Maxon GPTLR Series Installation Manual

M-18-14 JANUARY 2019 To fi nd maintenance & parts information for your GPTLR Liftgate, go to www. maxonlift.com. Click the PRODUCTS, TUK-A-WAY & GPTLR buttons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A-WAY & GPTLR buttons.

WARNINGS ........................................................................................................................... 4 SAFETY INSTRUCTIONS .................................................................................................... 5 NOTICE ................................................................................................................................. 5 GPTLR LIFTGATE COMPONENTS ...................................................................................... 6 GPTLR-SERIES INSTALLATION PARTS BOXES ................................................................ 7 GPTLR-SERIES MANUALS & DECALS ............................................................................... 8 VEHICLE REQUIREMENTS ................................................................................................. 9 CENTER OF MASS ............................................................................................................ 15 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE ....................................................... 16 BOLT EXTENSION PLATE.................................................................................................. 16 WELD EXTENSION PLATE (ALTERNATE METHOD) ........................................................ 19 STEP 2 - WELD LIFTGATE TO VEHICLE ......................................................................... 21 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) . 25 STEP 4 - RUN POWER CABLE .......................................................................................... 32 STEP 5 - CONNECT POWER CABLE ................................................................................ 34 STEP 6 - CONNECT GROUND CABLE ............................................................................. 36 STEP 7 - INSTALL CONTROL SWITCH ............................................................................. 38 STEP 8 - CHECKING HYDRAULIC FLUID ......................................................................... 40 STEP 9 - CONNECT POWER CABLE TO BATTERY ......................................................... 42 STEP 10 - REMOVE LOCKING BRACKETS & CHECK .......................................................... 43 FOR INTERFERENCE ........................................................................................................ 43 STEP 11 - ADJUST PLATFORM (IF REQUIRED) ............................................................... 48 STEP 12 - FINISH WELDING LIFTGATE TO VEHICLE ..................................................... 57 STEP 13 - WELD TRUCK BODY TO FRAME ..................................................................... 58 (TRUCKS ONLY) ................................................................................................................ 58

STEP 15 - ADJUST UNDERRIDE ...................................................................................... 62 STEP 16 - VEHICLE TAILLIGHT POSITIONING (IF REQUIRED) ...................................... 76 ATTACH DECALS ............................................................................................................... 77 DECALS & PLATES ........................................................................................................... 78 ATTACH NONSKID & SAFETY STRIPING ......................................................................... 79 TOUCHUP GALVANIZED FINISH ...................................................................................... 80 SYSTEM DIAGRAMS ......................................................................................................... 81 PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) ........................................ 81 PUMP & MOTOR SOLENOID OPERATION (POWER DOWN) .......................................... 82 HYDRAULIC SCHEMATIC (GRAVITY DOWN) ................................................................... 83 HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 84 ELECTRICAL SCHEMATIC (GRAVITY DOWN) ................................................................. 85 CABLE WITH ...................................................................................................................... 85 175 AMP FUSE ................................................................................................................... 85 ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 86 GPTLR ELECTRICAL VALUES & TORQUE SPECIFICATIONS ........................................ 87 OPTIONS ............................................................................................................................ 88 OPTIONAL LIFTGATE COMPONENTS .............................................................................. 88 PRE-DELIVERY INSPECTION FORM ................................................................................ 89

4 Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates. See Operation Manual for operating safety requirements. Installing and maintaining a liftgate can expose you to chemicals, including lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To mini- mize exposure, install and maintain liftgate in a well-ventilated area and wear proper Personal protective equipment (PPE). For more information go to www.P65Warnings.ca.gov. WARNING ! 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. • 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. • Correctly stow platform when not in use. Extended platforms could create a hazard for people and vehicles passing by. 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. ! • Recommended practices for welding galvanized steel are contained in the current AWS (Ameri- can 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.

5 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS • 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. • 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. • Do not allow untrained persons or children to operate the Liftgate. • 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. • 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. • 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.

6 GPTLR LIFTGATE COMPONENTS 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 (800) 227-4116 or Send e-mail to [email protected] GPTLR COMPONENTS FIG. 6-1 LIFTGATE ! 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. PARTS BOXES

7 GPTLR-SERIES INSTALLATION PARTS BOXES PARTS BOX B WITHOUT POWER CABLE, GROUND CABLE, OR FRAME CLIPS TABLE 7-2 ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER REF PARTS BOX B 1 297318-01 1 TOGGLE SWITCH ASSEMBLY 1 296855-01 2 INSTALLATION BRACKET 2 269462-01 3 HEX HEAD NUT, 1/2”-13 2 901011-9 4 SHIM, PLATFORM ADJUSTMENT, 1/8” 2 281166-02 5 SHIM, PLATFORM ADJUSTMENT, 1/16” 2 281166-01 6 SCREW, SELF TAPPING, #10-24 X 1-1/2” LG 2 900057-7 7 LUG, 2 GUAGE, COPPER, 5/16” 1 906497-02 8 CAP SCREW, HEX HEAD, 1/2”-13 X 1-1/2” LG. 2 900035-3 PARTS BOX A WITH POWER CABLE TABLE 7-1 PARTS BOX C WITH GROUND CABLE TABLE 7-3 ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER REF PARTS BOX C 1 297502-02 1 SPRING CLIP 20 050079 2 PLASTIC TIE 4 206864 3 GROMMET, 1” DIA, 2 HOLES 1 266428-09 4 CABLE ASSY, 175 AMP 38 FT LG 1 264422 5 GROUND CABLE ASSY, 2 GA X 38FT LG 1 269191-01 6 #10 LOOM CLAMP 2 801681 7 SELF-TAPPING SCREW, 10 X 1/2” LG. 2 030458 ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER REF PARTS BOX A 1 297502-01 1 SPRING CLIP 10 050079 2 PLASTIC TIE 2 206864 3 #10 LOOM CLAMP 2 801681 4 SCREW TAPPING #10 X 1/2” LG. 2 030458 5 GROUND CABLE ASSEMBLY, 2GA, 48” LG 1 251871-26 6 CABLE ASSEMBLY, 2GA, 49-3/4” LG. (GROUND) 1 268226-11 7 CAP SCREW, 5/16”-18 X 3/4” LG 1 900009-3 8 CABLE ASSEMBLY, 175A, 38 FT LG. 1 264422

8 GPTLR-SERIES MANUALS & DECALS ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER REF DECAL & MANUAL KIT 1 299460-01 (GPTLR-25) 299460-02 (GPTLR-33) 299460-06 (GPTLR-25, SWG EXT) 299460-05 (GPTLR-33, SWG EXT) 299459-01 (GPTLR-44) 299459-02 (GPTLR-55) 1 INSTALLATION MANUAL 1 M-18-14 2 OPERATION MANUAL 1 M-18-15 3 DECALS (SEE DECAL PAGES IN THIS MANUAL) 1 (ALL GPTLR’S) TABLE 8-1 NOTE: To fi nd maintenance & parts information for your GPTLR Liftgate, go to www.maxonlift.com. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A- WAY & GPTLR buttons.

9 1. Check for correct clearances (FIGS. 9-1 and 9-2) on vehicle to prevent interference between vehicle and Liftgate. Refer to FIGS. 10-1, 11-1, and 11-2 for additional clearances and dimensions. GPTLR-25 & -33 LIFTGATE CLEARANCE DIMENSIONS (FOR REFERENCE) FIG. 9-1 36” GPTLR-44 & -55 LIFTGATE CLEARANCE DIMENSIONS (FOR REFERENCE) FIG. 9-2 VEHICLE REQUIREMENTS NOTE: • BODY maximum and minimum operating bed height for GPTLR-25, GPTLR-33, GPTLR-44, & GPTLR-55 with standard platform: Maximum height is 55” (Unloaded). Minimum height is 44” (Loaded). If Liftgate is equipped with Canadian (CMVSS) underride, minimum height is 49”. Refer to Canadian underrides listed in OPTIONS, and underride adjustment procedure. • Make sure vehicle is parked on level ground while preparing vehicle and installing Liftgate. • On vehicle bodies equipped with swing open doors, the extension plate and vehicle body must be modifi ed to install this Liftgate. • Dimensions are provided as reference for fi tting Liftgate to vehicle body. 55” MAX. BED HEIGHT (UNLOADED) 44” MIN. BED HEIGHT (LOADED) 21-3/8” MAX. 10-3/8” MIN. 25-3/8” 23-1/4” 55” MAX. BED HEIGHT (UNLOADED) 44” MIN. BED HEIGHT (LOADED) 38” 21-3/4” MAX. 10-3/4” MIN. 24-1/2” 26-3/4” 14” 33-3/4” 36” 14”

10 VEHICLE REQUIREMENTS - Continued VEHICLE BODY CORNER POST CLEARANCE (FOR REFERENCE) FIG. 10-1 BODY FLOOR (REFERENCE) 5-5/8” (GPTLR-44/-55) 6-1/8” (GPTLR-25/-33) LIFT ARM BODY CORNER POST

11 VEHICLE REQUIREMENTS - Continued GPTLR EXTENSION PLATE DIMENSIONS FOR 102” WIDE BODY FIG. 11-2 102” 85” 1/2” 1/2” GPTLR EXTENSION PLATE DIMENSIONS FOR 96” WIDE BODY FIG. 11-1 96” 79” 4-7/16” (GPTLR-25 & -33) 5-7/16” (GPTLR-44 & -55) 1/2” 1/2” 4-7/16” (GPTLR-25 & -33) 5-7/16” (GPTLR-44 & -55)

12 VEHICLE REQUIREMENTS - Continued VEHICLE FRAME CUT FOR GPTLR-25 & GPTLR-33 FIG. 12-1 5” 12” 24” TRUCK FRAME BODY FLOOR BODY CROSS MEMBERS REAR SILL PLATFORM CLEARANCE CUTOUT AREA (WITHIN DASHED LINES) WOODEN SPACER LONG SILL 2. Fit the Liftgate to vehicle body by cut- ting vehicle frame as shown in FIGS. 12-1 or 13-1. NOTE: The platform cutout area shown below applies to trucks and trailers. Typical truck frame is shown. For installation on frameless trailers, kit must be select- ed from the OPTIONAL COMPONENTS section in this manual. NOTE: For Liftgates installed on trailers, refer to FIG. 14-1 for lift arm and platform clearances on the rear sill. If necessary, remove the interfering portions of the rear sill according to dimensions shown in FIG. 14-1 . • To prevent aluminum platform from being damaged, make sure vehicle frame is cut correctly and rear sills are modifi ed if over 5” in height. If the cutouts are incorrect, platform may hit vehicle frame or underbody when stowing the Liftgate. The bottom of the platform may also hit the sill. CAUTION • Installer is responsible for ensuring that vehicle body and frame modifi cations do not adversely affect the integrity of the body and frame. NOTE: The dimensions, shown in the illustration below, are maximums except as indicated. NOTE: Refer to the platform clearance cutout area in FIGS. 12-1 and 13-1. Remove any part of the rear sill that protrudes into this area.

13 VEHICLE FRAME CUT FOR GPTLR-44 & GPTLR-55 FIG. 13-1 VEHICLE REQUIREMENTS - Continued 5-1/2” 13” 24” TRUCK FRAME BODY FLOOR BODY CROSS MEMBERS REAR SILL WOODEN SPACER LONG SILL PLATFORM CLEARANCE CUTOUT AREA (WITHIN DASHED LINES)

14 3. If necessary, cut trailer rear sill as shown in FIG. 14-1. VEHICLE REQUIREMENTS - Continued REAR SILL CUTS FOR ALL GPTLR LIFTGATES FIG. 14-1

15 CENTER OF MASS GPTLR-25 & GPTLR-33 CENTER OF MASS (STOWED POSITION) FIG. 15-1 12-3/4” CENTER OF MASS 8-1/2” GPTLR-44 & GPTLR-55 CENTER OF MASS (STOWED POSITION) FIG. 15-2 CENTER OF MASS 12-1/2” 8-1/2”

16 STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE 1. Mark and drill holes into rear sill as shown in FIGS. 16-1 and 17-1. REAR SILL - HOLE LOCATIONS FOR 96” WIDE VEHICLE FIG. 16-1 USE 9/16” DRILL (19 PLACES) 1-1/4” 3-1/8” REAR SILL 1-1/2” 19” 24” 14” 34” 41” 48” 55” 62” 72” 77” 82” 94-1/2” 96” BOLT EXTENSION PLATE NOTE: 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 recom- mends 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 weld- ing instructions for the extension plate. CAUTION To preserve the corrosion-resistant properties of the galvanized fi nish, MAXON recommends bolting the galvanized extension plate to vehicle. CAUTION 6-1/2” 6-1/2” 1-1/2” 1-1/4”

17 REAR SILL - HOLE LOCATIONS FOR 102” WIDE VEHICLE FIG. 17-1 1-1/4” 1-1/2” 27” 37” 44” 51” 58” 65” 75” 80” 85” 95-1/2” 100-1/2” 102” 22” 17” STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued REAR SILL USE 9/16” DRILL (19 PLACES) 6-1/2” 6-1/2” 3-1/8”

18 2. Bolt extension plate to vehicle as shown in FIG. 18-1. 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. 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. STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued 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. CAUTION NOTE: Weld the LH and RH ends of the extension plate to vehicle body as shown in FIG. 18-1 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 BOLTING EXTENSION PLATE (96” WIDE EXTENSION PLATE SHOWN) FIG. 18-1 BOLTS (KIT ITEMS) EXTENSION PLATE VEHICLE BODY TEARDROP LOCK NUTS (KIT ITEMS) 3/16” 3/16” WRAP WELD HORIZONTAL 2” MIN/6” MAX WRAP WELD HORIZONTAL 2” MIN/ 6” MAX

19 WELD EXTENSION PLATE (ALTERNATE METHOD) STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued 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. 19-1 and 20-1. EXTENSION PLATE WELDS - VIEWED FROM ABOVE FIG. 19-1 3/16” 3/16” EXTENSION PLATE VEHICLE BODY 3/16” WELD LENGTH & SPACE: 2”- 11 3/4” ( 96”W VEHICLE) 2”- 12 1/2” (102”W VEHICLE) To preserve the corrosion-resistant properties of the galvanized fi nish, MAX- ON recommends bolting the galvanized extension plate to vehicle. CAUTION NOTE: For welding galvanized steel, refer to recommended practices as outlined in AWS (American Welding Society) D19.0 Welding Zinc-Coated Steel.

20 EXTENSION PLATE BRACKET (2 PLACES) BOLTING ON INSTALLATION BRACKETS FIG. 20-2 CAP SCREW 1/2”-13 X 1-1/2” LG. (2 PLACES) HEX NUT 1/2”-13 (2 PLACES) 2. Bolt 2 installation brackets (parts bag items) on the extension plate as shown in FIG. 20-2. Tighten hex nuts securely. EXTENSION PLATE WELDS - VIEWED FROM UNDERNEATH FIG. 20-1 3/16” EXTENSION PLATE VEHICLE BODY WELD LENGTH & SPACE: 2”- 11 3/4” ( 96”W VEHICLE) 2”- 12 1/2” (102”W VEHICLE) NOTE: During installation of liftgate, installation brackets keep the heel of the platform 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. STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE - Continued

21 BOLT ON MOUNTING PLATES FOR INSTALLATION ON TRUCKS & TRAILERS (REAR VIEW OF LIFTGATE) FIG. 21-1 NOTE: GPTLR 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. RH PLATE LH PLATE STEP 2 - WELD LIFTGATE TO VEHICLE “D” INSIDE “D” OUTSIDE If it’s necessary to unbolt mounting plates from main frame (FIG 21-1), torque mounting plate nuts and bolts 220-240 lb-ft (GPTLR-25/GPTLR-33) or 350-375 lb-ft (GPTLR-44/GPTLR-55). BOLT & LOCK NUT (6 PLACES) BOLT & LOCK NUT (6 PLACES) TABLE 21-1 LIFTGATE MODEL “D” INSIDE “D” OUTSIDE APPLICATION GPTLR-25/GPTLR-33 34-1/4” 35-1/4” Common truck chassis width 32-3/4” 33-3/4” Trailer applications 34-13/16” 35-13/16” Trailer applications (91 cm) TABLE 21-2 LIFTGATE MODEL “D” INSIDE “D” OUTSIDE APPLICATION GPTLR-44/GPTLR-55 34-1/4” 35-1/4” Common truck chassis width 33-1/4” 34-1/4” Trailer applications 34” 35” 34-13/16” 35-13/16” Trailer applications (91 cm) 37-1/4” 38-1/4” Trailer applications MAIN FRAME

22 1. Unfold the platform and fl ipover (FIG. 22-1). PLATFORM & FLIPOVER UNFOLDED FIG. 22-1 FLIPOVER PLATFORM MOUNTING PLATES 2. Unbolt opener from mounting bracket (shipping position) and save to reinstall (FIG. 22-1). OPENER STEP 2 - WELD LIFTGATE TO VEHICLE - Continued OPENER MOUNTING BRACKET

23 To prevent damage to aluminum fl ipover, NEVER hoist the Liftgate by the fl ipover as illustrated below. Hoist the Liftgate by the platform only as shown in the illustration below. CAUTION 4. Hoist the Liftgate (FIG. 23-1). Then, place fl oor jack under center of main frame (FIG. 23-1). Jack the Liftgate into position. Make sure vehicle fl oor is hori- zontal. Maintain distance between fl oor and top of main frame as shown in FIG. 23-1. ! STEP 2 - WELD LIFTGATE TO VEHICLE - Continued 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”. Nev- er apply force at the ends of the main frame tube to change the fl oor clearance. CAUTION FLOOR JACK (CENTERED ON MAIN FRAME TUBE) HOIST CHAIN MAIN FRAME VEHICLE FLOOR (HORIZONTAL) MOUNTING PLATE FLIPOVER PLATFORM C-CLAMP (2 PLACES) * TOLERANCE IS +/- 1/4” CCORRECT WAY TO HOIST LIFTGATE FIG. 23-1 INCORRECT * 23-1/4” (GPTLR-25/-33) * 24-1/2” (GPTLR-44/-54) 3. Make sure hoist is not set up the incorrect way (FIG. 23-1). Place a “C” clamp on each side of platform (FIG. 23-1) to prevent hoist chain from slipping off platform. Wrap chain around plat- form (FIG. 23-1).

24 STEP 2 - WELD LIFTGATE TO VEHICLE - Continued 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. 24-1. VEHICLE FRAME CUTOUT (TYPICAL TRUCK FRAME SHOWN) MOUNTING PLATE BED LEVEL WELD TO VEHICLE FRAME AND MAIN FRAME (RH SIDE SHOWN) FIG. 24-1 2” LG. 4 PLACES (TYPICAL - RH & LH MOUNTING PLATES) 5/16” 6. Weld the mounting plates to vehicle frame as shown in FIG. 24-1. Remove clamps. * TOLERANCE IS +/- 1/4” 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 MAIN FRAME 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. * 23-1/4” (GPTLR-25/-33) * 24-1/2” (GPTLR-44/-54)

25 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) 1. Liftgate and optional battery box are typically installed on trailers as shown in FIG. 25-1 and on trucks as shown in FIG. 25-2. See the fol- lowing page for battery and cable connections. LIFTGATE OPTIONAL BATTERY BOX, TYPICAL LOCATION RECOMMENDED LIFTGATE & OPTIONAL BATTERY BOX INSTALLATION ON TRAILER FIG. 25-1 150 AMP CIRCUIT BREAKER 175 AMP FUSED CABLE TRACTOR BATTERIES, TYPICAL LOCATION LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE & BATTERY BOX INSTALLATION ON TRUCK FIG. 25-2 150 AMP CIRCUIT BREAKER 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. LIFTGATE POWER UNIT 175 AMP FUSED CABLE 175 AMP FUSED CABLE TRUCK BATTERIES, TYPICAL LOCATION OPTIONAL BATTERY BOX, TYPICAL LOCATION 150 AMP CIRCUIT BREAKER

26 CROSS MEMBER CAP SCREW WASHER WASHER LOCK NUT TRAILER BODY CROSS MEMBER TRUCK BODY CROSS MEMBER MOUNTING BRACKETS BATTERY BOX FRAME BATTERY BOX FRAME BATTERY BOX FRAME MOUNTING BRACKETS MOUNTING BRACKETS BOLTING BRACKETS (8 PLACES) FIG. 26-1C FLUSH BRACKETS FOR TRAILERS (8 PLACES) FIG. 26-1B FLUSH BRACKETS FOR TRUCKS (8 PLACES) FIG. 26-2 ALIGNING BATTERY BOX FRAME (TRAILER SHOWN) FIG. 26-1A 2. Select holes on top of battery box frame to align mounting brackets fl ush to cross members. Refer to FIGS. 26-1A & 26-1B for trail- ers and FIG. 26-2 for trucks. Bolt mounting brackets to battery box frame as shown in FIG. 26-1C. Torque each bolt and lock nut to 85-128 lb-ft. STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued

27 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued 3. Using mounting brackets as a tem- plate mark and drill holes through cross members (FIG. 27-1). Bolt mounting brackets to cross mem- bers as shown in FIGS. 27-2A and 27-2B. Torque bolts and lock nuts to 85-128 lb-ft. NOTE: If welding mounting brackets to cross members, skip instruction 3. CROSS MEMBER CROSS MEMBERS MOUNTING BRACKETS 1/2” HOLES BOLTING BATTERY BOX FRAME FIG. 27-2A BOLTING BRACKETS (8 PLACES) FIG. 27-2B CROSS MEMBER CAP SCREWS (2 PLACES) WASHERS (4 PLACES) LOCK NUTS (2 PLACES) MOUNTING BRACKETS MARK AND DRILL BRACKET HOLES FIG. 27-1

28 Cover pump box and optional battery box with fl ame-resistant covering before welding pump box frame to vehicle. CAUTION To prevent pump box components from being damaged by electric current from welding, connect welder grounding cable to the part being welded. CAUTION BOLTING PUMP & BATTERY BOX FRAME FIG. 28-1A CROSS MEMBERS CROSS MEMBERS BRACKET WELDING BRACKETS (8 PLACES) FIG. 28-1B 3/16” 3/16” 3/16” IF ACCESSIBLE STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued Recommended practices for welding on steel parts are contained in the cur- rent AWS (American Welding Society) D1.1 Structural Welding Code - Steel. Damage to Liftgate and/or vehicle, and personal injury can result from welds that are done incorrectly. WARNING ! 4. Weld each bracket to cross members as shown in FIGS. 28-1A and 28-1B. Weld top of bracket if accessible.

29 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued 5. Connect battery cables, fused cables, and ground cables for 12 volt power as shown in FIG. 29-1. Refer to FIG. 29-1 for connecting 24 volt power. 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. FUSED CABLE (SEE NOTE) FUSED CABLE TO PUMP BOX (IN PARTS BOX) 8” LG. RED CABLE GROUND CABLE TO PUMP BOX OR COMMON CHASSIS GROUND, 74” LG. (BATTERY BOX KIT ITEM) 12 VOLT BATTERY CONNECTIONS FOR 12 VOLT POWER FIG. 29-1 Remove all rings, watches and jewelry before doing any electrical work. WARNING ! 150 AMP CIRCUIT BREAKER (-) BATTERY CABLE TO COMMON GROUND 8” LG. BLACK CABLE 12” LG. RED CABLE

30 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. WARNING ! BATTERY BOX ASSEMBLY (REAR VIEW SHOWN) FIG. 30-1 VENTILATION HOLES STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued

31 STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) - Continued BATTERY BOX ASSEMBLY FIG. 31-1 BATTERY PLATE BATTERY STRAP LOCK NUT, 1/4”-20 (2 PLACES) HEX NUT 1/2”-20 (4 PLACES) LOCK WASHER 9/16” (4 PLACES) FLAT WASHER 9/16” (4 PLACES) J-BOLT ANCHOR (PART OF BATTERY PLATE) FLAT WASHER 1/4” (4 PLACES) PAN HEAD SCREW 1/4”-20 X 1” LG. (2 PLACES) CAP SCREW 1/2”-20 X 2 1/4” LG. GR8 (4 PLACES) J-BOLT BATTERY TIE DOWN 175 AMP FUSED CABLE TO PUMP BOX GROUND CABLE TO PUMP BOX CHARGE LINE FROM VEHICLE BATTERY 150 AMP CIRCUIT BREAKER FLAT WASHER 5/16” (3 PLACES) HEX NUT 5/16”-18, GR8 (3 PLACES)

32 STEP 4 - RUN POWER CABLE 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 RECOMMENDED LIFTGATE & POWER CABLE INSTALLATION ON TRAILER FIG. 32-1 175 AMP FUSED CABLE TRACTOR BATTERIES, TYPICAL LOCATION LIFTGATE LIFTGATE POWER UNIT RECOMMENDED LIFTGATE & POWER CABLE INSTALLATION ON TRUCK FIG. 32-2 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. LIFTGATE POWER UNIT 175 AMP FUSED CABLE TRUCK BATTERIES, TYPICAL LOCATION 175 AMP FUSED CABLE RECOMMENDED CONFIGURATION

33 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. FIG. 33-1 Never route an energized wire. Make sure the vehicle battery is disconnected. Always route electrical wires clear of moving parts, brake lines, sharp edges and exhaust systems. Avoid making sharp 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. CAUTION 175 AMP FUSE SHORTEST CABLE END TERMINAL LUG (TO VEHICLE BATTERY) VEHICLE FRAME (TRUCK FRAME SHOWN) 18” - 24” SPACING CHARGE LINE (TO PUMP BOX) CABLE CLIPS ! FRONT OF VEHICLE REAR OF VEHICLE STEP 4 - RUN POWER CABLE - Continued

34 1. Unbolt and remove pump cover as shown in FIG. 34-1. STEP 5 - CONNECT POWER CABLE UNBOLTING PUMP COVER FIG. 34-1 CAP SCREW, 5/16”-18 (2 PLACES) HOLDER FLAT (2 PLACES) FLAT WASHER, 5/16” (2 PLACES) NYLON NUT, 5/16”-18 (2 PLACES) PUMP COVER POWER UNIT (REF)

35 STEP 5 - CONNECT POWER CABLE - Continued TYPICAL FUSED POWER CABLE CONNECTION (GRAVITY DOWN PUMP SHOWN) FIG. 35-3 3. On the bare wire end of fused power cable, keep enough length to attach copper terminal lug and reach starter solenoid without putting tension on cable (after connection) (FIG. 35-1). Measure (if needed) and then cut excess cable from bare wire end of cable. Put heat shrink tubing (parts box) (FIG. 35-1) on the end of the cable (leave room for terminal lug). Crimp copper terminal lug (from parts box) on the fused power cable and shrink the heat shrink tubing (FIG. 35-2). PLACING TERMINAL LUG & HEAT SHRINK TUBING ON FUSED POWER CABLE FIG. 35-1 TYPICAL FUSED POWER CABLE WITH TERMINAL LUG INSTALLED FIG. 35-2 4. Remove hex nut and lock wash- er from battery terminal post on the starter solenoid. Connect the fused power cable to the starter solenoid as shown in FIG. 35-3. Reinstall and tighten lock washer and hex nut. Torque hex nut to 35 lb-in maximum. NOTE: Electrical lines must be run into pump box through sealing grom- mets (FIG. 35-3). To ensure a good seal on hydraulic & electrical lines, never cut the sealing grommets. 2. Run fused power cable through grom- met on pump mounting plate (FIG. 35-3). BATTERY TERMINAL POST FUSED POWER CABLE STARTER SOLENOID LOCK WASHER HEX NUT GROMMET PUMP MOUNTING PLATE COPPER TERMINAL LUG FUSED POWER CABLE (BARE WIRE END) HEAT SHRINK TUBING (P/N 253316-04) Do not over-tighten the terminal nuts on starter solenoid. For the load terminals, torque nuts to 35 lb.-in. max. Torque the nuts on #10- 32 control terminals 15 lb-in max. CAUTION COPPER TERMINAL LUG DRIP LOOP

36 STEP 6 - CONNECT GROUND CABLE CONNECTING EXTERNAL GROUND CABLE FIG. 36-1 INSERTING GROUND CABLE THROUGH GROMMET FIG. 36-1A BOLTING GROUND CABLE TO PUMP FIG. 36-1B NOTE: To ensure power unit is correctly grounded, connect 2 gauge ground cable to grounding connection on pump. 1. Insert external ground cable (parts box) through grommet on pump mounting plate (FIGS. 36-1 & 36-1A). 2. Bolt ground cable to ground connection on pump using existing bolt (FIGS. 36-1 & 36-1B). 3. Form a drip loop on the ground cable where it enters the grommet from outside the pump mounting plate (FIGS. 36-1 & 36-1B). TERMINAL LUG TERMINAL LUG (EXTERNAL GROUND (EXTERNAL GROUND CABLE) CABLE) GROUND GROUND CABLE CABLE GROMMET GROMMET PUMP MOUNTING PUMP MOUNTING PLATE PLATE NOTE: Electrical lines must be run into pump box through sealing grommets (FIG. 36-1A). To ensure a good seal on the electrical lines, never cut the sealing grommets. GROUND GROUND CONNECTION CONNECTION BOLT BOLT DRIP LOOP DRIP LOOP

37 STEP 6 - CONNECT GROUND CABLE - Continued NOTE: If there is a grounding point on the frame, use it to connect ground cable. Then, skip the step for drilling a hole. 4. Extend the ground cable to reach vehicle frame (FIG. 37-1) without putting tension on cable (after con- nection). Connect to an existing grounding point if available. 7. Bolt the ground cable terminal lug to vehicle frame as shown in FIG. 37-1. NOTE: Clean the ground cable connection point on the frame down to bare metal. 5. If necessary, drill a 11/32” (0.343”) hole in vehicle frame for bolting the ground cable terminal lug (FIG. 37-1). FIG. 37-1 TERMINAL LUG (GROUND CABLE) 5/16"-18 X 1" LG CAP SCREW 5/16” FLAT WASHER 5/16”-18 LOCK NUT VEHICLE CHASSIS (TRUCK FRAME SHOWN) BARE METAL 6. To prevent corrosion, paint or use galvanized spray on bare metal area FIG. 37-1.

38 STEP 7 - INSTALL CONTROL SWITCH 1. Measure, mark and drill one 3/4“ hole and two #21–size holes in the vertical post on curb side of vehicle body as shown in FIG. 38-1. DRILLING MOUNTING HOLES FIG. 38-1 VEHICLE BODY VERTICAL POST (CURB SIDE) 3/4” HOLE VEHICLE BODY VERTICAL POST 2. Insert control switch wir- ing harness (parts box) into 3/4” hole on corner post and down the vertical post and under the vehicle body to the pump assembly. (See dashed line - FIG. 38-2.) CONTROL SWITCH SELF-TAPPING SCREW (2 PLACES) ROUTING CONTROL SWITCH WIRING FIG. 38-2 3. Push control switch and cable back into the 3/4” hole in the vertical post until con- trol switch touches the post (FIG. 38-2). Attach control switch to vertical post with 2 self-tapping screws (parts box) (FIG. 38-2). 4. If necessary, use clamps and self-tapping screws (parts box) to secure switch cable to vehicle under-body and frame (FIG. 38-2).

39 STEP 7 - INSTALL CONTROL SWITCH - Continued CONTROL SWITCH WIRING CONNECTIONS (GRAVITY DOWN) FIG. 39-1 CONTROL SWITCH JUNCTION BLOCK TERMINAL 1 GREEN WIRE WHITE WIRE BLACK WIRE STARTER SOLENOID FUSE HOLDER ASSEMBLY NOTE: Electrical lines must be run into pump box through sealing grommets (FIGS. 39-1 & 39-2). To ensure a good seal on the electrical lines, never cut the sealing grommets. 5. Insert switch wiring through grom- met on pump mounting plate (FIGS. 39-1 & 39-2). Connect the switch wiring to the pump assembly as shown in FIGS. 39-1 & 39-2. GROMMET WIRING HARNESS CONTROL SWITCH WIRING CONNECTIONS (POWER DOWN) FIG. 39-2 POWER DOWN MODULE CONTROL SWITCH WIRING HARNESS GROMMET FUSE HOLDER ASSEMBLY STARTER SOLENOID GREEN WIRE BLACK WIRE WHITE WIRE DRIP LOOP DRIP LOOP

40 STEP 8 - CHECKING HYDRAULIC FLUID 1. Unbolt and remove pump cover (FIG. 40-1). UNBOLTING PUMP COVER FIG. 40-1 3. If needed, add fl uid to the reservoir as fol- lows. Pull out (no threads) fi ller cap (FIG. 40-2). Fill the reservoir with hydraulic fl uid to level shown in FIG. 40-2. Reinstall fi ller cap (FIG. 40-2). POWER UNIT FLUID LEVEL FIG. 40-2 2. 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. 40-2. CAUTION Pump cover must be correctly secured to prevent it from be- coming a hazard. To secure pump cover, the long side of the holder fl ats must butt against pump cov- er as shown in the illustration. 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. +50 to +120 Degrees F - Grade ISO 32 Below + 70 Degrees F - Grade ISO 15 or MIL-H-5606 NOTE: Liftgate is shipped with ISO 32 oil. Use correct oil for climate conditions. See TABLES 40-1 & 40-2 for recommended brands of ISO 32 & ISO 15 oils. 4. Bolt on the pump cover as shown in FIG. 40-1. Torque the bolts (cap screws) to 10-14 lb-ft. CAP SCREW, 5/16”-18 (2 PLACES) HOLDER FLAT (2 PLACES) FLAT WASHER, 5/16” (2 PLACES) NYLON NUT, 5/16”-18 (2 PLACES) PUMP COVER POWER UNIT (REF) FILLER CAP RESERVOIR 3” +/- 1/2” (PD) 2” +/- 1/2” (GD)

41 STEP 8 - CHECKING HYDRAULIC FLUID - Continued TABLE 41-1 ISO 32 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER CHEVRON HIPERSYN 32 KENDALL GOLDEN MV SHELL TELLUS S2 VX 32 EXXONMOBIL UNIVIS N-32, DTE-24 ISO 15 OR MIL-H-5606 HYDRAULIC OIL RECOMMENDED BRANDS PART NUMBER CHEVRON FLUID A, AW-MV-15 KENDALL GLACIAL BLU SHELL TELLUS S2 VX 15 EXXONMOBIL UNIVIS HVI-13 ROSEMEAD THS FLUID 17111 TABLE 41-2

42 STEP 9 - CONNECT POWER CABLE TO BATTERY 1. Remove nut from negative (-) battery terminal (FIG. 42-1). Dis- connect negative (-) battery cable (FIG. 42-1). RECONNECTED BATTERY CABLES FIG. 42-3 2. Remove nut from positive (+) battery terminal (FIG. 42-1). 3. Connect fused positive (+) cable to positive (+) battery terminal (FIG. 42-2). Then, reinstall nut on positive (+) battery terminal (FIG. 42-2). 4. Reconnect negative (-) battery cable to negative (-) battery ter- minal (FIG. 42-3). Then, reinstall nut on negative (-) battery termi- nal (FIG. 42-3). CONNECTING FUSED (+) CABLE FIG. 42-2 POSITIVE (+) BATTERY TERMINAL FUSED (+) CABLE NEGATIVE (-) BATTERY CABLE NEGATIVE (-) BATTERY TERMINAL NUT NUT DISCONNECTING (-) BATTERY CABLE FIG. 42-1 NEGATIVE (-) BATTERY TERMINAL NEGATIVE (-) BATTERY CABLE POSITIVE (+) BATTERY TERMINAL POSITIVE (+) BATTERY CABLE NUT NUT

43 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE 1. Remove fl oor jack and hoist supporting Liftgate (FIG. 43-1). REMOVING JACK FIG. 43-1 FLOOR JACK 2. Lower platform to ground level (FIG. 43-2). Refer to operating in- structions in Operation Manual. LOWERING PLATFORM FIG. 43-2

44 REMOVING LOCKING BRACKETS FIG. 44-1 3. Unbolt the locking brackets from both cylinders (FIG. 44-1). To prevent damage to Liftgate, the locking bracket on each cylinder must be removed before operating Liftgate. CAUTION LOCKING BRACKET CAP NUT FLAT WASHER BOLT LH CYLINDER RH CYLINDER LOCKING BRACKET (2 PLACES) STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued

45 FIG. 45-1 LIFT ARM EXTENSION PLATE STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued 4. Raise the platform (FIG. 45-1). Look for any interference between liftgate and vehicle as platform is raised. 5. Lower platform to the ground (FIG. 45-2). Look for any interference between 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 escap- ing into the hydraulic fl uid reservoir. Then, raise the platform (FIG. 45-3). Look for any interference between liftgate and vehicle as platform is raised. Repeat step until there is no air left in the system and platform lowers smoothly (FIG. 45-3). LOWERING PLATFORM FIG. 45-2 RAISING PLATFORM FIG. 45-3

46 6. Lower platform to the ground (FIG. 46-1). REMOVING INSTALLATION BRACKETS FIG. 46-2 7. Unbolt the 2 installation brackets from extension plate (FIG. 46-2). EXTENSION PLATE LOWERING PLATFORM FIG. 46-1 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued BRACKET & NUT (2 PLACES) BOLT (2 PLACES)

47 STEP 10 - REMOVE LOCKING BRACKETS & CHECK FOR INTERFERENCE - Continued 8. Raise the platform to vehicle fl oor level (FIG. 47-1). Refer to operating instruc- tions in Operation Manual. Check for 5/8” gap between platform and edge of extension plate (FIG. 47-1). PLATFORM EXTENSION PLATE NOTE: Correct any fi t and interference problems before continuing with installation. CHECKING GAP BETWEEN PLATFORM AND EXTENSION PLATE FIG. 47-1 5/8” +/- 1/8” 5/8” +/- 1/8”

48 STEP 11 - ADJUST PLATFORM (IF REQUIRED) 1. RAISE platform to bed height. Check the platform as follows. Inboard edge on top of platform must be no more than 1/4” from diamond plate surface on top of extension plate (FIGS. 48-1A & 48-1B). The maximum allowable horizontal gap between inboard edge of platform and adjacent edge of exten- sion plate is 5/8” +/- 1/8” (FIGS. 48-1A & 48-1C). LOWER platform to ground level. Shackles and tip of fl ipover should touch the ground at the same time (FIG. 48-2). Tip of fl ipover must not be higher than 1/4” above the ground. If all indica- tions are correct (FIGS. 48-1A, 48-1B, 48-1C, & 48-2), Liftgate is installed correctly and no adjustment is needed. If the tip of fl ipover is too high above the ground, if shackles are off the ground, or if there is too much gap between platform and extension plate, continue doing this procedure. PLATFORM & SHACKLES TOUCH GROUND FIG. 48-2 NOTE: In most cases, if Liftgate is installed according to the instructions in this manual, platform will not require adjustment. Use the following instruc- tions to check the platform. Adjust the platform only if required. NOTE: Before doing the following procedure, make sure vehicle is still parked on level ground. TIP OF FLIPOVER 1/4” (MAX.) NOTE: If the shackles do not touch the ground (see FIG. 49-1), do instruction 2. If the tip of the fl ipover is more than 1/4” above the ground (see FIG. 48-2), skip instructions 2 - 5 and do instruction 6. If there is too much vertical space (FIG. 48-1B) or horizontal space (FIG. 48-1C) between platform and exten- sion plate, start with instruction 7 to remove and reinstall Liftgate. HORIZONTAL GAP FIG. 48-1C PLATFORM AT BED LEVEL FIG. 48-1A 5/8”+/- 1/8” VERTICAL GAP FIG. 48-1B PLATFORM EXTENSION PLATE PLATFORM EXTENSION PLATE 1/4” MAX.

49 TABLE 49-1 2. Make sure platform is still at ground level. If the shack- les are not touching the ground, measure and com- pare distance “A” (FIG. 49-1) with TABLE 49-1 to determine the correct shim. RAISE TIP OF FLIPOVER THIS DISTANCE “A” REQUIRED SHIM THICKNESS WELD SIZE “W” 1” 1/16” 1/32” 2” 1/8” 1/16” STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued SHACKLES DO NOT TOUCH GROUND FIG. 49-1 FIG. 49-2A 3. Fold the fl ipover and platform. Then, raise the platform to position shown in FIG. 49-2A. 4. Use TABLE 49-1 to select the correct size shim from the parts box. Weld shim to pin as shown in FIG. 49-2B. FIG. 49-2B PIN SHIM (TABLE 49-1) “W” (TABLE 49-1) SHACKLE “A” (TABLE 49-1) 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 to one of the parts being welded, as close to the weld as pos- sible. Failure to comply could result in damage to cylinders and electrical parts.

50 NOTE: For an aluminum platform & fl ipover equipped with retention ramp, 2” of ground clearance is acceptable at the tip of fl ipover. STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 5. Lower platform to the ground. Unfold platform and fl ipover. RAISE the platform to bed height, then LOWER it to the ground. The tip of fl ipover and shackle should touch the ground as shown in FIG. 50-1. Tip of fl ipover must not be higher than 1/4” above the ground. 6. If the tip of fl ipover is more than 1/4” above the ground (FIG. 50-2), note the distance “B” above ground level. See the exception in the NOTE above. Distance “B” will be used for adjusting the platform later in this procedure. FIG. 50-2 “B” PLATFORM & SHACKLES TOUCH GROUND FIG. 50-1 TIP OF FLIPOVER 1/4” (MAX.)

51 7. Reinstall locking brackets on both cylinders (FIG. 51- 1). Bolt each locking bracket in place. STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 9. RAISE platform to position just below extension plate (see FIG. 51-2). Refer to operating instructions in Operation Manual. FIG. 51-2 8. Review the WARNING page at the front of this manual before continuing this procedure. Stay clear of moving Liftgate parts. REINSTALLING LOCKING BRACKETS FIG. 51-1 LOCKING BRACKET CAP NUT FLAT WASHER BOLT LH CYLINDER RH CYLINDER LOCKING BRACKET (2 PLACES)

52 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued ! WARNING To prevent accidental personal injury and equipment damage, make sure power is disconnected from Liftgate while installing parts. 10. Disconnect power to the pump by disconnecting negative (-) and positive (+) cables from battery (FIG. 52-1). Reinstall nuts on negative (-) and positive (+) battery terminals. POSITIVE (+) BATTERY POST NEGATIVE (-) BATTERY CABLE NEGATIVE (-) BATTERY POST NUT POSITIVE (+) BATTERY CABLE DISCONNECTING BATTERY POWER FIG. 52-1 11. Support the Liftgate under main frame with a fl oor jack (FIG. 52-2). FLOOR JACK MAIN FRAME SUPPORTING LIFTGATE FIG. 52-2

53 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 12. Measure distance “C” from the tip of the fl ipover to ground level (FIG. 53-1). Next, subtract the distance “B” measured in instruction 6. The result is distance “D” for the platform adjustment (FIG. 53-3). For ex- ample, if you measured 50” for “C” and 1” for “B”, the calculat- ed distance “D” for the platform adjustment is 49”. 14. Raise or lower the fl oor jack to adjust distance “D” between tip of fl ipover and ground level (FIG. 53-3). Use the distance “D” cal- culated in instruction 12. 13. Remove welds from RH side and LH side mounting plates (FIG. 53-2). LIFTGATE CLEARANCE DIMENSIONS FIG. 53-1 REMOVING WELDS FROM MOUNTING PLATE (RH SIDE SHOWN) FIG. 53-2 “C” LIFTGATE CLEARANCE DIMENSIONS FIG. 53-3 “D” REMOVE WELDS MOUNTING PLATE MAIN FRAME (CUT-AWAY VIEW) VEHICLE FRAME (TYPICAL TRUCK FRAME SHOWN)

54 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued WELD TO VEHICLE FRAME AND MAIN FRAME (RH SIDE SHOWN) FIG. 54-1 15. Clamp the RH side and LH side mounting plates to vehicle frame. Weld the mounting plates to vehicle frame as shown in FIG. 54-1. Remove clamps. 17. Lower the fl oor jack and move it away from the Liftgate. CAUTION Prevent damaged hydraulic hoses. Before welding next to hydraulic hoses, protect the hoses with a heat-resistant cover. 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. 16. Reconnect power to the pump by reconnecting positive (+) and negative (-) cables to battery (FIG. 54-2). Reinstall and tighten nut when each battery cable is reconnected. RECONNECTING POWER FIG. 54-2 POSITIVE (+) BATTERY POST NEGATIVE (-) BATTERY CABLE NEGATIVE (-) BATTERY POST NUT POSITIVE (+) BATTERY CABLE 1/4” MOUNTING PLATE 2” LG. 4 PLACES (TYPICAL - RH & LH MOUNTING PLATES) MAIN FRAME (CUT-AWAY VIEW) VEHICLE FRAME (TYPICAL TRUCK FRAME SHOWN) 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.

55 STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued 18. LOWER the Liftgate to ground level (FIG. 55- 2A). Remove the installation brackets from RH side and LH side of plat- form (FIG. 55- 2B). REMOVING INSTALLATION BRACKETS FIG. 55-2A EXTENSION PLATE BRACKET & NUT (2 PLACES) BOLT (2 PLACES) FIG. 55-2B

56 REMOVING LOCKING BRACKETS FIG. 56-1 LOCKING BRACKET CAP NUT FLAT WASHER BOLT LH CYLINDER RH CYLINDER LOCKING BRACKET (2 PLACES) 19. Unbolt the locking brackets from both cylinders (FIG. 56- 1). Re- move the locking brackets. STEP 11 - ADJUST PLATFORM (IF REQUIRED) - Continued

57 STEP 12 - FINISH WELDING LIFTGATE TO VEHICLE WELD TO VEHICLE FRAME (RH SIDE SHOWN) FIG. 57-1 Weld the mounting plates to vehicle frame as shown in FIG. 57-1. TYPICAL - RH & LH MOUNTING PLATES 1/4” VEHICLE FRAME (TYPICAL TRUCK FRAME SHOWN) MOUNTING PLATE CAUTION Prevent damage to hydraulic hoses. Before welding next to hydraulic hoses, protect the hoses with a heat-resistant cover. CAUTION To protect the original paint system, a 3” wide area of paint must be re- moved from all sides of the weld area before welding. WARNING ! Liftgate is shipped from factory with mounting plates bolted to the main frame. Weld the mounting plates as shown in illustrations before operating Liftgate. 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.

58 STEP 13 - WELD TRUCK BODY TO FRAME (TRUCKS ONLY) 1. Fabricate two fl ats, from 1/4” thick x 4” wide steel, that will fi t in the area on the truck frame shown in FIG. 58-1. 2. Weld fl at to the truck frame and the C-channel on the RH side of truck body as shown in FIG. 58-1. Ensure welds on fl at are the same length above and below the wood spacer (FIG. 58-1). Repeat for the LH side of the truck body. WELDING TRUCK BODY TO FRAME (RH SIDE SHOWN) FIG. 58-1 TRUCK BODY C-CHANNEL FLAT TRUCK FRAME CAUTION To protect the original paint sys- tem, a 3” wide area of paint must be removed from all sides of the weld area before welding. CAUTION To prevent truck body from moving out of position, weld the C-channels on each side of truck body to truck frame. CAUTION When using an electric welder, connect the welder 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. 1/4” 2 PLACES AS MUCH AS POSSIBLE (TYPICAL - RH & LH SIDES OF TRUCK BODY) WOOD SPACER

59 CAUTION ! To prevent injury, unfold platform before repositioning opener. PLATFORM LOWERED FROM STOWED POSITION (RH SIDE VIEW) FIG. 59-1 1. The MAXON-recommended proce- dure for repositioning the opener is as follows. Lower the platform from stowed position (FIG. 59-1). 2. Unfold the platform (FIG. 59-2). UNFOLDING PLATFORM FIG. 59-2 NOTE: The platform must always stow and unfold without hitting underside of vehicle. Platform should unfold as close as possible to position shown in FIG. 59-1, but must never be positioned so it falls open. PLATFORM 3. Unfold the fl ipover (FIG. 59-3). UNFOLDING FLIPOVER FIG. 59-3 4. Measure vehicle bed height. Then move the opener, as required, to the matching bed height position for your Liftgate as shown in FIG. 60-1B and FIG. 61-1B. FLIPOVER STEP 14 - ADJUST OPENER (IF REQUIRED) PLATFORM SHACKLES TOUCHING THE GROUND

60 STEP 14 - ADJUST OPENER (IF REQUIRED) - Continued GPTLR-25 OR GPTLR-33 FIG. 60-1A 49” - 51” 44” - 48” OPENER 52” - 53” 52” - 55” ICC BUMPER OPENER POSITIONS BASED ON BED HEIGHT FIG. 60-1B 3-POSITION ROLLER MAIN FRAME OPENER BRACKET 3-POSITION ROLLER CAUTION To prevent damage to ICC bumper, opener must not rub against bumper. Ensure the 3-position roller remains in contact with ICC bumper at fi rst contact and through the full range of motion to highest position. Bolt roller in one of the 3 hole positions that best maintains contact between roller and bumper. NOTE: Opener can be repositioned to best open the platform when vehicle bed heights are 46” to 55”. The platform must always stow and unfold without hitting underside of vehicle. Platform should unfold as close as possible to position shown in FIG. 59-1, but must never be positioned so it falls open.

61 STEP 14 - ADJUST OPENER (IF REQUIRED) - Continued GPTLR-44 & GPTLR-55 FIG. 61-1A 44” - 47” 48” - 51” 55” 52” - 54” NOTE: Opener can be repositioned to best open the platform when vehicle bed heights are 44” to 55”. The platform must always stow and unfold without hitting underside of vehicle. Platform should unfold as close as possible to position shown in FIG. 59-1, but must never be positioned so it falls open. OPENER POSITIONS BASED ON BED HEIGHT FIG. 61-1B OPENER MAIN FRAME OPENER BRACKET 3-POSITION ROLLER

62 GPTLR-44 OR GPTLR-55 LIFTGATE, EQUIPPED WITH STANDARD UNDERRIDE, SHOWN WITH MAXIMUM ALLOWABLE CLEARANCES FIG. 62-1 STEP 15 - ADJUST UNDERRIDE NOTE: This underride adjustment procedure is for: • GPTLR-25 & GPTLR-33 with Federal Motor Vehicle Safety Standard (FMVSS) optional underride • GPTLR-44 & GPTLR-55 with standard FMVSS underride • GPTLR-44 & GPTLR-55 with Canadian Motor Vehicle Safety Standard (CMVSS) underride NOTE: For 5” tubular underride to meet applicable FMVSS and CMVSS regulations, ground clearance must not exceed 21-1/2” from the bottom of the tube. Also, the rear-facing part of the underride tube must not exceed 11” from the rear extreme of the vehicle. Refer to FIG. 62-1. 21-1/2” MAX. 11” MAX. UNDERRIDE TUBE REAR EXTREME OF VEHICLE GROUND

63 1. Stow the Liftgate under hydraulic pressure (FIG. 63-1). LIFTGATE WITH PLATFORM STOWED (STANDARD UNDERRIDE SHOWN ) FIG. 63-1 2. Measure vehicle bed height (FIG. 63-2). NOTE: If underride is already bolted in correct position for your bed height, and if tube posi- tion is adjustable, go to the instructions for ADJUSTING UNDERRIDE TUBE. MEASURING BED HEIGHT (STANDARD UNDERRIDE SHOWN) FIG. 63-2 BED HEIGHT (UNLOADED) STEP 15 - ADJUST UNDERRIDE - Continued 3. Refer to FIGS. 64-1B, 64-2B, and 65- 1B to fi nd the hole position that match- es your model of Liftgate, underride, and bed height.

64 STEP 15 - ADJUST UNDERRIDE - Continued UNDERRIDE 55” 53”- 54” 51”- 52” 48”-50” 47” 44” 6 4 5 1 3 2 GPTLR-25 & GPTLR-33 FMVSS UNDERRIDE BRACKET SETTINGS BASED ON BED HEIGHT (RH BRACKET SHOWN) FIG. 64-1B GPTLR-25 & GPTLR-33 OPTIONAL FMVSS UNDERRIDE FIG. 64-1A UNDERRIDE GPTLR-44 & GPTLR-55 STANDARD FMVSS UNDERRIDE FIG. 64-2A LIFT ARM ACCESS HOLE 55” 53”- 54” 51”- 52” 48”- 50” 47” 44” GPTLR-44 & GPTLR-55 FMVSS UNDERRIDE BRACKET SETTINGS BASED ON BED HEIGHT (RH BRACKET SHOWN) FIG. 64-2B 6 4 5 1 2 3

65 STEP 15 - ADJUST UNDERRIDE - Continued GPTLR-44 & GPTLR-55 OPTIONAL CMVSS UNDERRIDE FIG. 65-1A GPTLR-44 & GPTLR-55 CMVSS UNDERRIDE BRACKET SETTINGS BASED ON BED HEIGHT (RH BRACKET SHOWN) FIG. 65-1B UNDERRIDE 55” 49” 6 4 5 21 3 7 53” 54” 52” 50” 51”

66 NOTE: Platform seats must be removed from lift arms to adjust position of underride assembly. Seats must be reinstalled after adjusting position. 5. Unbolt each of the 2 platform seats (FIG. 66-1B). ADJUSTING UNDERRIDE ASSEMBLY 4. Lower platform to the ground. Then, unfold platform and fl ipover (FIG. 66-1A). LH SEAT RH SEAT UNBOLTING PLATFORM SEAT (LH SEAT SHOWN) FIG. 66-1B PLATFORM SEAT LOCK NUT (2 PLACES) FLAT WASHER (2 PLACES) CAP SCREWS (2 PLACES) LIFTGATE WITH PLATFORM ON THE GROUND (STANDARD FMVSS UNDERRIDE SHOWN) FIG. 66-1A STEP 15 - ADJUST UNDERRIDE - Continued NOTE: If your underride is not in the correct position for bed height of vehicle, per- form the following procedure.

67 UNBOLTING/BOLTING UNDERRIDE BRACKET (LH BRACKET SHOWN) FIG. 67-1B STEP 15 - ADJUST UNDERRIDE - Continued ADJUSTING UNDERRIDE (STANDARD FMVSS UNDERRIDE SHOWN) FIG. 67-1A UNDERRIDE BRACKET LOCK NUT FLAT WASHER (2 PLACES) CAP SCREW LH LIFTING ARM NOTE: At the lowest bed heights, underride may have too little ground clearance for a jack. If necessary, raise the platform up to 6” to get a jack in position to support the underride. UNDERRIDE JACK (UNDERRIDE SUPPORT) 6. Adjust position of the underride assembly as follows. Support underride with fl oor jack (FIG. 67-1A). Next, unbolt LH un- derride bracket (FIG. 67-1B) and RH underride bracket from lifting arms. 8. Lower and remove fl oor jack (FIG. 67-1A). 7. Swing the underride to the hole setting observed in FIGS. 64-1B, 64-2B or 65-1B. Bolt the underride brackets in the new posi- tion (FIG. 67-1B). Torque the 1/2”-13 cap screws to 85 lb-ft.

68 STEP 15 - ADJUST UNDERRIDE - Continued 9. Stow the platform. Refer to FIG. 68-1. Loosen bolt and lock nut, at each end of tube, just enough to move underride tube (FIG. 68-1). Rotate the tube up or down, and slide the tube outward or inward to the dimensions shown in FIG. 68-1. Tighten bolts and lock nuts to secure tube in correct position. UNDERRIDE TUBE ADJUSTMENT (RH SIDE SHOWN) FIG. 68-1 BOLT, WASHER & LOCK NUT (2 PLACES) ADJUSTING UNDERRIDE TUBE MAIN FRAME 21-1/2” TUBE 11” EXTENSION PLATE (REF) NOTE: The only models with an adjustable underride tube are • Optional FMVSS underride (GPTLR-25 & GPTLR-33) • Standard FMVSS underride (GPTLR-44 & GPTLR-55).

69 CAUTION To protect the original paint system, a 3” wide area of paint must be re- moved from all sides of the weld area before welding. CAUTION Prevent the date of manufacture decal from being damaged. Cover decal when welding underride support brackets. STEP 15 - ADJUST UNDERRIDE - Continued 10. Tack weld fl at, on underride tube, to RH support bracket (FIG. 69-1). Repeat for LH support bracket. TACK WELDING FLATS TO SUPPORT BRACKETS (RH SIDE SHOWN) FIG. 69-1 UNDERRIDE TUBE FLAT RH UNDERRIDE SUPPORT BRACKET 1/4” 2 PLACES CAUTION When using an electric welder, connect the welder 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.

70 STEP 15 - ADJUST UNDERRIDE - Continued 11. With platform stowed, measure and record ground clearance “H” (FIG. 70-1). Then, lower the platform to the ground to measure ground clearance “H1” (FIG. 70-2). Compare measurements with TABLES 71-1, 72-1 and 72-2. STANDARD FMVSS UNDERRIDE FIG. 70-1 “H” (21-1/2”) “H1” (OFF THE GROUND) 11” STANDARD FMVSS UNDERRIDE FIG. 70-2

71 STEP 15 - ADJUST UNDERRIDE - Continued NOTE: The bed height dimensions, for each underride hole shown below, apply to an unloaded vehicle. RECOMMENDED BOLTED HOLE POSITIONS FOR OPTIONAL FMVSS UNDERRIDE INSTALLED ON GPTLR-25 & GPTLR-33 BED HEIGHT UNDER- RIDE HOLE NO. “H” EXPECTED UN- DERRIDE GROUND CLEARANCE (PLATFORM STOWED) “H1” EXPECTED UNDERRIDE GROUND CLEAR- ANCE & MAX SPRING DEFLECTION OF VEHICLE WITH LOAD (PLATFORM ON THE GROUND) 55” 1 21.5” 6.3” 54” 2 21.5” 5.5” 53” 2 21.5” 4.7” 52” 3 21.5” 4.0” 51” 3 21.5” 3.4” 50” 4 21.5” 2.9” 49” 4 21.5” 2.4” 48” 4 21.5” 2.0” 47” 5 21.5” 1.7” 44” 6 21.5” 1.4” TABLE 71-1

72 RECOMMENDED BOLTED HOLE POSITIONS FOR OPTIONAL CMVSS UNDERRIDE INSTALLED ON GPTLR-44 & GPTLR-55 BED HEIGHT UNDER- RIDE HOLE NO. “H” EXPECTED UN- DERRIDE GROUND CLEARANCE (PLATFORM STOWED) “H1” EXPECTED UNDERRIDE GROUND CLEAR- ANCE & MAX SPRING DEFLECTION OF VEHICLE WITH LOAD (PLATFORM ON THE GROUND) 55” 1 21.35” 4.16” 54” 2 21.36” 3.37” 53” 3 21.38” 2.70” 52” 4 21.40” 2.17” 51” 5 21.41” 1.75” 50” 6 21.42” 1.44” 49” 7 21.42” 1.24” TABLE 72-2 RECOMMENDED BOLTED HOLE POSITIONS FOR STANDARD FMVSS UNDERRIDE INSTALLED ON GPTLR-44 & GPTLR-55 BED HEIGHT UNDER- RIDE HOLE NO. “H” EXPECTED UN- DERRIDE GROUND CLEARANCE (PLATFORM STOWED) “H1” EXPECTED UNDERRIDE GROUND CLEAR- ANCE & MAX SPRING DEFLECTION OF VEHICLE WITH LOAD (PLATFORM ON THE GROUND) 55” 1 21.5” 3.6” 54” 2 21.5” 2.9” 53” 2 21.5” 2.3” 52” 3 21.5” 1.8” 51” 3 21.5” 1.3” 50” 4 21.5” 0.9” 49” 4 21.5” 0.6” 48” 4 21.5” 0.3” 47” 5 21.5” 0.1” 44” 6 21.5” 0” TABLE 72-1 STEP 15 - ADJUST UNDERRIDE - Continued NOTE: The bed height dimensions, for each underride hole shown below, apply to an unloaded vehicle.

73 WELDING FLATS TO SUPPORT BRACKETS (RH SIDE SHOWN) FIG. 73-1 12. When the underride is in correct position, weld the fl ats on the tube to the RH and LH underride support brackets as shown in FIG. 73-1. UNDERRIDE TUBE FLAT RH UNDERRIDE SUPPORT BRACKET 1/4” 2 PLACES 1/4” 2 PLACES DATE OF MFR DECAL (INBOARD OF BRACKET) STEP 15 - ADJUST UNDERRIDE - Continued CAUTION Prevent the date of manufacture decal from being damaged. Cover decal when welding underride support brackets. CAUTION To protect the original paint system, a 3” wide area of paint must be re- moved from all sides of the weld area before welding. CAUTION When using an electric welder, connect the welder 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.

74 STEP 15 - ADJUST UNDERRIDE - Continued BOLTING ON PLATFORM SEAT (LH SEAT SHOWN) FIG. 74-1B LIFTGATE WITH PLATFORM ON THE GROUND (STANDARD FMVSS UNDERRIDE SHOWN) FIG. 74-1A LH SEAT RH SEAT LIFTING ARM 13. Lower platform to the ground (FIG. 74-1A). Then, bolt the LH platform seat (FIG. 74-1B) and the RH platform seat in position. Torque the cap screws and lock nuts to 42 lb-ft. NOTE: For some bed heights, platform seat may be bolted against the underride bracket. PLATFORM SEAT LOCK NUT (2 PLACES) FLAT WASHER (2 PLACES) CAP SCREWS (2 PLACES)

75 STEP 15 - ADJUST UNDERRIDE - Continued 14. Stow platform (FIG. 75-1). Next, center conspi- cuity (refl ective) tape on the underride tube as shown in FIG. 75-1. Remove backing from tape. Then, attach tape to underride (FIG. 75-1). ATTACH CONSPICUITY TAPE FIG. 75-1 CONSPICUITY TAPE CENTER OF TUBE UNDERRIDE TUBE

76 STEP 16 - VEHICLE TAILLIGHT POSITIONING (IF REQUIRED) NOTE: Taillights may interfere with Liftgate. Taillights and attaching hardware are not provided with the Liftgate. If needed, install vehicle taillights to comply with state and federal vehicle lighting requirements, such as FMVSS 108.

77 ATTACH DECALS FIG. 77-1 STOW WARNING DECAL P/N 282847-02 CAPACITY DECAL (SEE TABLE 77-1) TABLE 77-1 INSTRUCTION DECAL P/N 299361-01 DECAL SHEET (SMALL, WARNING & CAUTION) P/N 282522-01 CAPACITY DECALS CAPACITY PART NO. 2500 LBS. 220382 3300 LBS. 220388-02 4400 LBS. 253155 5500 LBS. 253161 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. NOTE: Ensure there is no residue, dirt or corrosion where decals are attached. If necessary, clean surface before attaching decals. UP DECAL (DECAL SHEET) DOWN DECAL (DECAL SHEET)

78 FIG. 78-1 WARNING DECAL P/N 265736-02 CAUTION DECAL (FLIPOVER EQUIPPED WITH LATCH ONLY) P/N 267694-01 WARNING DECAL P/N 265736-03 DECALS & PLATES PARTS QR CODE DECAL P/N 299348-08 SERIAL PLATE (REF) MAXON 24/7 SUPPORT DECAL P/N 298634-01 MAXON PLATE P/N 280004-01 NOTE: MAXON 24/7 LIFTGATE SUPPORT service is only available in the Continental U.S.

79 SAFETY STRIPE TAPE (2 PLACES) P/N 096018-10 NONSKID (LH) P/N 281204-01 NONSKID (RH) P/N 281204-02 ATTACH NONSKID & SAFETY STRIPING FIG. 79-1

80 TOUCHUP GALVANIZED FINISH CAUTION Damaged cylinder seals and contaminated hydraulic fl uid can result from apply- ing cold galvanized fi nish to the polished portion of the cylinder rod. To prevent damage, protect the exposed polished portion of the cylinder rod while spraying. • 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.

81 SYSTEM DIAGRAMS GRAVITY DOWN POWER UNIT FIG. 81-1 PUMP & MOTOR SOLENOID OPERATION (GRAVITY DOWN) TABLE 81-1 POWER UNIT MOTOR & SOLENOID OPERATION LIFTGATE FUNCTION PORT SOLENOID OPERATION ( MEANS ENERGIZED) MOTOR VALVE “A” LOCK VALVE RAISE A - - LOWER VENT - REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC STARTER SOLENOID “A” VALVE MOTOR DIRECTION OF CONTROLLED FLOW

82 POWER DOWN POWER UNIT FIG. 82-1 PUMP & MOTOR SOLENOID OPERATION (POWER DOWN) TABLE 82-1 POWER UNIT MOTOR & SOLENOID OPERATION LIFTGATE FUNCTION PORT SOLENOID OPERATION ( MEANS ENERGIZED) MOTOR VALVE “S2” VALVE “S1” LOCK VALVE RAISE A - - LOWER B - REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC STARTER SOLENOID “S2” VALVE “S1” VALVE MOTOR DIRECTION OF CONTROLLED FLOW

83 HYDRAULIC SCHEMATIC (GRAVITY DOWN) FIG. 83-1 M 4.5 GPM FLOW CONTROL VALVE VALVE “A” RELIEF VALVE (SET AT 3250 PSI) PUMP MOTOR (REF) RESERVOIR CHECK VALVE FILTER DRAIN HOLE (PLUGGED) HYDRAULIC CYLINDERS FILL HOLE (PLUGGED) HYDRAULIC LOCK VALVE VENT PORT AUX. HAND PUMP PORT (PLUGGED) PORT B - RETURN (PLUGGED) PORT A - RAISE

84 FIG. 84-1 HYDRAULIC SCHEMATIC (POWER DOWN) HYDRAULIC CYLINDERS PORT B - POWER DOWN PORT A - RAISE RELIEF VALVE 2 (SET AT 1100 PSI) PUMP AUX. HAND PUMP PORT (PLUGGED) VALVE “S2” RESERVOIR DRAIN HOLE (PLUGGED) FILTER MOTOR (REF) RELIEF VALVE 1 (SET AT 3250 PSI) HYDRAULIC LOCK VALVE 4.5 GPM FLOW CONTROL VALVE FILTER VALVE “S1”

85 FIG. 85-1 ELECTRICAL SCHEMATIC (GRAVITY DOWN) (DOWN) (UP) CONTROL SWITCH STARTER SOLENOID MOTOR FUSE HOLDER WITH 10 AMP FUSE JUNCTION BLOCK WHITE BLACK GREEN 1 1 2 2 CYCLE COUNTER (IF EQUIPPED) BATTERY SOLENOID VALVE “A” LOCK VALVE CABLE WITH 175 AMP FUSE

86 FIG. 86-1 ELECTRICAL SCHEMATIC (POWER DOWN)

87 TABLE 87-1 GPTLR ELECTRICAL VALUES & TORQUE SPECIFICATIONS SYSTEM DIAGRAMS Solenoid Switch 12V 24V Coil resistance: 5.4Ω @70ºF. ±15% 20.1Ω @70ºF. ±15% Ampere: 2.2A 1.2A Coil terminal torque: 10-15 lb-in max. Contact terminal torque: 30-35 lb-in max. Solenoid Valves (A, S1, & S2) Coil resistance: 4.0Ω @ 70ºF. ±15% 26.7Ω @ 70ºF. ±15% Ampere: 3A, 2.5A @10V 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: 8.0Ω @ 70ºF. ±15% 30Ω @ 70ºF. ±15% Ampere: 1.5A 0.8A Coil nut torque: 3-4.5 lb-ft max. Valve cartridge torque: 18.5-22 lb-ft max. Digital Cycle Counter Input voltage 4V - 30V 4V - 30V Ampere <2mA Ground Cable Cap screw torque: 24 lb-ft max.

88 OPTIONS OPTIONAL LIFTGATE COMPONENTS MISCELLANEOUS KITS PART NO. IN CAB ON-OFF SWITCH 250477 FRAMELESS TRAILER, GPTLR, 102” WIDE 282562-01 FRAMELESS TRAILER, GPTLR, 102” WIDE, GALVANIZED 282562-01G FRAMELESS TRAILER, GPTLR, 96” WIDE 282562-02 FRAMELESS TRAILER, GPTLR, 96” WIDE, GALVANIZED 282562-02G CIRCUIT BREAKER (150 AMP) 251576 TRAFFIC CONES 268893-01 FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS, GALVANIZED 282372-01G FRAME MOUNTING BRACKET FOR 2 OVAL LIGHTS, NO FINISH 282372-03 HAND PUMP, GPTLR, GRAVITY DOWN 287369-01 HAND PUMP, GPTLR, POWER DOWN 287389-01 EXTRA CONTROLS & CONTROL KITS PART NO. HAND HELD CONTROL, TUK-A-WAY 280570-07 HAND HELD CONTROL, TUK-A-WAY, 120” 263260-13 HAND HELD CONTROL, TUK-A-WAY, 240” 263260-14 STREET SIDE CONTROL, TUK-A-WAY 297116-01 DUAL CONTROL, TUK-A-WAY 297115-01 STEP KITS PART NO. DUAL STEP, GPTLR-25/33, GALVANIZED 281312-01G DUAL STREET SIDE STEP GPTLR-25/33 GALVANIZED 281312-02G DUAL CURB SIDE STEP, GPTLR-25/33 GALVANIZED 281312-03G DUAL STEP, GPTLR-44/55, GALVANIZED 281311-01G DUAL STEP, GPTLR, GALVANIZED (FOR 283678-01G EXTENSION PLATE ASSEMBLY, 102” LG.) 283685-01G FOLD DOWN STEP ALL GPTLR’S (1 KIT PER SIDE) 267835-01 PLATFORM RAIL INSTALLATION PART NO. PLATFORM RAIL INSTALLATION, GPTLR, GALVANIZED 298495-01G

89 Pre-Installation Inspection: Correct model Correct capacity Correct platform size Correct options Manuals & decals Structural Inspection: Inspect alignment of fi nal assembly Inspect pump box secure mounting Inspect all installation welds Check roll pins, bolts and fasteners Inspect tightness of hardware used to secure liftgate to vehicle. Ensure platform ramp tip touches ground or is not more than 1/4” off the ground. Ensure bottom of underride tube is not more than 21-1/2” off the ground and not more than 11” forward of the extreme rear of vehicle. Hydraulic Inspection: Proper fl uid level (See CHECKING HYDRAULIC FLUID step in this manual.) Check hydraulic fi ttings in pump box for leaks Check hydraulic line connections for leaks Electrical Inspection: Check power/charge plug and terminal Check for tight wire connections Circuit breaker (150A) installed in battery box (if equipped) or by truck/tractor battery. Ensure batteries are fully charged, all cable connections are tight & tiedowns are tight. Inspect all solenoid connections Check all wiring harness connections Check electrical cable connections are tight & secure. Operation Inspection: Check operation of all main and optional control switches. GPTLR-25 or GPTLR-33 only Unloaded platform lowers in 6 sec. Unloaded platform raises in 15 sec. GPTLR-44 or GPTLR-55 only Unloaded platform lowers in 10 sec. Unloaded platform raises in 25 sec. All GPTLR: Unloaded platform raises and lowers evenly. At the extension plate, platform must not be more than 1/4” uneven, from side to side. All GPTLR: Breakaway force to unfold plat- form is 30 lb-ft maximum. Breakaway force to fold platform is 40 lb-ft maximum. All GPTLR: Platform stores securely under vehicle body Check if cycle counter works Decals in correct location and legible Verify all lights are operational (For lights supplied by MAXON only) Platform lights turn ON when platform is un- folded, and turn OFF when platform is stowed. Taillights, stop lights, turn lights, and backup lights turn ON and OFF correctly. NOTE: The following times are for 55” bed height, aluminum platform and fl ipover, Exxon Univis HVI-13 oil, & temperature at 70°F. Times are for reference only and may vary for larger platforms, smaller platforms, or temperature changes. Model:______________________ Date: ____________________ Serial Number: _______________ Technician: _______________ PRE-DELIVERY INSPECTION FORM Important! This pre-delivery checklist is to aid the installer in confi rming the proper installation of this Maxon product. It is not a comprehensive list and does not replace the use of the installation manual. The installer is responsible for following all instructions in the installation manual.