M-08-12 REV. C MARCH 2011 INSTALLATION MANUAL GPSLR-33 & GPSLR-44 © MAXON Lift Corp.
TABLE OF CONTENTS WARNINGS ........................................................................................................................... 3 SAFETY INSTRUCTIONS .................................................................................................... 3 GPSLR INSTALLATION PARTS BOX ................................................................................... 4 OPTIONAL INSTALLATION JIG ............................................................................................
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing Liftgates. Refer to WARNING, CAUTION, and SAFETY INSTRUCTIONS decals on Liftgate. ! 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.
GPSLR INSTALLATION PARTS BOX QTY. PART NUMBER 1 GUSSET, GPSLR MOUNT 8 268674-01 2 PLATE, GPSLR SUPPORT 6 268675-01 3 PLATE, GPSLR MOUNT 6 268676-01 4 CAP SCREW, 1/2”-20 X 2” LG, GRADE 8 12 900033-5 5 FLAT WASHER, 1/2” X 3/32” THICK 24 902013-13 6 LOCK NUT, NYLON, 1/2”-20 12 901008 7 TAPPING SCREW, #10-24 X 1/2” LG. 4 030444 8 ANGLE (STEEL), 2” X 2” X 1/8” X 6” LG. 2 901008 TABLE 4-1 OPTIONAL INSTALLATION JIG INSTALLATION JIG PN 268592-01 4 11921 Slauson Ave.
VEHICLE REQUIREMENTS The sliding axel assembly on a trailer can collide with a Liftgate mounted on the slide rails. To prevent damage to Liftgate and trailer, install stops on the slide rails to keep the sliding axels from hitting Liftgate. Refer to Liftgate clearance dimensions in this section of the manual. NOTE: BODY maximum and minimum operating bed height: Maximum height is 53” (Unloaded). Minimum height is 46” (Loaded).
3-1/4”- 65-3/4” 4” 53” MAX. BED HEIGHT 46” MIN. BED HEIGHT 12-5/8” TO 16-5/8” VEHICLE WITH 4” CROSSMEMBERS FIG. 6-1 NOTE: For installation of this Liftgate, the maximum thickness of the vehicle floor and body is 6”. 57-5/8” 6” MAX 96” FIG. 6-2 6 11921 Slauson Ave. Santa Fe Springs, CA.
STEP 1 - REMOVE SIDE PLATES RIGHT SIDE PLATE CONDUIT FIG. 7-1 7 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 1. Disconnect conduit from right side plate as shown in FIG. 7-1.
STEP 1 - REMOVE SIDE PLATES - Continued 2. Unbolt side plates as shown in FIG. 8-1. BOLT (2 PLACES) FLAT WASHERS (2 PLACES) SIDE PLATES FLAT WASHERS (2 PLACES) LOCK NUT (2 PLACES) FLAT WASHERS (2 PLACES) BOLT (2 PLACES) LOCK NUT (2 PLACES) FLAT WASHERS (2 PLACES) FIG. 8-1 8 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 NOTE: Save bolts, nuts, and flat washers for reinstallation.
NOTE: Parts box contains 2 angle steel pieces for positioning side plates under vehicle body. The angles allow side plates to be positioned and clamped to bottom of chassis crossmembers before welding the side plates. 1. Position RH side plate with rounded corners facing up (FIG. 9-1). ROUNDED CORNER CLAMPS ROUNDED CORNER SIDE PLATE CONDUIT BRACKET (RH SIDE PLATE ONLY) ANGLE STEEL FIG. 9-1 NOTE: Angle steel pieces must be butted against the side plate and flush with the edge of the side plate.
NOTE: The instruction below only applies to trailers with 3” crossmembers. If trailer has 4” crossmembers, go to the next page. NOTE: To mark a position between 2 crossmembers, attach tape from crossmember-tocrossmember. Remove slack before marking the tape. 3. For 3” trailer crossmembers, mark position for side plate on crossmember (FIG. 10-1 and TABLE 10-1). CROSSMEMBER FLOOR 3” X (TABLE 10-1) SIDE VIEW - 3” TRAILER CROSSMEMBERS FIG.
NOTE: The instruction below only applies to trailers with 4” crossmembers. If trailer has 3” crossmembers, go to the previous page. NOTE: To mark a position between 2 crossmembers, attach tape from crossmember-tocrossmember. Remove slack before marking the tape. 4. For 4” trailer crossmembers, mark position for side plate on crossmember (FIG. 11-1 and TABLE 11-1). FLOOR CROSSMEMBER 4” X (TABLE 11-1) SIDE VIEW - 4” TRAILER CROSS MEMBERS FIG.
STEP 2 - WELD SIDE PLATE - Continued Example where D = 50” : Y = (52 7/8” - 50”) x 1/2, Y = 2 7/8” / 2, Y = 1 7/16” CENTER LINE SLIDE RAILS SIDE PLATE SIDE PLATE D Y 52-7/8” (MEASURE INSIDE, CENTER TO BODY) FIG. 12-1 6. Adjust a combination square to the “Y” dimension (FIG. 12-2) or fabricate a spacer equal to the thickness of “Y”. SLIDE RAILS COMBINATION SQUARE FIG. 12-2 12 Y 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 5. Refer to FIG. 12-1.
STEP 2 - WELD SIDE PLATE - Continued CAUTION To avoid personal injury, use at least 2 people to position the side plate. 7. Line up end of the side plate with “X” mark on crossmember (FIG. 13-1A) and with the slide rail (FIG. 13-1B). “X” MARK SIDE PLATE CROSSMEMBER ALIGNING SIDE PLATE FIG. 13-1A SLIDE RAIL COMBINATION SQUARE SIDE PLATE FIG. 13-1B 13 11921 Slauson Ave. Santa Fe Springs, CA.
STEP 2 - WELD SIDE PLATE - Continued To protect the original paint system on the Liftgate, a 3” wide area of paint must be removed from all sides of the weld area before welding. 8. Tack weld side plate as shown in FIG. 14-1. 1/4” TACK WELDING SIDE PLATES TO CROSSMEMBER FIG. 14-1 9. Remove clamps and the 2 angles. 10. Repeat 1 through 9 for the LH side plate. 14 TACK 11921 Slauson Ave. Santa Fe Springs, CA.
STEP 2 - WELD SIDE PLATE - Continued 52-7/8” (CENTER TO BODY) SIDE PLATE SIDE PLATE SLIDE RAILS 90° 90° X X REAR SILL CHECKING FOR CORRECT DIMENSIONS FIG.
STEP 2 - WELD SIDE PLATE - Continued To protect the original paint system on the Liftgate, a 3” wide area of paint must be removed from all sides of the weld area before welding. NOTE: Support plates were made for crossmembers positioned at 12” center distance. If distance is less than 12”, cut support plate to the applicable length. 12. Tack weld RH side plate and support plate to crossmembers (FIG. 16-1). Repeat for LH side plate.
STEP 2 - WELD SIDE PLATE - Continued 1/4” 1/4” 1/4” SUPPORT PLATES (3 PLACES) SIDE PLATE MOUNT PLATES (3 PLACES) 1/4” WELDING SIDE PLATE TO CROSSMEMBERS (RH SHOWN) FIG. 17-1 14. Weld gussets to RH side plate as shown in FIG. 17-2. Repeat step for LH side plate. GUSSETS (4 PLACES) SIDE PLATE 1/4” WELDING GUSSETS TO SIDE PLATE (RH SHOWN) FIG. 17-2 17 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 13.
STEP 3 - PLACE SLIDER ASSEMBLY ON OPTIONAL JIG Use forklift to place slider assembly on the installation jig. Ensure the slider assembly is: • Centered on the jig (FIG. 18-1) • Correctly supported by the jig (FIG. 18-2) CENTER SLIDER ASSY JIG SLIDER ASSEMBLY CENTERED ON JIG (FRONT VIEW) FIG. 18-1 SLIDER ASSY JIG SLIDER ASSEMBLY SUPPORTED BY JIG (LH SIDE VIEW) FIG. 18-2 18 11921 Slauson Ave. Santa Fe Springs, CA.
NOTE: Refer to TABLES 19-1 (3” Crossmembers) & 19-2 (4” Crossmembers) for correct mounting distance and slot information. TOP MIDDLE BOTTOM 1. Raise Liftgate to line up the holes in the slider with the proper mounting slots on the side plates (FIGS. 19-1A & 19-1B). FIG. 19-1B SIDE PLATE SLIDER OPTIONAL JIG LINING UP SLIDER WITH SIDE PLATES (RH SIDE SHOWN) FIG.
STEP 4 - BOLT ON LIFTGATE - Continued 2. Bolt Liftgate to RH side plate as shown in FIG. 20-1. Repeat step for LH side plate. Before bolts are tightened, position Liftgate all the way toward rear of vehicle body (FIG. 20-2). FLAT WASHERS (2 PLACES) BOLT (2 PLACES) LOCK NUT (2 PLACES) FLAT WASHERS (2 PLACES) BOLTING LIFTGATE TO SIDE PLATES (RH SIDE SHOWN) FIG. 20-1 BOLTS FIG. 20-2 20 11921 Slauson Ave. Santa Fe Springs, CA.
1. Reconnect conduit to right side plate as shown in FIG. 21-1. SIDE PLATE CONDUIT RECONNECTING CONDUIT TO RH SIDE PLATE FIG. 21-1 CAUTION Prevent damage to control box. Make sure installed control box does not protrude from the vehicle body. CAUTION To protect the original paint system, a 3” wide area of paint must be removed from bracket on all sides of the weld area before welding. 2. Weld the control box bracket to vehicle crossmembers on the RH side (curbside) near rear sill of vehicle (FIG.
1. Use internal control switch bracket to mark and drill 4 holes for mounting next to vertical post (curb side). Bolt internal control box to vehicle body with self-tapping screws (FIG. 22-1). INTERNAL CONTROL SWITCH BRACKET 18”- 24” VEHICLE BODY VERTICAL POST (CURB SIDE) BOLTING INTERNAL SWITCH BRACKET TO VEHICLE BODY FIG. 22-1 2. Drill 1/2“ hole through vehicle floor as shown in FIGS. 22-2A and 22-2B. USE 1/2” DRILL VERTICAL POST VEHICLE WALL VERTICAL POST HOLE LOCATION FIG.
NOTE: MAXON recommends using dielectric grease on all electrical connections. 3. Run control cable from external control box, under vehicle body (see dashed line, FIG. 23-1A), and up through vehicle floor. Pull control cable through 3/4“ hole (FIG. 23-1A). 4. Connect the control cable to the internal control switch (FIG. 23-1B). INTERNAL CONTROL SWITCH GREEN BLACK WHITE CONTROL CABLE EXTERNAL CONTROL BOX CONNECTING CONTROL CABLE FIG. 23-1B 3/4” HOLE CONNECTING CONTROL BOX CABLE FIG.
NOTE: MAXON does not supply the angle steel shown below. 5. Tack weld angle steel to vehicle wall and vehicle post (FIG. 24-1). INTERNAL CONTROL SWITCH VERTICAL POST TACK ANGLE STEEL 1/4” VEHICLE WALL RUNNING CONTROL BOX CABLE FIG. 24-1 24 11921 Slauson Ave. Santa Fe Springs, CA.
NOTE: Make sure the Liftgate power unit, and all batteries on the vehicle for the power unit, are connected correctly to a common chassis ground. 1. Liftgate and additional battery box are typically installed on trailers as shown in FIG. 25-1 and on trucks as shown in FIG. 25-2. See the following page for battery and cable connections.
NOTE: Always connect fused end of power cable to battery positive (+) terminal. 2. Recommended battery box setup for 6 volt batteries is shown in FIG. 26-1. (+) BATTERY CABLES 150 AMP CIRCUIT BREAKER 150 AMP CIRCUIT BREAKER (NEAR TRUCK OR TRACTOR BATTERY AND/OR NOSE OF TRAILER) 175 AMP FUSED POWER CABLE (SEE NOTE) CHARGE LINE TO TRUCK OR TRACTOR BATTERY POWER CABLE ASSEMBLY TO PUMP BOX (-) BATTERY CABLE 6 VOLT BATTERY CONNECTIONS FIG.
STEP 8 - CONNECTING POWER Connect power cable as shown in FIG. 27-1. POWER CABLE TO PUMP BOX POWER CABLE FROM BATTERY BOX FIG. 27-1 27 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 NOTE: MAXON recommends using dielectric grease on all electrical connections.
STEP 9 - LEVELING PLATFORM PLATFORM Operate Liftgate with caution until installation is complete. VEHICLE FLOOR NOTE: Refer to Operating Instructions decal and applicable WARNING & CAUTION decals. 1. Raise platform above vehicle floor height (FIG. 28-1). PLATFORM ABOVE VEHICLE FLOOR FIG. 28-1 BOLTS 2. Loosen bolts on both side plates (FIG. 28-2). Lower platform flush with vehicle floor (FIG. 28-3). Next, nudge the Liftgate toward the front of vehicle (FIG. 28-1). Then tighten bolts.
TOP SLOT NOTE: Six holes must be drilled through each side of the slider frame to bolt RH and LH side plates to slider frame on the Liftgate. (See FIGS. 29-1A, 29-1B, 29-1C & 29-1D.) USE TOP HOLES 1. Use side plate as a template to drill 6 holes (1/2” dia.) in slider frame (FIG. 29-1A). Repeat for LH side. FIG. 29-1B MIDDLE SLOT USE TOP HOLES FIG. 29-1C BOTTOM SLOT REFER TO FIG. 29-1B, 29-1C & 29-1D USE BOTTOM HOLES FIG. 29-1D SLIDER FRAME SIDE PLATE FIG. 29-1A 29 11921 Slauson Ave.
STEP 10 - FINAL BOLTING - Continued FLAT WASHER (6 PLACES) BOLTS (6 PLACES) SIDE PLATE FLAT WASHER (6 PLACES) LOCK NUT (6 PLACES) SLIDER FRAME FIG. 30-1 30 11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 2. Bolt RH side plate to slider frame as shown in FIG. 30-1. Repeat for LH side. Torque each bolt to 120 lb-ft.
NOTE: Park vehicle on level ground and unload vehicle before doing this procedure. 1. Lower platform to ground and unfold flipover (FIG. 31-1A). LIMIT BOLT 2. Loosen adjustment and limit bolts on both sides of platform (FIG. 311B). ADJUSTMENT BOLT 3. Turn adjustment bolts counterclockwise to tilt the tip of platform up (FIG. 31-2), or turn clockwise to tilt down (FIG. 31-3). 4. Once platform is adjusted, tighten limit bolts securely on both sides of platform (FIG. 31-1B). TILT ADJUSTMENT (RH SHOWN) FIG.
STEP 12 - ATTACH SLIDING AXEL STOPS (IF REQUIRED) The sliding axel assembly on a trailer can collide with a Liftgate mounted on the slide rails. To prevent damage to Liftgate and trailer, install stops on the slide rails to keep the sliding axels from hitting Liftgate. Refer to Liftgate clearance dimensions in this section of the manual. If the Liftgate is mounted on a slide-axel trailer, attach stops on the slide rails to prevent the slide axels from hitting the Liftgate.
DECAL “B” DECAL “A” DECAL “C” DECAL “G” DECAL “D” DECAL “F” SERIAL PLATE (REF) DECAL P/N 268417-01 P/N 267431-01 (GPSLR-33) & P/N 267431-02 (GPSLR-44) FIG. 33-1 33 11921 Slauson Ave. Santa Fe Springs, CA.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 ATTACH DECALS - Continued WITH SMART STOW GPSLR 33 ONLY GPSLR 44 ONLY DECAL SHEET FIG.
CAUTION DECAL P/N 282682-01 CAUTION DECAL P/N 282683-01 DECAL “A” DECAL “C” DECAL “B” DECAL “G” DECAL “F” OPERATION DECAL P/N 282681-01 SERIAL PLATE (REF) P/N 282464-01 (GPSLR-33) & P/N 282464-02 (GPSLR-44) FIG. 35-1 35 11921 Slauson Ave. Santa Fe Springs, CA.
GPSLR 33 ONLY GPSLR 44 ONLY DECAL SHEET FIG. 36-1 36 11921 Slauson Ave. Santa Fe Springs, CA.
DECAL P/N 264507 DECAL “L” DECAL “K” DECAL “F” DECAL “I” DECAL “J” DECAL “L” DECAL “M” DECAL “A” DECAL “L” DECAL “K” DECAL “K” DECAL “B” DECAL “L” DECAL “H” DECAL “H” DECAL “M” DECAL “G” 37 11921 Slauson Ave. Santa Fe Springs, CA.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 DECAL POSITIONS - Continued DECAL SHEET 267432-01 FIG.
SYSTEM DIAGRAMS “S2” VALVE “S1” VALVE “S3” VALVE PORT L PORT B PORT A LOCK VALVE LOCK VALVE ON CYLINDER STARTER SOLENOID MOTOR POWER UNIT MOTOR & SOLENOID OPERATION LIFTGATE FUNCTION SOLENOID OPERATION ( MEANS ENERGIZED) PORT MOTOR RAISE L LOWER L SLIDE OPEN A SLIDE CLOSED B VALVE “S1” VALVE “S2” VALVE “S3” - - - - - - - REFER TO VALVES SHOWN ON HYDRAULIC SCHEMATIC TABLE 39-1 39 LOCK VALVE - - - - 11921 Slauson Ave. Santa Fe Springs, CA.
SYSTEM DIAGRAMS - Continued CYLINDERS LOCK VALVES LOCK CYLINDER HYDRAULIC MOTOR FLOW CONTROL VALVE (2 GPM) VALVE S3 FILTER A B (OPEN) (CLOSE) CHECK VALVE CHECK VALVE FLOW CONTROL VALVE (4 GPM) VALVE S2 CHECK VALVE PRV 1015 PSI PRV 2250 PSI M FLOW CONTROL VALVE (2 GPM) PUMP FILTER RESERVOIR NOTE: PRV (PRESSURE RELIEF VALVE) FIG. 40-1 40 VALVE S1 PRV 1015 PSI P (TEST PORT) CHECK VALVE 11921 Slauson Ave. Santa Fe Springs, CA.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC (SMART STOW) FIG.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713 SYSTEM DIAGRAMS - Continued ELECTRICAL SCHEMATIC (WITHOUT CONTROLLER) FIG.
