M-04-04 REV. E JUNE 2009 MAINTENANCE MANUAL GPTLR-25, GPTLR-33, GPTLR-44, & GPTLR-55 © MAXON Lift Corp.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 LIFT CORP. CUSTOMER SERVICE: TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116 FAX: (888) 771-7713 NOTE: For latest version of all Manuals (and replacements), download the Manuals from Maxon’s website at www.maxonlift.com.
TABLE OF CONTENTS WARNINGS ........................................................................................................................... 6 SAFETY INSTRUCTIONS .................................................................................................... 6 LIFTGATE TERMINOLOGY .................................................................................................. 9 PERIODIC MAINTENANCE..............................................................................................
PLATFORM & FLIPOVER ASSEMBLY WITH SINGLE RETENTION RAMP (ALUMINUM) ...................................................................................... 61 FLIPOVER WITH SINGLE RETENTION RAMP (ALUMINUM)........................................... 63 PLATFORM & FLIPOVER ASSEMBLY (STEEL) ................................................................ 65 PUMP COVER & MOUNTING PLATE ASSEMBLY (GRAVITY DOWN) ............................. 67 PUMP COVER & MOUNTING PLATE ASSEMBLY (POWER DOWN) ......................
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining Liftgates. See Operation Manual for operating safety requirements. WARNINGS ! WARNING • Do not stand, 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.
• 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. Listen for scraping, grating and binding noises and correct the problem before continuing to operate Liftgate. • Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial number information with your parts order. Order replacement parts from: MAXON LIFT CORP. Customer Service 11921 Slauson Ave.
11921 Slauson Ave. Santa Fe Springs, CA.
EXTENSION PLATE CONTROL SWITCH LIFT CYLINDER PARALLEL ARM PUMP BOX PLATFORM SPRING ASSIST TORSION BAR HYDRAULIC LOCK TORSION SPRING MAIN FRAME PLATFORM OPENER FLIPOVER WITH FIXED RAMP 9 LIFT ARM PLATFORM SUPPORT 11921 Slauson Ave. Santa Fe Springs, CA.
PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHECKS ! WARNING Never operate the Liftgate if parts are loose or missing. NOTE: Make sure vehicle is parked on level ground while performing the maintenance checks. Quarterly or 1250 Cycles (whichever occurs first) 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 Check the hydraulic fluid level in the pump reservoir. Refer to the CHECKING HYDRAULIC FLUID procedure in the PERIODIC MAINTENANCE section.
Annually or 5000 Cycles (whichever occurs first) Visually check the entire Liftgate for excessively worn parts and broken welds, especially hinge pins. See PARTS BREAKDOWN section for replacement parts. Check the platform and flipover as follows. Unfold the platform and flipover. Raise the platform to vehicle bed height and then lower it to the ground. Check if the shackles and tip of flipover touch the ground at the same time (FIG. 11-1).
PERIODIC MAINTENANCE Annually or 5000 Cycles - Continued 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 To prevent unnecessary wear on parallel arms, check for worn thrust bearings as follows. Position the platform 1”-2” above ground (FIG. 12-1A). Push against the shackle (Item 1, FIG. 12-1B) and measure clearance (Item 1, FIG. 12-1B). Then, push against other side of shackle (Item 2, FIG. 12-1B) and measure clearance (Item 2, FIG. 12-1B). Repeat for LH side shackle.
PERIODIC MAINTENANCE CHECKLIST Quarterly or 1250 Cycles (whichever occurs first) Check the level and condition of the hydraulic fluid. Visually check all hoses and fittings for chafing and fluid leaks, and check hydraulic lock. Check electrical wiring for chafing and make sure wiring connections are tight and free of corrosion. Check that all WARNING and instruction decals, nonskid stickers, and safety striping are in place.
PERIODIC MAINTENANCE CHECKING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination. NOTE: Use correct grade of hydraulic fluid for your location. 11921 Slauson Ave. Santa Fe Springs, CA.
ISO 32 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER AMSOIL AWH-05 CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS T-32 EXXON UNIVIS N-32 MOBIL DTE-13M, DTE-24, HYDRAULIC OIL-13 TABLE 15-1 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER AMSOIL AWF-05 CHEVRON FLUID A, AW-MV-15 KENDALL GLACIAL BLU SHELL TELLUS T-15 EXXON UNIVIS HVI-13 MOBIL DTE-11M ROSEMEAD THS FLUID 17111 TABLE 15-2 15 11921 Slauson Ave. Santa Fe Springs, CA.
PERIODIC MAINTENANCE CHANGING HYDRAULIC FLUID CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination. NOTE: Use correct grade of hydraulic fluid for your location. 11921 Slauson Ave. Santa Fe Springs, CA.
1. Lower platform to ground. Pull out (no threads) drain plug (FIG. 17-1). Drain hydraulic fluid from system. Reinstall drain plug. FILLER CAP RESERVOIR 2. Pull out (no threads) filler cap (FIG. 17-1) and refill reservoir with hydraulic fluid to level shown in FIG. 17-1. Reinstall filler cap (FIG. 17-1). 2” 3. Stow the Lift and do the CHECKING HYDRAULIC FLUID procedure in this section of the manual. DRAIN PLUG GRAVITY DOWN PUMP & MOTOR FIG. 17-1 POWER DOWN LIFTGATES 1.
PERIODIC MAINTENANCE GRAVITY DOWN & POWER DOWN LIFTGATES CAUTION 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 Pump cover must be correctly secured to prevent it from becoming a hazard. To secure pump cover, the long side of the holder flats must butt against pump cover as shown in the illustration. NUTS (2 PLACES) Bolt on the pump cover as shown in FIG. 18-1. Torque the 5/16”-18 cover bolts from 10 to 14 lbs.-ft.
NOTE: Perform the following adjustment if platform feels heavy as you start to fold it for stowing. If adjusted as follows, the torsion springs will reduce the amount of effort you need to start folding the platform. 1. Make sure vehicle is parked on level ground. LOWER the Liftgate about 1” above the ground (FIG. 19-1). 90 DEGREES +2/-0 1” LIFTGATE OFF THE GROUND FIG.
PERIODIC MAINTENANCE PLATFORM TORSION SPRING ADJUSTMENT - Continued NOTE: If there is little or no gap, a shim is not required. Skip to step 7. 3/4” 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 4. Fabricate 2 shims from A-36 steel as shown in FIG 20-1. The thickness must be equal to the “H” measurement taken in the previous step and an added 1/16”. For example, if you measured 1/8” for “H”, add another 1/16” to make the shim 3/16” thick.
FOLDING PLATFORM FIG. 21-1 UNFOLDING PLATFORM FIG. 21-2 CAUTION Stow Liftgate under hydraulic pressure. 7. Fold platform and stow Liftgate (FIG. 21-3). LIFTGATE STOWED FIG. 21-3 21 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 6. LOWER platform to the ground. Make sure platform easily folds (FIG. 21-1) and unfolds (FIG. 21-2).
PERIODIC MAINTENANCE REPLACING PLATFORM TORSION SPRING NOTE: The following procedure shows how to replace torsion spring on RH side of platform. Use this procedure for replacing torsion spring on the LH side. 1. Fold flipover onto platform. SPRING BRACKET BOLT HINGE BRACKET BOLT 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 2. Fold platform. WASHER WASHER SHACKLE LOCK NUT 3.
BOLT SPRING BRACKET SHORT CHAMFERED HINGE BRACKET LEG BOLT LONG LEG WASHER 6. Drive the hinge pin into correct position through the hinge bracket as shown in FIG. 23-1. Line up the bolt hole in the hinge pin with the hole in the shackle and spring bracket. Bolt the hinge pin to hinge bracket and spring bracket with bolts, washers, lock nuts (FIG. 23-1). Torque the 3/8”-16 spring pin bolt and 3/8”-16 spring bracket bolt 35 to 52 lbs.-ft. WASHER LOCK NUT SHACKLE FIG. 23-1 7.
PARTS BREAKDOWN MAIN ASSEMBLY: GPTLR-25 & GPTLR-33 (ALUMINUM PLATFORM) 1A REFER TO PUMP COVER, HYDRAULIC COMPONENTS, & POWER UNITS 1 11921 Slauson Ave. Santa Fe Springs, CA.
1 1 DESCRIPTION 281090-01 EXTENSION PLATE ASSEMBLY (96” WIDE) 281090-02 EXTENSION PLATE ASSEMBLY (102” WIDE) 1A 6 207644 RIVET, 3/16” X .40” GRIP 1B 1 050175 MAXON PLATE 2 5 902000-14 FLAT WASHER, 1/2” 3 2 900035-3 CAP SCREW, 1/2”-13 X 1-1/2” LG. 4 5 901010 LOCK NUT, 1/2”-13 5 1 281580-01 ICC BUMPER (96” WIDE) 281580-02 ICC BUMPER (102” WIDE) 2 908088-01 BEARING, FLANGED 6 2 902013-21 FLAT WASHER, 1-3/8” 7 2 221416 ROLL PIN, 3/8” X 2” LG.
PARTS BREAKDOWN MAIN ASSEMBLY: GPTLR-25 & GPTLR-33 (ALUMINUM PLATFORM) - Continued 27 28 29 30 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 17 2 902013-09 FLAT WASHER, 1/4” 18 2 901000 LOCK NUT, 1/4”-20 19 1 281154-01 LATCH BRACKET 20 2 900044-7 SOCKET SCREW, 1/4”-20 X 1-1/4” LG. 21 2 900035-7 CAP SCREW, 1/2”-13 X 2-1/2” LG.
PARTS BREAKDOWN MAIN ASSEMBLY: GPTLR-44 & GPTLR-55 (ALUMINUM PLATFORM) 1A REFER TO PUMP COVER, HYDRAULIC COMPONENTS, & POWER UNITS 1 11921 Slauson Ave. Santa Fe Springs, CA.
1 1 DESCRIPTION 281120-01 EXTENSION PLATE ASSEMBLY (96” WIDE) 281120-02 EXTENSION PLATE ASSEMBLY (102” WIDE) 1A 6 207644 RIVET, 3/16” X .40” GRIP 1B 1 050175 MAXON PLATE 2 5 902000-14 FLAT WASHER, 1/2” 3 2 900035-3 CAP SCREW, 1/2”-13 X 1-1/2” LG. 4 5 901010 LOCK NUT, 1/2”-13 5 1 281399-01 UNDERRIDE (96” WIDE) 281399-02 UNDERRIDE (102” WIDE) 2 908088-01 BEARING, FLANGED 6 2 902013-21 FLAT WASHER, 1-3/8” 7 2 221416 ROLL PIN, 3/8” X 2” LG.
PARTS BREAKDOWN MAIN ASSEMBLY: GPTLR-44 & GPTLR-55 (ALUMINUM PLATFORM) - Continued 27 28 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 17 2 902013-09 FLAT WASHER, 1/4” 18 2 901000 LOCK NUT, 1/4”-20 19 1 281154-01 LATCH BRACKET 20 2 900044-7 SOCKET SCREW, 1/4”-20 X 1-1/4” LG. 21 2 900035-7 CAP SCREW, 1/2”-13 X 2-1/2” LG.
PARTS BREAKDOWN MAIN ASSEMBLY: GPTLR-25 & GPTLR-33 (STEEL PLATFORM & RAMP OPTION) NOTCHES FOR RAMP OPTION ONLY 1A REFER TO PUMP COVER, HYDRAULIC COMPONENTS, & POWER UNITS 1 11921 Slauson Ave. Santa Fe Springs, CA.
1 1 DESCRIPTION 281090-01 EXTENSION PLATE ASSEMBLY (96” WIDE) 281090-02 EXTENSION PLATE ASSEMBLY (102” WIDE) 281484-01 EXTENSION PLATE ASSEMBLY (96” WIDE RAMP OPTION) 281484-02 EXTENSION PLATE ASSEMBLY (102” WIDE RAMP OPTION) 1A 6 207644 RIVET, 3/16” X .40” GRIP 1B 1 050175 MAXON PLATE 2 5 902000-14 FLAT WASHER, 1/2” 3 2 900035-3 CAP SCREW, 1/2”-13 X 1-1/2” LG.
PARTS BREAKDOWN MAIN ASSEMBLY: GPTLR-25 & GPTLR-33 (STEEL PLATFORM & RAMP OPTION) - Continued 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 11 1 902000-20 FLAT WASHER, 3/4” 12 1 905033-2 ROLL PIN, 1/4” X 1-1/4” 13 1 282272-01 OPENER TORSION SPRING 14 4 901016-4 LOCK NUT, 3/8”-16 15 2 900035-7 CAP SCREW, 1/2”-13 X 2-1/2” LG. 16 1 281673-01 STOP BLOCK 17 2 902000-16 FLAT WASHER, 5/8” 18 4 900014-5 CAP SCREW, 3/8”-16 X 1-1/4” LG, GRADE 8 19 4 902000-10 FLAT WASHER, 3/8” 35 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 ITEM QTY. PART NO.
PARTS BREAKDOWN MAIN FRAME, LIFTING ARMS, & PARALLEL ARMS: GPTLR-25 & GPTLR-33 4 5 3 (4 PLACES) 8 3 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 280910-01 MAIN FRAME (96” WIDE GPTLR-25/33) 280910-02 MAIN FRAME (102” WIDE GPTLR-25/33) 2 040103-5 SPLIT LOOM, 1/2” X 5” LG. 3 7 905322-01 PLASTIC TIE, 8” LG. 4 2 280969-02 PIN, 1-1/4” DIA X 5-13/16” LG. 5 2 280968-01 PIN, 1-3/8” DIA X 5-7/8” LG. 6 2 281005-01 PIN, 7” LG. 7 2 282435-01 PARALLEL ARMS 7A 4 905112-04 BEARING, SELF-LUBE, 1-1/2” LG. 7B 1 906796-01 45° LUBE FITTING 7C 4 905112-03 BEARING, SELF-LUBE, 1-3/8” LG.
PARTS BREAKDOWN MAIN FRAME, LIFTING ARMS, & PARALLEL ARMS: GPTLR-25 & GPTLR-33 - Continued 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 14 1 281515-01 BRACKET, REINFORCEMENT, RH 15 1 282440-01 LIFT ARM, RH 15A 4 908047-02 BEARING, SELF-LUBE 15B 2 224342 LUBE FITTING 1 282440-02 LIFT ARM, LH 16A 4 908047-02 BEARING, SELF-LUBE 16B 2 224342 LUBE FITTING 17 2 900014-10 CAP SCREW, 3/8”-16 X 2-1/2” LG, GRADE 8 18 2 902000-10 FLAT WASHER, 3/8” 19 1 281515-02 BRACKET, REINFORCEMENT, LH 20 4 901002 LOCK NUT, 3/8”-16 21 2 900014-11 CAP SCREW, 3/8”-16 X 3” LG.
PARTS BREAKDOWN MAIN FRAME, LIFTING ARMS, & PARALLEL ARMS: GPTLR-44 & GPTLR-55 4 3 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 282545-01 MAIN FRAME (96” WIDE GPTLR-44/55) 282545-02 MAIN FRAME (102” WIDE GPTLR-44/55) 2 040103-5 SPLIT LOOM, 1/2” X 5” LG. 3 7 905322-01 PLASTIC TIE, 8” LG. 4 4 280968-04 PIN, 1-3/8” DIA X 7-1/8” LG. 5 2 281005-02 PIN, 8-1/16” LG. 6 10 904717-08 ROLL PIN, 3/8” X 2-1/2” LG. 7 2 282546-01 PARALLEL ARMS 7A 4 908065-04 BEARING, SELF-LUBE, 1-1/2” LG.
PARTS BREAKDOWN MAIN FRAME, LIFTING ARMS, & PARALLEL ARMS: GPTLR-44 & GPTLR-55 - Continued 24 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 13 1 281515-01 BRACKET, REINFORCEMENT, RH 14 1 282543-01 LIFT ARM, RH 14A 4 908047-02 BEARING, SELF-LUBE 14B 2 224342 LUBE FITTING 1 282543-02 LIFT ARM, LH 15A 4 908047-02 BEARING, SELF-LUBE 15B 2 224342 LUBE FITTING 16 2 900014-10 CAP SCREW, 3/8”-16 X 2-1/2” LG, GRADE 8 17 6 902000-10 FLAT WASHER, 3/8” 18 1 281515-02 BRACKET, REINFORCEMENT, LH 19 4 901002 LOCK NUT, 3/8”-16 20 2 900014-11 CAP SCREW, 3/8”-16 X 3” LG.
PARTS BREAKDOWN OPENER (GPTLR-25 & GPTLR-33) 5 (8 PLACES) 1 (4 PLACES) 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 2 (4 PLACES) 3 (4 PLACES) ITEM 4 (4 PLACES) QTY PART NO. DESCRIPTION REF 1 282275-01 OPENER ASSEMBLY, GPTLR 25/33 1 4 280082-01 ROLLER, OPENER, 3-1/2” X 1-1/4” X 1/2” 2 4 900035-11 CAP SCREW, 1/2”-13 X 4” LG.
5 (8 PLACES) 1 (4 PLACES) 2 (4 PLACES) 3 (4 PLACES) ITEM 4 (4 PLACES) QTY PART NO. DESCRIPTION REF 1 282505-01 OPENER ASSEMBLY, GPTLR 44/55 1 4 280082-01 OPENER ROLLER, 3-1/2” X 1-1/4” X 1/2” 2 4 900035-11 CAP SCREW, 1/2”-13 X 4” LG. 3 4 902000-14 FLAT WASHER, 1/2” 4 4 901010 LOCK NUT, 1/2”-13 5 8 092028-10 SPACER 45 11921 Slauson Ave. Santa Fe Springs, CA.
PARTS BREAKDOWN LH & RH PLATFORM SEATS: GPTLR-25 & GPTLR-33 (ALUMINUM PLATFORM WITH FIXED RAMP OR CART STOPS ONLY) 1A (2 PLACES) 1B 2A (2 PLACES) 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 2B 1C (2 PLACES) 1D (2 PLACES) 1 2 2C (2 PLACES) 2D (2 PLACES) ITEM QTY. PART NO. 1 DESCRIPTION 1 281650-02 PLATFORM SEAT, LH (1/2” THICK PAD) 1A 2 900025-1 SOCKET SCREW, 1/4”-20 X 1” LG.
1A (2 PLACES) 1B 2A (2 PLACES) 2B 1C (2 PLACES) 1D (2 PLACES) 1 2 2C (2 PLACES) 2D (2 PLACES) ITEM QTY. PART NO. 1 DESCRIPTION 1 281653-02 PLATFORM SEAT, LH (3/4” THICK PAD) 1A 2 900025-5 SOCKET SCREW, 1/4”-20 X 1-1/4” LG. 1B 1 281652-01 PLASTIC PAD (3/4” THICK PAD) 1C 2 902013-09 FLAT WASHER, 1/4” 1D 2 901000 LOCK NUT, 1/4”-20 1 281653-01 PLATFORM SEAT, RH (3/4” THICK PAD) 2A 2 900025-5 SOCKET SCREW, 1/4”-20 X 1-1/4” LG.
PARTS BREAKDOWN LH & RH PLATFORM SEATS: GPTLR-25 & GPTLR-33 (STEEL PLATFORM ONLY) 1A (2 PLACES) 1B 2A (2 PLACES) 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 2B 1C (2 PLACES) 1D (2 PLACES) 1 2 2C (2 PLACES) 2D (2 PLACES) ITEM QTY. PART NO. 1 DESCRIPTION 1 281650-02 PLATFORM SEAT, LH (1/2” THICK PAD) 1A 2 900025-1 SOCKET SCREW, 1/4”-20 X 1” LG.
1A (2 PLACES) 1B 2A (2 PLACES) 1C (2 PLACES) 2B 1 1D (2 PLACES) 2 2C (2 PLACES) 2D (2 PLACES) ITEM QTY. PART NO. 1 DESCRIPTION 1 281698-02 PLATFORM SEAT, LH (1/2” THICK PAD) 1A 2 900025-1 SOCKET SCREW, 1/4”-20 X 1” LG. 1B 1 281649-01 PLASTIC PAD (1/2” THICK PAD) 1C 2 902013-09 FLAT WASHER, 1/4” 1D 2 901000 LOCK NUT, 1/4”-20 1 281716-01 PLATFORM SEAT, RH (3/4” THICK PAD) 2A 2 900025-5 SOCKET SCREW, 1/4”-20 X 1-1/4” LG.
PARTS BREAKDOWN LH & RH PLATFORM SEATS: GPTLR-44 & GPTLR-55 (ONLY PLATFORM WITH RETENTION RAMP) 1A (2 PLACES) 1B 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 2A (2 PLACES) 1C (2 PLACES) 2B 1 1D (2 PLACES) 2 2C (2 PLACES) 2D (2 PLACES) ITEM QTY. PART NO. 1 DESCRIPTION 1 281698-02 PLATFORM SEAT, LH (1/2” THICK PAD) 1A 2 900025-1 SOCKET SCREW, 1/4”-20 X 1” LG.
11921 Slauson Ave. Santa Fe Springs, CA.
PARTS BREAKDOWN PLATFORM & FLIPOVER ASSEMBLY (ALUMINUM) 9D (5 PLACES) 11921 Slauson Ave. Santa Fe Springs, CA.
1 QTY. PART NO. 1 DESCRIPTION 282515-01 FLIPOVER ASSEMBLY, 79-1/2” (WIDE) 282515-02 FLIPOVER ASSEMBLY, 85-1/2” (WIDE) 282514-01 FLIPOVER WELDMENT, 79” (WIDE) 282514-02 FLIPOVER WELDMENT, 85” (WIDE) 1A 1 1B 1 281635-01 SIDE PLATE, FLIPOVER RH 1C 9 900705-01 SELF-TAPPING SCREW, 1/4”-20 X 1” LG. 1D 1 281636-01 SIDE PLATE, FLIPOVER LH 2 15 281010-01 HINGE ASSEMBLY 3 2 263456-12 HINGE, ROD, 80” LG. (79-1/2” WIDE PLATFORM) 263456-13 HINGE, ROD, 86” LG.
PARTS BREAKDOWN PLATFORM & FLIPOVER ASSEMBLY WITH CART STOPS (ALUMINUM) 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 1 1 281410-01 TORSION BAR HOLDER 2 15 281010-01 HINGE ASSEMBLY 3 2 263456-12 HINGE, ROD, 80” LG. (79-1/2” WIDE PLATFORM) 263456-13 HINGE, ROD, 86” LG. (85-1/2” WIDE PLATFORM) 4 4 905015-1 ROLL PIN, 3/16” X 3/4” LG.
PARTS BREAKDOWN FLIPOVER WITH SINGLE CART STOP (ALUMINUM) 2 9 11921 Slauson Ave. Santa Fe Springs, CA.
1 1 DESCRIPTION 282535-03 FLIPOVER ASSEMBLY, 79-1/2” (WIDE) 282535-04 FLIPOVER ASSEMBLY, 85-1/2” (WIDE) 282512-01 FLIPOVER WELDMENT, 79” (WIDE) 282512-02 FLIPOVER WELDMENT, 85” (WIDE) 1A 1 1B 1 281635-01 SIDE PLATE, FLIPOVER RH 1C 9 900705-01 SELF-TAPPING SCREW, 1/4”-20 X 1” LG. 1D 1 281636-01 SIDE PLATE, FLIPOVER LH 2 2 903705-06 RIVET, BLIND, 1/4” X 1-7/32” LG.
PARTS BREAKDOWN FLIPOVER WITH DUAL CART STOPS (ALUMINUM) 8 7 6 (2 PLACES) 3 11921 Slauson Ave. Santa Fe Springs, CA.
1 1 DESCRIPTION 282535-01 FLIPOVER ASSEMBLY, 79-1/2” (WIDE) 282535-02 FLIPOVER ASSEMBLY, 85-1/2” (WIDE) 282512-01 FLIPOVER WELDMENT, 79” (WIDE) 282512-02 FLIPOVER WELDMENT, 85” (WIDE) 1A 1 1B 1 281635-01 SIDE PLATE, FLIPOVER RH 1C 9 900705-01 SELF-TAPPING SCREW, 1/4”-20 X 1” LG. 1D 1 281636-01 SIDE PLATE, FLIPOVER LH 2 1 267581-01 SPRING, FLIPOVER, 42” LG. 3 2 903409-07 FENDER WASHER, 9/32” X 1-1/4” O.D. 4 2 267094-03 PIN, 5” LG.
PARTS BREAKDOWN PLATFORM & FLIPOVER ASSEMBLY WITH SINGLE RETENTION RAMP (ALUMINUM) NOTE: This platform & flipover with retention ramp is only available for GPTLR-44 & GPTLR-55. 12D (5 PLACES) 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 1 1 281410-01 TORSION BAR HOLDER, LH 2 15 281010-01 HINGE ASSEMBLY 3 2 263456-12 HINGE, ROD, 80” LG. (79-1/2” WIDE PLATFORM) 263456-13 HINGE, ROD, 86” LG. (85-1/2” WIDE PLATFORM) 4 4 905015-1 ROLL PIN, 3/16” X 3/4” LG.
PARTS BREAKDOWN FLIPOVER WITH SINGLE RETENTION RAMP (ALUMINUM) 21 (4 PLACES) 1 20 21 (4 PLACES) 11921 Slauson Ave. Santa Fe Springs, CA.
DESCRIPTION 282533-01 FLIPOVER ASSEMBLY, 79-1/2” (WIDE) 282533-02 FLIPOVER ASSEMBLY, 85-1/2” (WIDE) 282532-01 FLIPOVER WELDMENT, 79-1/2” (WIDE) 282532-02 FLIPOVER WELDMENT, 85-1/2” (WIDE) 267045-01 HINGE, ROD, 78-9/16” LG. (79-1/2” WIDE FLIPOVER) 267045-03 HINGE, ROD, 84-9/16” LG. (85-1/2” WIDE FLIPOVER) 267045-02 HINGE, ROD, 78-3/4” LG. (79-1/2” WIDE FLIPOVER) 267045-04 HINGE, ROD, 84-3/4” LG. (85-1/2” WIDE FLIPOVER) 10 311022-10 HINGE ASSEMBLY 5 2 905007-07 ROLL PIN, 5/32” X 1” LG.
PARTS BREAKDOWN PLATFORM & FLIPOVER ASSEMBLY (STEEL) NOTE: This steel platform & flipover assembly is only available for GPTLR-25 & GPTLR-33. 11921 Slauson Ave. Santa Fe Springs, CA.
1 1 DESCRIPTION 282510-01 FLIPOVER ASSEMBLY, 79” (WIDE) 282510-02 FLIPOVER ASSEMBLY, 85” (WIDE) 282507-01 FLIPOVER WELDMENT, 79” (WIDE) 282507-02 FLIPOVER WELDMENT, 85” (WIDE) 1A 1 1B 4 900044-5 FLAT HEAD SKT SCREW, 1/4”-20 X 7/8” LG, GRADE 8 1C 1 267201-03 SLAM LATCH, 1/2” LG.
PUMP COVER & MOUNTING PLATE ASSEMBLY (GRAVITY DOWN) 7 6 8 8 7 5 9 10 11 12 MAIN FRAME (REF) 4 3 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 2 1 6 5 4 3 REFER TO 12 VDC POWER UNIT (GRAVITY DOWN) NOTE: LEAVE 1/4” GAP FOR DRAINAGE. ITEM QTY. PART NO. DESCRIPTION REF 1 281059-01 PUMP ASSEMBLY 1 1 281038-01 COVER ASSY 2 1 093203-10 GASKET, RUBBER CHANNEL, 60” LG. 3 2 900009-8 CAP SCREW, 5/16”-18 X 2” LG.
7 7 8 6 8 5 10 11 9 12 4 MAIN FRAME (REF) 3 2 1 6 5 4 3 REFER TO 12 VDC POWER UNIT (POWER DOWN) NOTE: LEAVE 1/4” GAP FOR DRAINAGE. ITEM QTY. PART NO. DESCRIPTION REF 1 282330-01 PUMP ASSEMBLY 1 1 281038-01 COVER ASSY 2 1 093203-10 GASKET, RUBBER CHANNEL, 60” LG. 3 2 900009-8 CAP SCREW, 5/16”-18 X 2” LG. 4 2 281062-02 HOLDER FLATS 5 2 902013-10 FLAT WASHER, 5/16” 6 2 901001 LOCK NUT, 5/16”-18 7 2 900064-05 BUTTONHEAD SCREW, 3/8”-16 X 1” LG.
PARTS BREAKDOWN GRAVITY DOWN HYDRAULIC COMPONENTS CAUTION To prevent incorrect operation & damage to Liftgate, make sure arrow on flow regulator valve points up as shown in illustration. RH CYLINDER LH CYLINDER 11921 Slauson Ave. Santa Fe Springs, CA.
PART NO.
PARTS BREAKDOWN POWER DOWN HYDRAULIC COMPONENTS CAUTION To prevent incorrect operation & damage to Liftgate, make sure arrow on flow regulator valve points up as shown in illustration. RH CYLINDER LH CYLINDER 11921 Slauson Ave. Santa Fe Springs, CA.
1 2 1A 4 PART NO.
PARTS BREAKDOWN 12 VDC POWER UNIT (GRAVITY DOWN) CAUTION Do not over-tighten the terminal nuts on starter solenoid. For the load terminals, torque nuts to 40 lbs.-in. max. Torque the nuts on #10-32 control terminals 15-20 lbs.-in. CAUTION 15 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 To prevent damage when installing 2-way valves, torque valve cartridge nut to 30 lbs.-in. max.
DESCRIPTION REF 1 282321-01 12 VDC POWER UNIT, GRAVITY DOWN 1 1 280374 12 VDC MOTOR 2 1 290002 3-PIECE GEAR PUMP 3 1 268029-01 SWITCH, SOLENOID (12 VDC) 4 1 290043 VALVE ASSEMBLY, 2-WAY 4A 1 290044 VALVE CARTRIDGE (2-WAY VALVE) 4B 1 290045 COIL, DOUBLE SPADE (2-WAY VALVE) 5 1 906737-01 CARTRIDGE RELIEF VALVE 6 1 906707-01 ELBOW, SAE #6, FACE SEAL O-RING, M-M 7 1 281438-01 RESERVOIR, VERTICAL (5 QUART) 8 1 280806-01 FILLER, BREATHER CAP 9 1 908016-01 RUBBER GRO
PARTS BREAKDOWN 12 VDC POWER UNIT (POWER DOWN) CAUTION Do not over-tighten the terminal nuts on starter solenoid. For the load terminals, torque nuts to 40 lbs.-in. max. Torque the nuts on #10-32 control terminals 15-20 lbs.-in. CAUTION 4 1 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 To prevent damage when installing 2-way valves, torque valve cartridge nut to 30 lbs.-in. max.
DESCRIPTION REF 1 282331-01 12 VDC POWER UNIT, POWER DOWN 1 1 268176-01 12 VDC MOTOR 2 1 268029-01 SWITCH, SOLENOID (12 VDC) 3 1 906821-01 VALVE ASSEMBLY, 2-WAY 3A 1 290045 COIL, DOUBLE SPADE (2-WAY VALVE) 3B 1 906822-01 VALVE CARTRIDGE (2-WAY VALVE) 4 1 280404 CABLE ASSEMBLY 5 1 290046 VALVE ASSEMBLY, 4-WAY 5A 1 290047 VALVE CARTRIDGE (4-WAY VALVE) 5B 1 290048 COIL, DOUBLE SPADE (4-WAY VALVE) 6 1 268079-01 WIRE ASSEMBLY, 18 GA, (#10 RING & 5/16 RING TERMINALS) 7
DECALS 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 WALK RAMP WARNING DECAL (WALK RAMP EQUIPPED VEHICLES ONLY) P/N 265441-01 WALK RAMP NOTICE DECAL (WALK RAMP EQUIPPED VEHICLES ONLY) P/N 266013-01 INSTRUCTION DECAL P/N 251867-09. CAPACITY DECAL (SEE TABLE 76-1) TABLE 76-1 WARNING DECAL P/N 264081 FIG.
CONTROL SWITCH DECAL P/N 264507 PAINT DECAL P/N 267338-01 CAUTION DECAL (FLIPOVER EQUIPPED WITH LATCH ONLY) P/N 267694-01 WARNING DECAL P/N 265736-02 FIG. 77-1 77 11921 Slauson Ave. Santa Fe Springs, CA.
PARTS BREAKDOWN NONSKID & SAFETY STRIPING NONSKID (LH) P/N 281204-01 NONSKID (RH) P/N 281204-02 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 SAFETY STRIPE TAPE (2 PLACES) P/N 096018-10 FIG.
NOTE: Use switch to RAISE and LOWER Liftgate to make sure switch operates as shown on the decal. NOTE: MAXON recommends using dielectric grease on all electrical connections. BLACK WHITE BLACK (FOR REFERENCESEE DECALS) WHITE GREEN 4 GREEN 3 RED (POWER DOWN VERSION ONLY) 2 FIG. 79-1 ITEM QTY. 1 1 2 1 3 PART NO. DESCRIPTION 268025-01 CABLE ASSEMBLY, 85” LG. (GRAVITY DOWN) 268170-01 CABLE ASSEMBLY, 85” LG.
SYSTEM DIAGRAMS PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) MOTOR 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 STARTER SOLENOID “A” VALVE GRAVITY DOWN POWER UNIT FIG.
MOTOR STARTER SOLENOID “A” VALVE “E” VALVE POWER DOWN POWER UNIT FIG. 81-1 POWER UNIT MOTOR & SOLENOID OPERATION LIFTGATE FUNCTION SOLENOID OPERATION ( MEANS ENERGIZED) PORT VALVE “A” MOTOR RAISE A LOWER B VALVE “E” - - - REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC TABLE 81-1 81 LOCK VALVE 11921 Slauson Ave. Santa Fe Springs, CA.
HYDRAULIC SCHEMATIC (GRAVITY DOWN) HYDRAULIC CYLINDERS 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 HYDRAULIC LOCK VALVE 4.5 GPM FLOW CONTROL VALVE PORT A - RAISE PORT B - RETURN (PLUGGED) VENT PORT FILL HOLE (PLUGGED) VALVE A RELIEF VALVE (SET AT 3250 PSI) CHECK VALVE AUX. HAND PUMP PORT (PLUGGED) PUMP M MOTOR (REF) FILTER RESERVOIR DRAIN HOLE (PLUGGED) FIG.
HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC LOCK VALVE 4.5 GPM FLOW CONTROL VALVE PORT B POWER DOWN PORT A - RAISE VALVE A FILTER RELIEF VALVE 2 (SET AT 1100 PSI) VALVE E RELIEF VALVE 1 (SET AT 3200 PSI) MOTOR (REF) PUMP FILTER RESERVOIR DRAIN HOLE (PLUGGED) FIG. 83-1 83 AUX. HAND PUMP PORT (PLUGGED) 11921 Slauson Ave. Santa Fe Springs, CA.
ELECTRICAL SCHEMATIC (GRAVITY DOWN) CONTROL SWITCH WHITE GREEN BLACK 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 WHITE GREEN BLACK CABLE ASSEMBLY WHITE WHITE SOLENOID, VALVE A THERMAL SWITCH SOLENOID, LOCK VALVE BLACK BLACK STARTER SOLENOID BLACK CABLE WITH 200 AMP FUSE MOTOR BATTERY FIG.
RED (DOWN) (UP) BLACK WHITE CONTROL SWITCH GREEN WHITE RED BLACK GREEN CABLE ASSEMBLY WHITE WHITE THERMAL SWITCH (IN MOTOR CASING) BLACK SOLENOID, VALVE A STARTER SOLENOID BLACK WHITE GREEN CABLE WITH 200 AMP FUSE BATTERY FIG. 85-1 85 SOLENOID, LOCK VALVE BLACK SOLENOID, VALVE E BLACK 11921 Slauson Ave. Santa Fe Springs, CA.
RECOMMENDED BOLT TORQUES CAUTION The torque values in the following table are provided for torquing grade 8 bolts on Liftgate mechanical parts. To prevent damage, never use the information in this table for torquing electrical or hydraulic hose connections on the pump assembly. 11921 Slauson Ave. Santa Fe Springs, CA.
11921 Slauson Ave. Santa Fe Springs, CA.
TROUBLESHOOTING PLATFORM WILL NOT RAISE & MOTOR WILL NOT RUN 1. Connect voltmeter between motor solenoid terminal “B” and ground wires connection on pump (FIG. 88-1). Verify that full battery voltage is at “B”. Recharge the battery if voltmeter indicates less than 12.6 volts dc. STARTER SOLENOID 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 TERMINAL “A” LOAD TERMINAL “C” GROUND (-) TERMINAL “D” SWITCHED BATTERY (+) TERMINAL “B” BATTERY (+) GRAVITY DOWN POWER UNIT FIG.
1. Do the CHECKING HYDRAULIC FLUID procedure in this manual. If necessary, add hydraulic fluid. ADJUSTMENT COVER 2. Check for structural damage and replace worn parts. CAUTION Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance. 3.
TROUBLESHOOTING PLATFORM RAISES BUT LEAKS DOWN 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Check if the “A” (lowering) solenoid valve is constantly energized. Connect voltmeter negative (-) lead to ground (-) wires connecSTARTER tion on pump and positive (+) lead SOLENOID to (+) terminal on the “A” (lowering) solenoid valve (FIG. 90-1). TERMINAL “A” If voltmeter reads battery voltage, LOAD check for faulty wiring or toggle TERMINAL “C” switch.
Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance. 2. Make sure platform is on the ground. Remove lowering solenoid valve (FIGS. 91-1 and 91-2). Push on the plunger in the valve by inserting small screwdriver in the open end (FIG. 91-3).
TROUBLESHOOTING PLATFORM RAISES PARTIALLY AND STOPS 1. Lower the opened platform to the ground. Do the CHECKING HYDRAULIC FLUID procedure in this manual. If necessary, add hydraulic fluid. ADJUSTMENT COVER 2. Use voltmeter to verify the battery voltage is 12.6 volts or more under load from pump motor. 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 3. Check for structural damage and poor lubrication. Replace worn parts.
6. Check pump oil filter in the reservoir (FIGS. 94-1 and 94-2). Clean or replace filter, if necessary. 93 LOWER PORT RAISE PORT FIG. 93-1 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 5. Check the hydraulic cylinder. With the platform at vehicle floor level, remove the hydraulic line from the LOWER port on the cylinder (FIG. 93-1). Hold the control switch in the “RAISE” position for two seconds while you watch for hydraulic fluid at the LOWER port.
TROUBLESHOOTING LIFTGATE WILL NOT LIFT RATED CAPACITY 1. Use voltmeter to verify the battery voltage is 12.6 volts or more under load from pump motor. 2. Check for structural damage or lack of lubrication. Replace worn parts. CAUTION 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 Keep dirt, water and other contaminants from entering the hydraulic system.
6. If pump cannot produce 3200 PSI or lift the load capacity with a minimum of 12.6 volts available, the pump is worn and needs to be replaced. LOWER PORT RAISE PORT FIG. 95-1 95 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 5. Check the hydraulic cylinder. With the platform at vehicle floor level, remove the hydraulic line from the LOWER port on the cylinder (FIG. 95-1).
TROUBLESHOOTING PLATFORM WILL NOT LOWER, LOWERS TOO SLOWLY, OR TOO QUICKLY 1. Connect voltmeter (+) lead to motor solenoid terminal “B” and the (-) lead to the ground wires connection on pump (FIG. 961). Verify that full battery voltage is at “B”. Recharge the battery if voltmeter indicates less than 12.6 volts dc. STARTER SOLENOID 11921 Slauson Ave. Santa Fe Springs, CA.
Keep dirt, water and other contaminants from entering the hydraulic system. Before opening the hydraulic fluid reservoir filler cap, drain plug and hydraulic lines, clean up contaminants that can get in the openings. Also, protect the openings from accidental contamination during maintenance. CAUTION FLOW CONTROL VALVE To prevent damage to flow control valve, do not disassemble the valve. 4. Make sure platform is on the ground. Check the flow control valve as follows. Remove flow control valve (FIG.
