Maxon GPC X1-LDF User manual

GPC X1-LDF liftgate
Installation Manual
for
Mercedes Benz Sprinter

LIFT CORP.
11921 Slauson Avenue
Santa Fe Springs, CA 90670-2221
P 800.227.4116 / 562.464.0099
F 888.771.7713
Date 07.2019
Part No. 20 912 027

Contact information
Contact information
MAXON LIFT CORP.
Corporate Office
11921 Slauson Avenue
Santa Fe Springs, CA 90670-2221
P 800.227.4116 / 562.464.0099
F 888.771.7713
Customer Service / Parts
USA/Canada
Mexico
P 800.227.4116
F 888.771.7713
P 01.664.231.6039

Contents
IV
Contents
Contact information ................................................................................................ III
Contents...................................................................................................................IV
1Safety.................................................................................................................. 1
1.1 Intended use ................................................................................................ 1
1.2 Requirements for personnel......................................................................... 1
1.3 Requirements for installation and commissioning........................................ 2
1.4 Fundamental hazards................................................................................... 2
1.5 Emergency procedure.................................................................................. 2
1.6 Presentation of warning notices ................................................................... 3
2Introduction ....................................................................................................... 4
2.1 Scope of delivery.......................................................................................... 4
2.1.1 Lifting gear ........................................................................................ 4
2.1.2 Platform............................................................................................. 4
2.1.3 Bridge plates (20 909 431)................................................................ 4
2.1.4 Accessories kit .................................................................................. 5
2.1.5 Installation adapter kit (22 911 216).................................................. 7
2.2 Damage during transport.............................................................................. 8
3Preparing for installation.................................................................................. 9
3.1 Requirements for installation........................................................................ 9
3.2 Lifting the vehicle ......................................................................................... 9
3.3 Preparing the vehicle ................................................................................... 9
3.3.1 Remove spare tire........................................................................... 10
3.3.2 Move exhaust pipe.......................................................................... 10
3.3.3 Mount supplementary battery.......................................................... 10
3.3.4 Install standard bumper on Mercedes Sprinter................................ 10
3.3.5 Deactivate parking sensors............................................................. 10
3.3.6 Remove trailer hitch or step ............................................................ 11
3.4 Unpacking the lifting gear, installation adapters, and accessories kit......... 11
3.5 Pre-installing the installation adapters........................................................ 11
3.6 Installing the cables/preparation................................................................. 15
3.6.1 Cable to the platform....................................................................... 15
3.6.2 Cable for the service switch ............................................................ 15
3.6.3 Routing the cables to the front of the vehicle .................................. 16
3.6.4 Control panel cable on the control unit............................................ 18
3.6.5 Handheld control (optional)............................................................. 18
3.7 Aligning the lifting gear............................................................................... 20
3.8 Mounting holes on the vehicle.................................................................... 21
4Installation ....................................................................................................... 22
4.1 Positioning the lifting gear.......................................................................... 22
4.2 Tightening the lifting gear fittings until hand-tight....................................... 23
4.3 Securing the lifting gear to the vehicle........................................................ 26
4.4 Laterally aligning the lifting gear................................................................. 27

Contents
V
4.5 Securing the axle assemblies..................................................................... 27
4.6 Securing the installation adapters.............................................................. 27
4.7 Connecting the cables to the lifting gear .................................................... 28
4.7.1 Installing and connecting the service switch.................................... 28
4.7.3 Installing and connecting the control panel ..................................... 29
4.7.4 Connecting the handheld control (optional)..................................... 33
4.7.5 Mounting the bracket for the handheld control (optional) ................ 33
4.7.6 Connecting the cables (front of vehicle).......................................... 33
4.8 Unpacking the platform .............................................................................. 36
4.9 Raising the platform ................................................................................... 36
4.10Installing the platform................................................................................. 37
4.11Mounting the platform lock on the closing arm........................................... 41
4.12Mounting the ground rollers........................................................................ 42
4.13Installing supports (vehicle-dependent)...................................................... 43
4.14Connecting the platform to the electrical system........................................ 43
4.14.1 Connecting the platform cable to the electrical system ................... 43
4.14.2 Connecting the license plate light.................................................... 44
4.15Mounting the license plate holder............................................................... 45
4.16Mounting the bridge plates (20 909 431).................................................... 45
4.17Mounting the warning flags ........................................................................ 45
4.18Affixing the danger notice sticker ............................................................... 48
5Adjusting the liftgate....................................................................................... 49
5.1 Setting the lift height to the vehicle floor level using the adjustable stop on
the axle assembly.............................................................................................. 49
5.2 Aligning the platform parallel to the vehicle floor........................................ 49
5.3 Aligning the platform (foldover section) parallel to the vehicle floor............ 50
5.4 Checking the stop on the foldover section of the platform.......................... 52
5.5 Setting the end stop for the closed platform............................................... 53
5.6 Adjusting the stopper for fastening the platform......................................... 55
5.7 Adjusting the support arm for the driving position using the Bowden cable 55
5.8 Programming the tilt sensor ....................................................................... 56
6Testing the liftgate........................................................................................... 58
6.1 Function test............................................................................................... 58
6.2 Testing the operating speed....................................................................... 58
6.2.1 Vertical speed ................................................................................. 58
6.2.2 Closing and opening speed (90° to 10°).......................................... 58
6.2.3 Tilting speed (10° to -10°)................................................................ 58
6.3 Load tests................................................................................................... 59
6.3.1 Static test ........................................................................................ 59
6.3.2 Dynamic test ................................................................................... 59
6.3.3 Testing against lifting an overload................................................... 59
6.3.4 Testing the safety devices............................................................... 59
6.4 Explanation of diagnostic LED on the control unit...................................... 60
6.4.1 Checking tilt sensors S1 and S2 in the platform.............................. 61
6.4.2 Checking pressure switch S4.......................................................... 61

Contents
VI
6.5 Entry in inspection record book.................................................................. 61
7Recommendations and instructions regarding the liftgate......................... 62
7.1 Hydraulic oil recommendations .................................................................. 62
7.2 Painting the lifting gear............................................................................... 62
7.3 Rating plate................................................................................................ 62
8Useful information........................................................................................... 63
8.1 About the service switch............................................................................. 63
8.2 Assembly drawings of installation adapters................................................ 65
8.3 Electrical circuit diagram ............................................................................ 66
8.4 Hydraulic circuit diagram............................................................................ 67
8.5 Torque table............................................................................................... 68
8.6 Activating the liftgate.................................................................................. 69
8.7 Operation using the control panel .............................................................. 69
8.8 Operation using the optional handheld control........................................... 70

Safety
1
1 Safety
1.1 Intended use
This liftgate was specially developed for cargo vans. It may be used only on the
vehicles for which it was designed.
To determine whether the liftgate may be installed on a specific vehicle, please
contact the manufacturer or customer service.
The liftgate is used for loading and unloading the vehicle and for transferring loads.
Any other use is prohibited.
Do not exceed the maximum load carrying capacity (see rating plate). Be sure to
correctly position the load on the platform.
Do not operate the liftgate with the vehicle in motion.
Do not use the liftgate to lift any person other than the operator.
This manual is intended for the manufacturer who installs the liftgate on the vehicle. It
contains information on transport, installation, and commissioning.
Read this manual before working on or operating the liftgate.
Do not deviate from the instructions contained in this manual. By doing so, you
risk injury, damage to property, and voiding of the warranty.
Make sure that this manual always remains with the liftgate or vehicle.
IMPORTANT: For information on operation, cleaning, maintenance,
decommissioning, disassembly, and disposal, refer to the accompanying user
manual.
1.2 Requirements for personnel
The tasks described in this manual may be performed only by qualified and
trained personnel.
Use personal safety gear when performing these tasks: protective goggles, work
gloves, and protective footwear.
Perform these tasks at an appropriate working height with the body in an
appropriate position. Avoid unusual positions.
Comply with valid legal and operational guidelines, such as occupational safety
regulations and environmental regulations.

Safety
2
1.3 Requirements for installation and commissioning
Follow the vehicle manufacturer’s current installation guidelines for the relevant
vehicle. Pay particular attention to safety instructions and warnings.
Changes to the liftgate’s axle assemblies and to the necessary installation
adapters are prohibited and invalidate approval by the German Federal Motor
Transport Authority.
Do not modify or remove safety equipment (pressure limiting valves, non-return
valves, electrical fuses, and software control routines). By doing so, you risk
serious injury.
Do not modify, cover, or remove product labels (warning labels, instructions,
rating plates).
1.4 Fundamental hazards
Electrical system with on-board voltage:
The liftgate receives electrical power from the vehicle’s on-board power supply (max.
48 V DC). The electrical system is designed using state-of-the-art technology.
Do not damage or modify electrical components or wiring.
High-pressure hydraulic system:
The liftgate’s hydraulic system operates at high pressure (max. 220 bar). The
hydraulic system is designed using state-of-the-art technology.
Do not damage or modify hydraulic components or hoses.
Moving parts with crushing points:
All parts that move in close proximity to one another can potentially crush fingers.
Watch out for the unexpected movement of moving parts.
Hinges with crushing points (on liftgate with platform foldover section):
Fingers are at risk of being crushed in the hinge area when the platform is folded and
unfolded.
Be careful when folding and unfolding the platform.
1.5 Emergency procedure
If you or another person working on or operating the liftgate experience a dangerous
situation:
Immediately stop what you’re doing and seek expert help.

Safety
3
1.6 Presentation of warning notices
The following types of notices are used in this manual to identify hazards and
complications:
WARNING
Failure to heed this notice can result in death or serious
injury.
CAUTION
Failure to heed this notice can result in minor or moderate
injury.
NOTICE
Failure to heed this notice can result in damage to property
or the environment.
And:
IMPORTANT
Important information or useful tip for correct use.

Introduction
4
2 Introduction
2.1 Scope of delivery
IMPORTANT: All illustrations of the lifting gear are shown without factory-installed
cables and hydraulic hoses.
2.1.1 Lifting gear
2.1.2 Platform
2.1.3 Bridge plates (20 909 431)
Fig. 3
Fig. 1
Fig. 2