102” wide vehicles. Refer to

Instruction Sheet M-09-06 supplied with kit.

FIG. 17-1

17

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -

Continued

WELD EXTENSION PLATE (ALTERNATE METHOD)

CAUTION

To preserve the corrosion-resistant properties of the galvanized fi nish,
MAXON recommends bolting the galvanized extension plate to vehicle.

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.

NOTE: Before welding extension plate to vehicle body, make sure:

• Inboard edge of extension plate is fl ush 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 sill as shown

in FIGS. 18-1 and 19-1.

3/16”

3/16”

WELD LENGTH & SPACE:
2”- 11 3/4” ( 96”W VEHICLE)
2”- 12 1/2” (102”W VEHICLE)

EXTENSION

PLATE

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

VEHICLE

BODY

3/16”

EXTENSION PLATE WELDS - VIEWED FROM ABOVE

FIG. 18-1

18

STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE -

Continued

EXTENSION

PLATE

VEHICLE

BODY

WELD LENGTH & SPACE:

3/16”

EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH

FIG. 19-1

NOTE: During installation of liftgate, installation brackets keep the heel of the plat-

form level with extension plate and maintain a ¾” gap between extension
plate and heel of platform. The extension plate has bolt holes for bolting on
the installation brackets provided in parts box.

2”- 11 3/4” ( 96”W VEHICLE)
2”- 12 1/2” (102”W VEHICLE)

2. Bolt 2 installation brackets (parts bag items) on the

extension plate as shown in FIG. 19-2. Tighten hex

nuts securely.

HEX NUT

1/2”-13

(2 PLACES)

BRACKET

(2 PLACES)

CAP SCREW

1/2”-13 X 1-1/2” LG.

(2 PLACES)

EXTENSION

PLATE

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

BOLTING ON INSTALLATION BRACKETS

FIG. 19-2

19

STEP 2 - WELD LIFTGATE TO VEHICLE

NOTE: GPTWR Liftgates are equipped with mounting plates installed at the

factory. Mounting plate widths are shown based upon truck or trailer
frame widths. Ensure you have the correct mounting plate kit for your
application.

If it’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).

BOLT &

LOCK NUT

(6 PLACES)

RH

PLATE

“D” OUTSIDE

“D” INSIDE

LH

PLATE

BOLT &

LOCK NUT

(6 PLACES)

BOLT ON MOUNTING PLATES FOR INSTALLATION ON TRUCKS &TRAILERS

(REAR VIEW OF LIFTGATE)

FIG. 20-1

LIFTGATE MODEL “D” INSIDE “D” OUTSIDE APPLICATION

34-1/4” 35-1/4” Common truck chassis width

GPTWR-25/GPTWR-3

32-1/4” 33-1/4” Trailer applications
34-7/8” 35-13/16” Trailer applications (91 cm)

LIFTGATE MODEL “D” INSIDE “D” OUTSIDE APPLICATION

GPTWR-4/GPTWR-5

TABLE 20-1

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

34-1/4” 35-1/4” Common truck chassis width
34-7/8” 35-13/16” Trailer applications (91 cm)

39” 40” Trailer applications

TABLE 20-2

20

STEP 2 - WELD LIFTGATE TO VEHICLE - Continued

1. Unfold the platform and fl ipover (FIG. 21-1).

LOCKING ANGLES

(REF)

PLATFORM

FLIPOVER

STOP

(2 PLACES)

OPENER

FLIPOVER

MOUNTING

PLATES

2. Unbolt opener from mounting bracket

(shipping position) and save to reinstall
(FIG. 21-1).

PLATFORM & FLIPOVER UNFOLDED

FIG. 21-1

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

21

STEP 2 - WELD LIFTGATE TO VEHICLE - Continued

!

CAUTION

To prevent damage to aluminum fl ipover, NEVER hoist the Liftgate by the
fl ipover. Hoist the Liftgate only by the platform. Refer to the illustrations below
for the “INCORRECT WAY” and the “CORRECT WAY”.

CAUTION

Correct fl oor clearance must be maintained when Liftgate is in position and
being welded. Maintain distance between vehicle fl oor and top of main frame
at center of main frame as shown in the instructions. Dimension tolerance is
+/- 1/4”. Never apply force at the ends of the main frame tube to change the
fl oor clearance.

3. Make sure hoist is not

set up the incorrect way

(FIG. 22-1). Place a “C”-

clamp on each side of

platform (FIG. 22-1) to

prevent hoist chain from
slipping off platform.
Wrap chain around plat-

form (FIG. 22-1).

4. Hoist the Liftgate. Then,

place fl oor jack under

center of main frame (FIG.
22-1). Jack the Liftgate into

position. Make sure vehicle
fl oor is horizontal. Maintain
distance between fl oor and
top of main frame as shown

in FIG. 22-1.

FLIPOVER

PLATFORM

INCORRECT

C-CLAMP
(2 PLACES)

FLOOR JACK

(CENTERED ON

MAIN FRAME TUBE)

HOIST CHAIN

* 23-7/8” (GPTWR-25/-3)
* 22-3/8” (GPTWR-4/-5)

* TOLERANCE IS +/- 1/4”

VEHICLE FLOOR

(HORIZONTAL)

CCORRECT WAY TO HOIST LIFTGATE

FIG. 22-1

MOUNTING

PLATE

MAIN

FRAME

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

22

STEP 2 - WELD LIFTGATE TO VEHICLE - Continued

CAUTION

Prevent damage to hydraulic hoses. If welding next to hydraulic hoses, use a
protective cover such 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

When using an electric welder, connect the welder ground to one of the parts
being welded, as close to the weld as possible. Failure to comply could result
in damage to cylinders and electrical parts.

5. Clamp both mounting plates

to vehicle frame. Check
the distance between bed
level and top of main frame.
Maintain the distance shown

in FIG. 23-1.

2” LG. 4 PLACES

(TYPICAL - RH & LH

MOUNTING PLATES)

5/16”

BED LEVEL

VEHICLE FRAME CUTOUT

(TYPICAL TRUCK

FRAME SHOWN)

6. Weld the mounting plates to

vehicle frame as shown in

FIG. 23-1. Remove clamps.

MOUNTING

PLATE

* 23-7/8” (GPTWR-25/-3)
* 22-3/8” (GPTWR-4/-5)

MAIN

FRAME

* TOLERANCE IS +/- 1/4”

WELD TO VEHICLE FRAME AND MAIN FRAME

(RH SIDE SHOWN)

FIG. 23-1

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

23

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED)

RECOMMENDED CONFIGURATION

NOTE: Make sure the Liftgate power unit, and all batteries on the vehicle for the

power unit, are connected correctly to a common chassis ground.

1. Liftgate and optional

battery box are typically
installed on trailers as

shown in FIG. 24-1 and
on trucks as shown in
FIG. 24-2. See the fol-

lowing page for battery
and cable connections.

LIFTGATE

LIFTGATE

POWER UNIT

FUSED CABLE

OPTIONAL

BATTERY BOX,

TYPICAL LOCATION

TRACTOR BATTERIES,

TYPICAL LOCATION

175 AMP

FUSED CABLE

175 AMP

CIRCUIT

BREAKER

RECOMMENDED LIFTGATE & OPTIONAL BATTERY BOX

INSTALLATION ON TRAILER

FIG. 24-1

TRUCK BATTERIES,
TYPICAL LOCATION

175 AMP

FUSED CABLE

175 AMP

FUSED CABLE

LIFTGATE

LIFTGATE

POWER UNIT

OPTIONAL

BATTERY BOX,

TYPICAL LOCATION

CIRCUIT

BREAKER

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

RECOMMENDED LIFTGATE & BATTERY BOX

INSTALLATION ON TRUCK

FIG. 24-2

24

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

2. Select holes on top of battery box

frame to align mounting brackets
fl ush to cross members. Refer

to FIGS. 25-1A & 25-1B for trail­ers and FIG. 25-2 for trucks. Bolt

mounting brackets to battery box

frame as shown in FIG. 25-1C.

Torque each bolt and lock nut to

85-128 lb-ft.

TRAILER BODY

CROSS MEMBER

MOUNTING
BRACKETS

BATTERY BOX

FRAME

LOCK NUT

WASHER

MOUNTING
BRACKETS

CROSS

MEMBER

WASHER

CAP SCREW

BOLTING BRACKETS

(8 PLACES)

FIG. 25-1C

BATTERY BOX

FRAME

FLUSH BRACKETS

FOR TRAILERS

(8 PLACES)

FIG. 25-1B

TRUCK BODY

CROSS MEMBER

MOUNTING

BRACKETS

FLUSH BRACKETS FOR TRUCKS

ALIGNING BATTERY

BOX FRAME

(TRAILER SHOWN)

FIG. 25-1A

BATTERY BOX

FRAME

(8 PLACES)

FIG. 25-2

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

25

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

NOTE: If welding mounting brackets to cross members, skip instruction 3.

3. Using mounting brackets 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.

MOUNTING
BRACKETS

1/2” HOLES

MARK AND DRILL BRACKET HOLES

FIG. 26-1

WASHERS

(4 PLACES)

CROSS

MEMBER

CROSS

MEMBERS

CROSS

MEMBER

CAP SCREWS

(2 PLACES)

LOCK NUTS

(2 PLACES)

MOUNTING

BRACKETS

BOLTING BRACKETS

(8 PLACES)

FIG. 26-2B

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

BOLTING BATTERY BOX FRAME

FIG. 26-2A

26

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

!

WARNING

Recommended practices for welding on steel parts are contained in the cur­rent AWS (American Welding Society) D1.1 Structural Welding Code - Steel.
Damage to Liftgate and/or vehicle, and personal injury can result from welds
that are done incorrectly.

CAUTION

To prevent pump box components from being damaged by electric current
from welding, connect welder grounding cable to the part being welded.

CAUTION

Cover pump box and optional battery box with fl ame-resistant covering before
welding pump box frame to vehicle.

4. Weld each bracket to cross
members as shown in FIGS.
27-1A and 27-1B. Weld top of

bracket if accessible.

MEMBERS

CROSS

IF ACCESSIBLE

3/16”

WELDING BRACKETS

3/16”

(8 PLACES)

FIG. 27-1B

CROSS

MEMBERS

3/16”

BRACKET

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

BOLTING PUMP & BATTERY

BOX FRAME

FIG. 27-1A

27

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

!

WARNING

Remove all rings, watches and jewelry before doing any electrical work.

NOTE: Always connect fused end of power cable to battery positive (+) terminal.

NOTE: To connect charge lines, refer to instructions provided with each charge

line kit.

5. Connect battery cables, fused cables, and ground
cables for 12 volt power as shown in FIG. 28-1 or
24 volt power as shown in FIG. 29-1.

GROUND CABLE TO PUMP

BOX OR COMMON CHASSIS

GROUND, 74” LG.

(BATTERY BOX KIT ITEM)

10” LG.

BLACK CABLE

(-) BATTERY CABLE

TO COMMON

GROUND

FUSED CABLE TO PUMP BOX

(IN PARTS BOX)

10” LG.

RED CABLE

12 VOLT BATTERY CONNECTIONS

FOR 12 VOLT POWER

FIG. 28-1

FUSED CABLE

(SEE NOTE)

150 AMP
CIRCUIT

BREAKER

12” LG.

RED CABLE

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

28

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

GROUND CABLE TO

PUMP BOX OR COMMON

CHASSIS GROUND, 74” LG.

(BATTERY BOX KIT ITEM)

(-) BATTERY CABLE

TO COMMON

GROUND

FUSED CABLE

(SEE NOTE)

FUSED CABLE TO PUMP

BOX, 42” LG.

(BATTERY BOX KIT ITEM)

CABLE
10” LG.

12 VOLT BATTERY CONNECTIONS

FOR 24 VOLT POWER

FIG. 29-1

150 AMP
CIRCUIT

BREAKER

CABLE

12” LG.

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

29

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

!

WARNING

Explosive hydrogen gas from charging batteries 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.

VENTILATION HOLES

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

BATTERY BOX ASSEMBLY

(REAR VIEW SHOWN)

FIG. 30-1

30

STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME

TO VEHICLE (IF EQUIPPED) - Continued

BATTERY BOX ASSEMBLY

175 AMP FUSED

CABLE TO

PUMP BOX

GROUND CABLE

TO PUMP BOX

HEX NUT

5/16”-18, GR8

(3 PLACES)

FLAT WASHER

5/16”

(3 PLACES)

LOCK NUT, 1/4”-20

PAN HEAD SCREW

1/4”-20 X 1” LG.

(2 PLACES)

(2 PLACES)

FLAT WASHER

1/4”

(4 PLACES)

CHARGE LINE FROM

VEHICLE BATTERY

150 AMP CIRCUIT

BREAKER

CAP SCREW

1/2”-20 X 2 1/4” LG. GR8

(4 PLACES)

J-BOLT

BATTERY

TIE DOWN

J-BOL T ANCHOR

(PART OF

BATTERY PLATE)

BATTERY

PLATE

BATTERY

STRAP

LOCK WASHER

9/16”

(4 PLACES)

FIG. 31-1

31

HEX NUT

1/2”-20

(4 PLACES)

FLAT WASHER

9/16”

(4 PLACES)

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

STEP 4 - RUN POWER CABLE

NOTE: Make sure the Liftgate power unit, and all batteries on the vehicle for the

power unit, are connected correctly to a 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 page for running
the power cable.

LIFTGATE

175 AMP

FUSED CABLE

LIFTGATE

POWER UNIT

TRACTOR BATTERIES,

TYPICAL LOCATION

175 AMP

FUSED CABLE

LIFTGATE

RECOMMENDED LIFTGATE & POWER CABLE

INSTALLATION ON TRAILER

FIG. 32-1

TRUCK BATTERIES,
TYPICAL LOCATION

175 AMP

FUSED CABLE

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

LIFTGATE

POWER UNIT

RECOMMENDED LIFTGATE & POWER CABLE

INSTALLATION ON TRUCK

FIG. 32-2

32

STEP 4 - RUN POWER CABLE - Continued

!

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

2. Clip fused power cable to vehicle chassis with fuse nearest

the vehicle battery, as shown in FIG. 33-1. Keep enough

cable near the battery to reach the positive terminal without
straining cable (after connection). Run cable to pump box
on Liftgate.

VEHICLE FRAME

(TRUCK FRAME SHOWN)

18” - 24”

SPACING

175 AMP FUSE

SHORTEST

CABLE END

TERMINAL LUG

(TO VEHICLE BATTERY)

CABLE

CLIPS

CHARGE LINE

(TO PUMP BOX)

FRONT OF VEHICLE

REAR OF VEHICLE

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

FIG. 33-1

33

STEP 5 - CONNECT POWER CABLE

1. Unbolt and remove pump cover

(FIG. 34-1).

POWER UNIT

(REF)

PUMP

COVER

UNBOLTING PUMP COVER

FIG. 34-1

2. On the bare wire end of fused power cable, keep enough length to attach copper

terminal lug and reach motor solenoid switch without putting tension on cable (after

connection) (FIG. 34-2A). Measure (if needed), and then cut excess 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 cable and shrink the heat shrink tubing (FIG. 34-2C).

HOLDER FLAT

(2 PLACES)

FLAT WASHER

(2 PLACES)

KNOB

(2 PLACES)

COPPER

TERMINAL

LUG

FIG. 34-2B

HEAT SHRINK

TUBING

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

FIG. 34-2C

FUSED

POWER CABLE

TYPICAL FUSED POWER CABLE ROUTING

FIG. 34-2A

34

STEP 5 - CONNECT POWER CABLE - Continued

CAUTION

Do not over-tighten the terminal nuts on solenoid switch. For the load
terminals, torque nuts to 35 lb.-in. max. Torque the nuts on #10-32 control
terminals to 15 lb-in.

NOTE: Do not remove fl at washer from

the battery power terminal.

3. Remove hex nut and lock washer

from battery power terminal on
the solenoid switch. Remove
fuse holder assembly. Connect
the power cable and fuse holder
assembly to the solenoid switch

as shown in FIG. 35-1. Reinstall

and tighten lock washer and hex
nut.

HEX NUT

LOCK

WASHER

SOLENOID

SWITCH

FUSE

HOLDER

ASSEMBLY

(10 AMP)

POWER CABLE

BATTERY

POWER

TERMINAL

FUSED

TYPICAL FUSED POWER

CABLE ELECTRICAL CONNECTION

FIG. 35-1

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

35

STEP 6 - CONNECT GROUND CABLE (RECOMMENDED)

TERMINAL LUG

(EXTERNAL GROUND

CABLE)

NOTE: To ensure power unit is correctly grounded, MAXON recommends

connecting 2 gauge ground cable from grounding connection on pump
mounting plate to a grounding point on the frame, or negative battery
terminal in the optional battery box.

TERMINAL LUG

1. Unbolt pump internal ground

cable from the pump mount­ing bracket. Then, bolt and
tighten internal ground cable
and external ground cable
(parts box) to mounting

bracket (FIG. 36-1).

INTERNAL

GROUND

CABLE

PUMP MOUNTING

BRACKET

(EXTERNAL GROUND

CABLE)

CAP SCREW

CONNECTING EXTERNAL GROUND 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.

NOTE: Clean the ground cable connection point

on the frame down to bare metal.

2. Extend the ground cable to reach
vehicle frame (FIG. 36-2) without

putting tension on cable (after con­nection). Connect to an existing
grounding point if available.

TERMINAL LUG

(GROUND CABLE)

3. If necessary, drill a 11/32” (0.343”)

hole in vehicle frame for bolting
the ground cable terminal lug

(FIG. 36-2).

4. To prevent corrosion, paint or

use galvanized spray on bare

metal area FIG. 36-2.

5/16"-18 X 1" LG

CAP SCREW

FIG. 36-1

VEHICLE CHASSIS

(TRUCK FRAME SHOWN)

BARE

METAL

5/16” FLAT

WASHER

LOCK NUT

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

5/16”-18

5. Bolt the ground cable terminal

lug to vehicle frame as shown in

FIG. 36-2.

FIG. 36-2

36

STEP 7 - 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. 37-1.

VEHICLE BODY

VERTICAL POST

(CURB SIDE)

DRILLING MOUNTING HOLES

FIG. 37-1

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

37

STEP 7 - INSTALL CONTROL SWITCH - Continued

2. Insert control switch wir-

ing into the 3/4” hole on the
corner post and run it under
the vehicle body to the pump

assembly. (See dashed line

- FIG. 38-1.) Insert switch

wiring through cord grip on

pump mounting plate (FIG.
38-2). Connect the switch

wiring to the pump assembly

as shown in (FIG. 38-2).

3. Push control switch and ca-

ble back into the ¾” hole in
the vertical post until con­trol switch cover touches

the post (FIG. 38-1). Attach

control switch to vertical
post with 2 self-tapping

screws (FIG. 38-1).

SELF-TAPPING

SCREW, 1-1/2” LG.

(2 PLACES)

CONTROL SWITCH

3/4” HOLE

(2 PLACES)

VEHICLE BODY

VERTICAL POST

CONTROL SWITCH

WIRING

ROUTING CONTROL SWITCH WIRING

FIG. 38-1

4. If necessary, use clamps

and self-tapping screws,
from installation parts
bag, to secure switch

cable to vehicle (FIG.

38-1).

FUSE HOLDER

BLACK WIRE

TO TERMINAL 2

CORD GRIP

WHITE WIRE

TO TERMINAL 1

GREEN WIRE

WHITE WIRE

ASSEMBLY

POWER DOWN MODULE

SOLENOID SWITCH

CONTROL SWITCH WIRING CONNECTIONS

FIG. 38-2

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

38

STEP 8 - CHECKING HYDRAULIC FLUID

CAUTION

Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic fl uid reservoir fi ller cap, drain plug and hydrau-
lic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.

NOTE: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions.

+50 to +120 Degrees F - Grade ISO 32
Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606

See TABLES 40-1 & 40-2 for recommended brands.

1. Check the hydraulic fl uid level in

reservoir as follows. With Liftgate
stowed, or platform at vehicle bed

height, level should be as shown in

FIG. 39-1.

2. If needed, add fl uid to the reservoir

as follows. Pull out (no threads) fi ller

cap (FIG. 39-1). Fill the reservoir with
hydraulic fl uid to level shown in (FIG.

39-1). Reinstall fi ller cap (FIG. 39-1).

CAUTION

Pump cover must be correctly se­cured to prevent it from becoming
a hazard. To secure pump cover,
the long side of the holder fl ats
must butt against pump cover as
shown in the illustration.

POWER UNIT FLUID LEVEL

POWER UNIT

(REF)

FILLER

CAP

RESERVOIR

3”

FIG. 39-1

LONGER SIDE OF

HOLDER FLATS BUTT

AGAINST COVER

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

3. Bolt on the pump cover as shown in
FIG. 39-2. Hand tighten the threaded

cover knobs.

39

PUMP

COVER

FLAT WASHER

(2 PLACES)

BOLTING ON PUMP COVER

FIG. 39-2

KNOB

(2 PLACES)

STEP 7 - CHECKING HYDRAULIC FLUID - Continued

ISO 32 HYDRAULIC OIL

RECOMMENDED

BRANDS

CHEVRON HIPERSYN 32

KENDALL GOLDEN MV

SHELL TELLUS S2 VX 32

EXXON UNIVIS N-32

MOBIL

PART NUMBER

DTE-13M, DTE-24,
HYDRAULIC OIL-13

TABLE 40-1

ISO 15 OR MIL-H-5606 HYDRAULIC OIL

RECOMMENDED

BRANDS

CHEVRON FLUID A, AW-MV-15

KENDALL GLACIAL BLU

SHELL TELLUS S2 VX 15

PART NUMBER

EXXON UNIVIS HVI-13

MOBIL DTE-11M

ROSEMEAD THS FLUID 17111

TABLE 40-2

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

40

STEP 9 - CONNECT POWER CABLE TO BATTERY

1. Remove nut from negative (-)

battery terminal (FIG. 41-1). Dis­connect negative (-) battery cable

(FIG. 41-1).

2. Remove nut from positive (+)
battery terminal (FIG. 41-1).

3. Connect fused positive (+) cable
to positive (+) battery terminal
(FIG. 41-2). Then, reinstall nut
on positive (+) battery terminal
(FIG. 41-2).

NUT

NEGATIVE (-)

BATTERY CABLE

DISCONNECTING (-) BATTERY CABLE

POSITIVE (+)

BATTERY CABLE

NUT

POSITIVE (+)

BATTERY TERMINAL

NEGATIVE (-)

BATTERY TERMINAL

FIG. 41-1

NUT

FUSED (+)

CABLE

POSITIVE (+)

BATTERY TERMINAL

4. Reconnect negative (-) battery

cable to negative (-) battery ter­minal (FIG. 41-3). Then, reinstall
nut on negative (-) battery termi­nal (FIG. 41-3).

NEGATIVE (-)

BATTERY CABLE

RECONNECTED BATTERY CABLES

41

CONNECTING FUSED (+) CABLE

FIG. 41-2

NEGATIVE (-)

BATTERY TERMINAL

NUT

FIG. 41-3

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

STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE

BOLTS, CHECK FOR INTERFERENCE

CAUTION

Check for leaking hydraulic fl uid as the system is being pressurized. If there is
leakage, stop & correct the problem before fully pressurizing the system.

1. Push control switch to UP position to pressurize hydraulic system. Listen for hydraulic

fl uid fl owing through the system. Check for fl uid leaks. When the sound of fl owing fl uid
stops, release control switch. Hydraulic system is ready.

NOTE: To operate Liftgate, locking angles must be removed from the lift arms and

shipping bolt must be removed from both knuckles.

2. Remove locking angles from lift arms (FIG. 42-1A).

3. With platform open (FIG. 42-1A), unbolt each knuckle as shown in FIG. 42-1B.

LOCKING

PLATFORM

ANGLES

FLIPOVER

FIG. 42-1A

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

BOLT

LOCK

WASHER

FLAT

WASHER

UNBOLTING KNUCKLE

FIG. 42-1B

42

STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE

BOLTS, CHECK FOR INTERFERENCE - Continued

4. Remove fl oor jack and hoist

supporting Liftgate (FIG. 43-1).

FLOOR JACK

REMOVING JACK

FIG. 43-1

5. Lower platform to the ground (FIG.

43-2). Look for any interference be-

tween 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

the DOWN position until you hear

air escaping into the hydraulic fl uid

reservoir. Then, raise the platform
(FIG. 43-3). Look for any interfer-

ence between liftgate and vehicle as
platform is raised. Repeat step until
there is no air left in the system and

platform lowers smoothly (FIG. 43-3).

LOWERING PLATFORM

FIG. 43-2

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

RAISING PLATFORM

FIG. 43-3

43

STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE

BOLTS, CHECK FOR INTERFERENCE - Continued

6. Lower platform to the ground (FIG. 44-1).

LOWERING PLATFORM

FIG. 44-1

7. Unbolt the 2 installation brackets

from extension plate (FIG. 44-2).

EXTENSION

PLATE

BRACKET & NUT

(2 PLACES)

BOLT

(2 PLACES)

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

REMOVING INSTALLATION BRACKETS

FIG. 44-2

44

STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE

BOLTS, CHECK FOR INTERFERENCE - Continued

NOTE: Correct any fi t and interference problems before continuing with installation.

8. Raise the platform to vehicle fl oor

level (FIG. 45-1). (Refer to GPT-25,
GPT-3, GPT-4, GPT-5, GPTWR-25,
GPTWR-3, GPTWR-4 & GPTWR-5
OPERATION MANUAL.) Check for

5/8” gap between platform and edge

of extension plate (FIG. 45-1).

5/8”

PLATFORM

EXTENSION

PLATE

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

5/8”

CHECKING GAP BETWEEN PLATFORM

AND EXTENSION PLATE

FIG. 45-1

45

STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE

BOLTS, CHECK FOR INTERFERENCE - Continued

NOTE: Correct any fi t and interference problems before continuing with installation.

9. Ensure top surface of platform

and extension plate are fl ush at
the RH & LH sides of platform

(FIGS. 46-1 and 46-2). The

allowable difference in height is
+/- 1/8” maximum as shown.

PLATFORM

+/- 1/8” (MAX)

EXTENSION

PLATE

SURFACES FLUSH

DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM

& EXTENSION PLATE (RH VIEW)

FIG. 46-1

SURFACES FLUSH

PLATFORM

+/- 1/8” (MAX)

EXTENSION

PLATE

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

DIFFERENCE IN HEIGHT FOR TOP OF PLATFORM

& EXTENSION PLATE (LH VIEW)

FIG. 46-2

46

STEP 11 - INSTALL OPENER & LICENSE PLATE

BRACKET WITH ICC BUMPER OR UNDERRIDE

NOTE: If Liftgate is equipped with underride, skip these instructions for installation with

ICC bumper. Go to the instructions for INSTALLATION WITH UNDERRIDE.

INSTALLATION WITH ICC BUMPER

1. Lower platform to ground level

(FIG. 47-1). Refer to operating in-
structions in Operation Manual.

!

WARNING

To prevent accidental personal 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 negative (-) and posi­tive (+) battery terminals.

LOWERING PLATFORM

NEGATIVE (-)

BATTERY CABLE

FIG. 47-1

BATTERY CABLE

NUT

NEGATIVE (-)

BATTERY POST

POSITIVE (+)

POSITIVE (+)

BATTERY POST

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

DISCONNECTING BATTERY POWER

FIG. 47-2

47

STEP 11 - INSTALL OPENER & LICENSE PLATE

BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d

NOTE: License plate bracket can be bolted in 4 positions on the ICC bumper

brackets. License plate bracket can be bolted on the inside or outside of
the LH bumper bracket or RH bumper bracket.

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.

CAP SCREW, 1-3/4” LG.

(2 PLACES)

LICENSE PLATE BRACKET

(OUTER LH POSITION SHOWN)

FLAT WASHER

(4 PLACES)

OPENER

LOCK NUT,

3/8”-16

(4 PLACES)

CAP SCREW, 2-1/4” LG.

(2 PLACES)

MAIN

FRAME

4. Reconnect power to the pump by

reconnecting positive (+) and nega­ tive (-) cables to battery (FIG. 48-2).

Reinstall and tighten nut when each
battery cable is reconnected.

5. Stow and unfold Liftgate several

times to verify there is no interfer­ence. Refer to operating instruc-

tions in Operation Manual.

BOLTING ON ICC BUMPER, OPENER &

LICENSE PLATE BRACKET

FIG. 48-1

POSITIVE (+)

BATTERY POST

NUT

NEGATIVE (-)

BATTERY CABLE

POSITIVE (+)

BATTERY CABLE

NEGATIVE (-)

BATTERY POST

BATTERY POWER RECONNECTED

FIG. 48-2

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

48

STEP 11 - INSTALL OPENER & LICENSE PLATE

BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d

INSTALLATION WITH UNDERRIDE

1. Lower platform to ground level. Refer
to operating instructions in Operation
Manual.

POSITIVE (+)

!

WARNING

To prevent accidental personal injury
and equipment damage, disconnect
(-) battery cable and (+) cable from
battery.

NUT

BATTERY CABLE

POSITIVE (+)

BATTERY POST

2. Disconnect power to the pump by dis-
connecting negative (-) and positive
(+) cables from battery (FIG. 49-1).

Reinstall nuts on negative (-) and
positive (+) battery terminals.

BATTERY CABLE

3. Bolt opener and license plate

bracket to main frame as shown

in FIG. 49-2. Then, torque bolts
and lock nuts to 105 lb-ft.

NEGATIVE (-)

BATTERY POST

NEGATIVE (-)

DISCONNECTING BATTERY POWER

FIG. 49-1

OPENER

CAP SCREW, 2-1/4” LG.

(2 PLACES)

LOCK NUT, 3/8”-16

(2 PLACES)

BOLTING ON OPENER & LICENSE

PLATE BRACKET

49

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

MAIN

FRAME

FLAT WASHER

(2 PLACES)

FIG. 49-2

STEP 11 - INSTALL OPENER & LICENSE PLATE

BRACKET WITH ICC BUMPER OR UNDERRIDE - Cont’d

INSTALLATION WITH UNDERRIDE - Continued

4. Reconnect power to the pump by

reconnecting positive (+) and nega­ tive (-) cables to battery (FIG. 50-1).

Reinstall and tighten nut when each
battery cable is reconnected.

POSITIVE (+)

BATTERY POST

NUT

POSITIVE (+)

BATTERY CABLE

5. Stow platform (FIG. 50-2). Refer

to operating instructions in

NEGATIVE (-)

BATTERY CABLE

Operation Manual.

NOTE: Ensure license plate bracket is

vertical with platform and underride

in the stowed position.

6. Put license plate bracket in desired position on

top of underride (FIG. 50-2). Next, use bottom

fl ange of license plate bracket to mark the two
holes on top of underride. Then, drill the 2 holes

with 1/4” drill bit (FIG. 50-2).

NEGATIVE (-)

BATTERY POST

BATTERY POWER RECONNECTED

FIG. 50-1

RIVETS

LICENSE PLATE

BRACKET

BOTTOM

FLANGE

7. Rivet license plate bracket
to underride (FIG. 50-2).

8. Stow and unfold platform

several times to verify there
is no interference.

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

UNDERRIDE

1/4” DIA.

HOLES

EXAMPLE FOR POSITIONING & RIVETING

LICENSE PLATE BRACKET TO UNDERRIDE

FIG. 50-2

50

STEP 12 - ADJUST PLATFORM (IF REQUIRED)

NOTE: Before doing the following proce-

dure, make sure vehicle is parked
on level ground.

OUTBOARD EDGE
1” MAX (UP TO 53” BED HT.)
0” LEVEL (OVER 53” BED HT.)

1. Lower platform to the ground. With the

platform and fl ipover unfolded, raise plat-

form to bed level (FIG. 51-1). Measure

how much the outboard edge of platform

rises above bed level (FIG. 51-1). The

outboard edge can be a maximum of 1”
above bed level if bed height is 48” to 53”.
If bed height is 54” to 55” the outboard

edge is level (FIG. 51-1). If indication is

correct, Liftgate is installed correctly and
no adjustment is needed. If the outboard

edge is below bed level, do instructions 2,
3, and 6. If outboard edge is higher than 1”,
do instructions 4 through 6.

2. Compare measurement “A” (FIG.

51-2) with the distances and shims

in TABLE 51-1. For example: If
measurement “A” (FIG. 51-2) is

1” below level and you want to raise
outboard edge of platform 1” above
level, use 1/8” shim to raise 2”

(TABLE 51-1).

EXTENSION

PLATE (REF)

LEVEL LINE

VEHICLE

FLOOR (REF)

PLATFORM EDGE AT OR

ABOVE BED LEVEL

FIG. 51-1

EXTENSION

PLATE (REF)

“A”

LEVEL LINE

VEHICLE

FLOOR (REF)

PLATFORM EDGE BELOW BED LEVEL

FIG. 51-2

RAISE PLATFORM

EDGE (OUTBOARD)

THIS DISTANCE (“A”)

1” 1/16” 1/16”
2” 1/8” 1/8”
3” 3/16” 3/16”
4” 1/4” 1/4”

REQUIRED SHIM

THICKNESS

TABLE 51-1

3. Weld shims (parts bag item) on both

platform stops (FIG. 51-3) to raise

outboard edge of platform to correct
position.

WELD SIZE

“W”

SHACKLE

(REF)

NEW SHIM

(TABLE 51-1)

2 PLACES

“W”

“W”

(TABLE 51-1)

WELDING SHIMS (CURBSIDE SHOWN)

FIG. 51-3

51

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

STEP 12 - ADJUST PLATFORM - Continued

4. Compare measurement “B” (FIG.
52-1) with the distances and grinding

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).

LOWER PLATFORM

EDGE (OUTBOARD)

THIS DISTANCE (“B”)

1” 1/16”
2” 1/8”
3” 3/16”
4” 1/4”

GRIND METAL

FROM PLATFORM

STOP

TABLE 52-1

EXTENSION

PLATE (REF)

“B”

LEVEL LINE

VEHICLE

FLOOR (REF)

PLATFORM EDGE ABOVE BED LEVEL

FIG. 52-1

5. Grind metal from platform stops (FIG.
52-2) to lower outboard edge of plat-

form to correct position.

6. Lower the platform, then raise it to bed

level. The outboard edge of platform should
be level or up to 1” maximum above bed

level (FIG. 52-3).

SHACKLE

(REF)

GRIND THIS FACE

(SEE TABLE 52-1)

GRINDING PLATFORM STOPS

(CURBSIDE SHOWN)

OUTBOARD EDGE
1” MAX (UP TO 53” BED HT.)
0” LEVEL (OVER 53” BED HT.)

FIG. 52-2

EXTENSION

PLATE (REF)

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

VEHICLE

FLOOR (REF)

LEVEL LINE

PLATFORM EDGE ABOVE BED LEVEL

FIG. 52-3

52

STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE

CAUTION

CAUTION

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

To protect the original paint system, a 3” wide area of paint must be removed
from all sides of the weld area before welding.

CAUTION

When using an electric welder, connect the welder ground to one of the parts
being welded, as close to the weld as possible. Failure to comply could result in
damage to cylinders and electrical parts.

1. Weld each of the two

mounting plates to vehicle

frame (FIG. 53-1A).

VEHICLE FRAME

(TYPICAL TRUCK FRAME

SHOWN)

VEHICLE FRAME CUTOUT

(DASHED LINES)

2. After welding is done and mount-

ing plates are cool, remove and
discard the 4 fi berglass sleeves

shown in FIG. 53-1B. Keep the

split looms to protect the hoses.

5/16”

MOUNTING

PLATE

WELDING MOUNTING PLATE

FIG. 53-1A

FIBERGLASS

TYPICAL

- BOTH
MOUNTING
PLATES

SLEEVES

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

SPLIT

LOOMS

53

FIBERGLASS

SLEEVES

MOUNTING

PLATES (REF)

FIG. 53-1B

STEP 14 - BOLT STEPS TO EXTENSION PLATE

1. Lower platform to the ground

(FIG. 54-1).

!

WARNING

To prevent accidental personal 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. 54-2).

Reinstall nuts on negative (-) and posi­tive (+) battery terminals.

PLATFORM LOWERED TO GROUND

FIG. 54-1

POSITIVE (+)

NUT

NEGATIVE (-)

BATTERY CABLE

BATTERY CABLE

NEGATIVE (-)

BATTERY POST

POSITIVE (+)

BATTERY POST

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

DISCONNECTING BATTERY POWER

FIG. 54-2

54

STEP 14- BOLT STEPS TO EXTENSION PLATE

- Continued

CAUTION

To prevent interference with Liftgate and possible damage, maintain 90º angle
between steps and extension plate. Tighten bolts only in the order shown in
illustration.

NOTE: If 102” extension kit is to be installed for 102” wide vehicle, install the exten-

sion kit before installing the steps. Refer to Instruction Sheet M-09-06 for

installing the extensions.

3. Line up the LH step (Kit item) on LH

side of the extension plate. Bolt step to

extension plate (FIG. 55-1). Tighten

bolts 1, 2, 3 and 4 in the numbered
order shown in FIG. 55-1. Then, torque
each bolt and lock nut to 105 lb-ft. in

the same order.

FLAT WASHER

(2 PLACES)

FLANGE LOCK NUT

(2 PLACES)

PART OF

EXTENSION

PLATE

LOCK NUT

(2 PLACES)

1/2” X 1-1/2” LG

FRAME BOLT

(4 PLACES)

3

4

LH STEP

1

2

90°

BOLTING STEP TO EXTENSION PLATE

(LH DUAL STEP SHOWN)

FIG. 55-1

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

55

STEP 14 - BOLT STEPS TO EXTENSION PLATE

4. Bolt the support (Kit item) to

mounting channel (Kit item)

(FIG. 56-1).

LH STEP

- Continued

REAR SILL

1/2” X 3-1/2” LG.

FRAME BOLT

(2 PLACES)

I-BEAM

(VEHICLE BODY)

LOCK NUT

(3 PLACES)

FLAT WASHER

(3 PLACES)

MOUNTING

CHANNEL

STEP SUPPORT

BOLTING SUPPORT TO MOUNTING CHANNEL &

STEP (LH STEP & SUPPORT SHOWN)

5. Butt the fl at part of the mounting

channel against bottom of vehicle
rear sill and I-beams. Then, butt the
support against back of the step

(FIG. 56-1).

6. Ensure slotted hole in the step sup-

port is lined up with the hole on

the step (FIG. 56-1). Then, bolt the
support to step (FIG. 56-1). Torque
the lock nuts (FIG. 56-1) to 105 lb-ft

force.

1/2” X 1-1/2” LG

FRAME BOLT

FIG. 56-1

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

56

STEP 14 - BOLT STEPS TO EXTENSION PLATE

- Continued

NOTE: Before welding mounting channel to

vehicle body, ensure step is straight
and steps are in vertical position.

7. Weld the fl at part of the mounting

channel to vehicle body as shown

in FIG. 57-1.

I-BEAM

(VEHICLE BODY)

MOUNTING

CHANNEL

3/16”
3/16”

REAR SILL

WELD TO AS MUCH
I-BEAM FLANGE &
REAR SILL AS POSSIBLE

8. Repeat instructions 3 through 7

for RH step. Use the RH Step As­sembly (Kit item).

9. Reconnect power to the pump by
reconnecting positive (+) and nega­ tive (-) cables to battery (FIG. 57-1).

Reinstall and tighten nut when each
battery cable is reconnected.

WELDING FLAT OF MOUNTING CHANNEL

TO VEHICLE BODY (LH STEP SHOWN)

FIG. 57-1

POSITIVE (+)

BATTERY POST

NUT

NEGATIVE (-)

BATTERY CABLE

POSITIVE (+)

BATTERY CABLE

NEGATIVE (-)

BATTERY POST

RECONNECTING POWER

FIG. 57-2

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

57

STEP 15 - ADJUST WALK RAMP PADS

1. Stow the platform (FIG. 58-1A).
NOTE: If necessary to lower each

walk ramp pad, the steel
shim under each pad can
be removed.

2. Loosen the socket head screws and

lock nuts (FIG. 58-1B). Slide the

pads toward the outside of the walk

ramp box (FIG. 58-1B).

NOTE: If a different ramp stop

method or equipment is
required, the ramp stops
shown in the illustration
can be removed.

3. Install the walk ramp (not shown)

according to manufacturer’s in­ structions.

SOCKET HEAD

SCREWS

(4 PLACES)

LIFTGATE WITH

PLATFORM STOWED

FIG. 58-1A

EXTENSION

PLATE

(REF)

WALK RAMP PAD

(2 PLACES)

WALK RAMP

BOX

SHIM

(REF)

RAMP STOP

(2 PLACES)

4. Slide the ramp pads to the edge of

the walk ramp (not shown) (FIG.
58-1B).

5. Tighten the socket head

screws and lock nuts securely

(FIG. 58-1B).

WALK RAMP LATCH

(REF)

INSERTED HERE

ADJUSTING WALK RAMP PADS

FIG. 58-1B

SHIM
(REF)

WALK RAMP

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

58

STEP 16 - LUBE GREASE FITTINGS AS NEEDED

NOTE: Lube fi ttings are shown for the RH cylinder, lift arm, and parallel

arm. There are also lube fi ttings at the same places on the LH
cylinder, lift arm, and parallel arm.

Refer to lubrication diagram (FIG. 59-1) to fi nd the

lube fi ttings on cylinders and arms. Pump EP chassis
grease in each lube fi tting on the cylinders and arms
until grease starts oozing from ends of the bearings.
Then, wipe off excess grease with a clean lint-free
cloth.

LH CYLINDER,
LIFT ARM &
PARALLEL ARM

LUBRICATION DIAGRAM

FIG. 59-1

59

RH CYLINDER,
LIFT ARM &
PARALLEL ARM

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

APPLY DECALS

NOTE: Ensure there is no residue, dirt or corrosion where decals are attached. If

necessary, clean surface 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 applied so that they are easily visible when approaching vehicle
to operate Liftgate. Use good common sense when locating these decals on
vehicle.

STOW WARNING DECAL

DECAL “D”

DECAL “E”

P/N 282847-02

DECAL “B”

DECAL “A”

FIG. 60-1

DECAL “C”

DECAL “H”

CAPACITY DECAL

(SEE TABLE 61-1)

DECAL “G”

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

60

APPLY DECALS - Continued

GPTWR-25 220382 2500 POUNDS

GPTWR-3 220388 3000 POUNDS

GPTWR-4 296274-01 4000 POUNDS

GPTWR-5 296274-02 5000 POUNDS

DECAL SHEET

P/N 297207-01

FIG. 61-1

MODEL DECAL P/N

CAPACITY DECAL

TABLE 61-1

61

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

CAPACITY

DECAL

DECALS & PLATES

NOTE: Preferred decal layout is shown. Decals on

the Liftgate are attached at the factory.

MAXON NAME PLATE

P/N 280004-01

PLATFORM WARNING DECAL

P/N 281189-02

(2 PLACES)

SERIAL PLATE

(REF)

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

PLATFORM LOADING DECAL

P/N 281326-01

(2 PLACES)

FIG. 62-1

62

TOUCH-UP PAINTED OR GALVANIZED FINISH

CAUTION

Damaged cylinder seals and contaminated hydraulic fl uid can result from
painting the polished portion of the cylinder rod. To prevent damage, protect
the exposed polished portion of the cylinder rod while painting.

• 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 original paint system, MAXON recom-

mends aluminum primer touch-up paint kit.

• If bare metal is exposed on galvanized portions of the Liftgate, touch up the galvanized

fi nish. To maintain the protection provided by the original galvanized fi nish, MAXON

recommends cold galvanize spray.

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

63

POWER DOWN

MODULE

MOTOR

SYSTEM DIAGRAMS

PUMP & MOTOR SOLENOID OPERATION

PORT A

“S2” VALVE

“S1” VALVE

SOLENOID

SWITCH

PORT B

POWER UNIT

FIG. 64-1

NOTE: Hydraulic lock valve is on the RH cylinder.

POWER UNIT MOTOR & SOLENOID OPERATION

SOLENOID OPERATION

LIFTGATE
FUNCTION

RAISE A - - -

LOWER B -

PORT

MOTOR

( MEANS ENERGIZED)

VALVE

“S2”

VALVE

“S1”

LOCK

VALVE

POWER

DOWN

MODULE

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

REFER TO VALVES SHOWN ON

HYDRAULIC SCHEMATIC

TABLE 64-1

64

HYDRAULIC SCHEMATIC (POWER DOWN)

HYDRAULIC

LOCK VALVE

PORT B - LOWER
(POWER DOWN)

HYDRAULIC
CYLINDERS

PORT A - RAISE

VALVE S2

4 GPM FLOW

CHECK VALVE

MOTOR

(REF)

CONTROL

VALVE

VALVE S1

FILTER

RELIEF VALVE 2

(SET AT 1100 PSI)

RELIEF VALVE 1

(SET AT 2750 PSI)

AUX. HAND

PUMP PORT

(PLUGGED)

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

PUMP

RESERVOIR

DRAIN HOLE

(PLUGGED)

FIG. 65-1

65

ELECTRICAL SCHEMATIC (POWER DOWN)

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

FIG. 66-1

66

SYSTEM DIAGRAMS

GPTWR ELECTRICAL VALUES

Solenoid Switch

Coil Resistance:

Ampere:

Coil terminal torque: 10-15 lb-in max.
Contact terminal torque: 30-35 lb-in max.

Solenoid Valves (A, S1, & S2)

Coil Resistance:

Ampere:

Coil terminal torque: 15-45 lb-in max.
Valve cartridge torque: 25-30 lb-ft max.
Coil nut torque: 15-45 lb-in

Solenoid Lock Valve

Coil Resistance:

12V 24V

5.4Ω @70ºF. ±15% 20.1Ω @70ºF. ±15%

2.2A 1.2A

4.0Ω @ 70ºF. ±15% 26.7Ω @ 70ºF. ±15%

3A, 2.5A @10V

8.0Ω @ 70ºF. ±15% 30Ω @ 70ºF. ±15%

Ampere:

Coil terminal torque: 3-4.5 lb-ft max.
Valve cartridge torque: 18.5-22 lb-ft max.

Ground Cable

Cap Screw Torque: 24 lb-ft max.

TABLE 67-1

1.5A 0.8A

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

67

OPTIONS

OPTIONAL LIFTGATE COMPONENTS

MISCELLANEOUS KITS PART NO.

FRAMELESS TRAILER BRACKET, MOUNTING (GALVANIZED) 282665-01G

FRAMELESS TRAILER BRACKET, MOUNTING (GALVANIZED) (REFRIGERATOR TRAILERS) 282970-01G

FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS (GALVANIZED) 282372-01G

FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS, NO FINISH (HAS RUST PREVENTIVE COAT) 282372-03

HAND PUMP, GPT SERIES 296075-01

TRAFFIC CONES 268893-01

ELECTRICAL KITS

IN CAB ON-OFF SWITCH 250477

CIRCUIT BREAKER (150 AMP) 251576

HAND HELD CONTROL, TUKS, 120” LG (OUTSIDE VEHICLE) 263260-13

HAND HELD CONTROL, TUKS, 240” LG (OUTSIDE VEHICLE) 263260-14

HAND HELD CONTROL, TUK-A-WAY (INSIDE VEHICLE) 280570-07

STREET SIDE CONTROL, GPT 297116-01

DUAL SWITCH CONTROL, GPT 297115-01

PLATFORM FLASHING LIGHTS, TOP MOUNT, GPT 297611-01

PLATFORM FLASHING LIGHTS, SIDE MOUNT, GPT 297611-02

REAR END PROTECTION KITS FOR TRUCKS AND TRAILERS

UNDERRIDE, 90", GPT-4 & GPT-5 (GALVANIZED) NOTE: COMPLIES WITH CANADIAN MVS

REGULATIONS & FMVSS “REAR IMPACT GUARD” REQUIREMENTS

UNDERRIDE, 95", GPT-4 & GPT-5 (GALVANIZED) NOTE: COMPLIES WITH CANADIAN MVS

REGULATIONS & FMVSS “REAR IMPACT GUARD” REQUIREMENTS

UNDERRIDE, 90", GPT-25 & GPT-3 (GALVANIZED) NOTE: COMPLIES WITH FMVSS “REAR IMPACT

GUARD” REQUIREMENTS

UNDERRIDE, 95", GPT-25 & GPT-3 (GALVANIZED) NOTE: COMPLIES WITH FMVSS “REAR IMPACT

GUARD” REQUIREMENTS

ICC BUMPER (GALVANIZED) NOTE: COMPLIES WITH OMCS REQUIREMENTS 283270-01G

287050-01G

287050-02G

287050-03G

287050-04G

DUAL STEP DOCK BUMPER KITS WITH BUMPERS

DUAL STEP (GALVANIZED) WITH 14” LG. RUBBER BUMPERS (2.5”W X 3”H X 14”LG) 288705-01G

DUAL STEP (GALVANIZED) WITH 13.5” LG. RUBBER BUMPERS (2.9”W X 1.5”H X 13.5”LG) 288705-02G

DUAL FLEX STEP (GALVANIZED),14” LG. RUBBER BUMPER 288705-21G

DUAL FLEX STEP (GALVANIZED),13.5” LG. RUBBER BUMPER WITH FLEXIBLE WIRE ROPE
LOWER STEP & 2.9”W X 1.5”H X 13.5”LG. POLYETHYLENE BUMPERS

DUAL STEP W/LIGHT (GALVANIZED), 14” LG. RUBBER BUMPERS 288705-31G

DUAL STEPS W/LIGHT (GALVANIZED), 13.5” LG. POLYETHYLENE BUMPERS 288705-32G

DUAL STEP (GALVANIZED), CURB SIDE, 14” LG. RUBBER BUMPERS 288705-03G

DUAL STEP (GALVANIZED), CURB SIDE, 13.5” LG. POLYETHYLENE BUMPERS 288705-04G

288705-22G

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

68

OPTIONAL LIFTGATE COMPONENTS - Continued

DUAL STEP DOCK BUMPER KITS WITH BUMPERS - CONTINUED

DUAL FLEX STEP (GALVANIZED), STREET SIDE, NO STEPS, 14” LG. RUBBER BUMPERS 288705-23G

DUAL FLEX STEP (PAINTED), STREET SIDE, NO STEPS, 13.5” LG. RUBBER BUMPERS 288705-24G

DUAL STEP W/LIGHT, (GALVANIZED) CURB SIDE, 14” LG. RUBBER BUMPERS 288705-33G

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 STEPS, NO BUMPERS 288705-06G

DUAL FLEX STEPS (GALVANIZED), NO BUMPERS 288705-25G

DUAL STEP FLEX STEPS (GALVANIZED), STREET SIDE, NO BUMPERS 288705-26G

DUAL STEPS WITH OVAL LIGHT (GALVANIZED), NO BUMPER 288705-35G

DUAL STEP W/LIGHT (GALVANIZED), STREET SIDE, NO STEPS, NO BUMPERS 288705-36G

BUMPER KITS

PLASTIC 13.5” BUMPER (2.9”W X 1.5”H x 13.5”LG.) 288707-01

RUBBER 14” BUMPER (2.5”W X 3”H X 14”LG.) 288706-01

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

69