Maxon GPTLR-44 User Manual

© MAXON Lift Corp. 2019
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.

Maxon GPTLR-44 Specifications

General

Brand	Maxon
Model	GPTLR-44
Category	Lifting Systems
Language	English

Summary

General Safety Information

California Proposition 65 Warning

General Liftgate Safety

Safety precautions for operating and installing the liftgate to prevent injury.

Operational Safety and Notices

Liftgate Safety Instructions

Guidelines for safe liftgate operation, including warnings and maintenance.

Vehicle Requirements and Clearances

Body Height and Clearance Requirements

Vehicle Frame Cutouts (GPTLR-25/33)

Vehicle Frame Cutouts (GPTLR-44/55)

Platform Clearance Cutout Diagram

Step 1: Attach Extension Plate to Vehicle

Bolting Extension Plate: Hole Locations

Instructions and diagram for marking and drilling holes for bolting the extension plate.

Hole Locations for 102" Wide Vehicle

Bolting Procedure and Torque Specs

Procedure for bolting the extension plate, including torque specifications and weld recommendations.

Bolting Installation Brackets

Step 1: Attach Extension Plate (Alternate Method)

Weld Extension Plate Procedure

Instructions for centering and welding the extension plate to the vehicle body sill.

Step 2: Weld Liftgate to Vehicle

Mounting Plate Installation and Torque

Information on mounting plates and torque specs for installing liftgate on trucks and trailers.

Hoisting and Positioning Liftgate

Correct procedure for hoisting the liftgate using a floor jack for positioning.

Weld Mounting Plates to Frame

Instructions for clamping and welding the mounting plates to the vehicle frame.

Step 3: Attach Optional Battery Box & Frame

Recommended Configuration Diagrams

Mounting Brackets for Trailers

Mark and Drill Bracket Holes

Welding Brackets to Cross Members

12 Volt Battery Connections Diagram

Battery Box Assembly Details

Mounting Brackets for Trucks

Step 4: Run Power Cable

Recommended Power Cable Routing

Diagrams showing recommended routing of power cables for liftgates on trailers and trucks.

Cable Routing and Securing Procedure

Procedure for clipping and routing the fused power cable along the vehicle chassis.

Step 5: Connect Power Cable

Removing Pump Cover

Terminal Lug and Heat Shrink Installation

Procedure for attaching a terminal lug and heat shrink tubing to the fused power cable.

Connecting to Starter Solenoid

Instructions for connecting the fused power cable to the starter solenoid and torque specs.

Step 6: Connect Ground Cable

Ground Cable Routing to Pump

Procedure for inserting the ground cable through the grommet and connecting it to the pump.

Ground Cable Connection to Frame

Instructions for extending and bolting the ground cable terminal lug to the vehicle frame.

Step 7: Install Control Switch

Drilling Mounting Holes Diagram

Diagrams showing hole drilling for mounting the control switch on the vehicle's vertical post.

Control Switch Wiring Connections

Diagrams showing control switch wiring connections to the pump assembly (gravity and power down).

Routing Control Switch Wiring

Procedure for routing the control switch wiring harness to the pump assembly.

Step 8: Checking Hydraulic Fluid

Pump Cover Removal and Fluid Check

Procedure for removing the pump cover and checking the hydraulic fluid level in the reservoir.

Recommended Hydraulic Oils

Step 9: Connect Power Cable to Battery

Disconnecting Battery Cables

Diagrams showing how to disconnect negative and positive battery cables.

Connecting Fused Positive Cable

Procedure for connecting the fused positive cable to the battery terminal.

Step 10: Remove Locking Brackets & Check Interference

Removing Floor Jack and Lowering Platform

Unbolting Cylinder Locking Brackets

Procedure for unbolting the locking brackets from the liftgate cylinders.

Checking Platform Interference (Raised)

Removing Installation Brackets

Checking Platform to Extension Plate Gap

Procedure to raise the platform and check for the specified gap between platform and extension plate.

Checking Platform Interference (Lowered)

Step 11: Adjust Platform (If Required)

Platform Adjustment Checks

Instructions to check platform gaps and contact points for correct installation.

Shackles Not Touching Ground: Shim Determination

Procedure to determine correct shim using distance 'A' and TABLE 49-1.

Platform and Flipover Ground Contact

Reinstalling Locking Brackets

Disconnecting Battery Power

Measuring and Calculating Distance 'D'

Procedure to measure and calculate distance 'D' for platform adjustment.

Welding Mounting Plates to Frame

Instructions for clamping and welding the mounting plates to the vehicle frame after adjustment.

Removing Installation Brackets (Lowered)

Removing Cylinder Locking Brackets

Shim Installation for Shackles

Raising Platform Below Extension Plate

Supporting Liftgate with Floor Jack

Removing Welds from Mounting Plates

Reconnecting Battery Power

Adjusting Distance 'D' with Floor Jack

Procedure to adjust distance 'D' by raising or lowering the floor jack.

Step 12: Finish Welding Liftgate to Vehicle

Weld Mounting Plates to Vehicle Frame

Final instructions for welding the liftgate mounting plates to the vehicle frame.

Step 13: Weld Truck Body to Frame (Trucks Only)

Fabricate and Weld Truck Body Flats

Step 14: Adjust Opener (If Required)

Lowering Platform for Opener Adjustment

Opener Positions for GPTLR-25/33

Diagrams showing opener mounting hole positions for different bed heights on GPTLR-25/33.

Opener Positions for GPTLR-44/55

Diagrams showing opener mounting hole positions for different bed heights on GPTLR-44/55.

Unfolding Platform and Flipover

Step 15: Adjust Underride

Underride Adjustment Notes and Clearances

Stow Liftgate and Measure Bed Height

Underride Bracket Settings (GPTLR-25/33 FMVSS)

Table and diagram for selecting bracket positions based on bed height for GPTLR-25/33 FMVSS.

Underride Bracket Settings (GPTLR-44/55 CMVSS)

Diagram for selecting bracket positions based on bed height for GPTLR-44/55 CMVSS.

Unbolting Platform Seats

Adjusting Underride Assembly Position

Procedure to support, unbolt, and reposition underride brackets using hole settings.

Adjusting Underride Tube Position

Welding Underride Support Brackets

Measuring Ground Clearance 'H' and 'H1'

Bolted Hole Positions for GPTLR-25/33 FMVSS

Bolted Hole Positions for GPTLR-44/55 FMVSS

Bolting Platform Seats

Maximum Allowable Underride Clearances

Underride Bracket Settings (GPTLR-44/55 FMVSS)

Table and diagram for selecting bracket positions based on bed height for GPTLR-44/55 FMVSS.

Bolted Hole Positions for GPTLR-44/55 CMVSS

System Diagrams: Gravity Down Operation

Gravity Down Power Unit Diagram

System Diagrams: Power Down Operation

Power Down Power Unit Diagram

Hydraulic Schematic: Gravity Down

Gravity Down Hydraulic Circuit Diagram

Hydraulic Schematic: Power Down

Power Down Hydraulic Circuit Diagram

Electrical Schematic: Gravity Down

Gravity Down Electrical Circuit Diagram

Electrical Schematic: Power Down

Power Down Electrical Circuit Diagram

Electrical Values and Torque Specifications

Solenoid, Valve, and Lock Valve Specs