Maxon GPTWR-25 Operating and maintenance instructions

M-17-06
JULY 2017
© MAXON Lift Corp. 2017
To find maintenance & parts information for your GPTWR Liftgate,
go to www.maxonlift.com. Click the PRODUCTS, TUK-A-WAY &
GPTWR buttons. Open the Maintenance Manual in the PRODUCT
DOCUMENTATION window. For parts, click on the PARTS PORTAL,
TUK-A-WAY & GPTWR buttons.

TABLE OF CONTENTS
SUMMARY OF CHANGES: M-17-06 ................................................................................... 4
WARNINGS........................................................................................................................... 5
SAFETY INSTRUCTIONS .................................................................................................... 6
NOTICE................................................................................................................................. 6
STANDARD LIFTGATE COMPONENTS .............................................................................. 7
GPTWR INSTALLATION PARTS BOX.................................................................................. 8
GPTWR-SERIES MANUALS & DECALS.............................................................................. 9
VEHICLE REQUIREMENTS............................................................................................... 10
CENTER OF MASS............................................................................................................. 13
STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE ....................................................... 15
BOLT EXTENSION PLATE .................................................................................. 15
WELD EXTENSION PLATE (ALTERNATE METHOD) ........................................ 18
STEP 2 - WELD LIFTGATE TO VEHICLE .......................................................................... 20
STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED). 24
STEP 4 - RUN POWER CABLE.......................................................................................... 32
STEP 5 - CONNECT POWER CABLE................................................................................ 34
STEP 6 - CONNECT GROUND CABLE (RECOMMENDED) ............................................. 36
STEP 7 - INSTALL CONTROL SWITCH ............................................................................. 37
STEP 8 - CHECKING HYDRAULIC FLUID......................................................................... 39
STEP 9 - CONNECT POWER CABLE TO BATTERY......................................................... 41
STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK FOR
INTERFERENCE................................................................................................................. 42
STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH
ICC BUMPER OR UNDERRIDE ......................................................................................... 47
INSTALLATION WITH ICC BUMPER ................................................................ 47
INSTALLATION WITH UNDERRIDE ................................................................. 49
STEP 12 - ADJUST PLATFORM (IF REQUIRED) .............................................................. 51
STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE ..................................................... 53
STEP 14 - BOLT STEPS TO EXTENSION PLATE ............................................................ 54
STEP 15 - ADJUST WALK RAMP PADS ............................................................................ 58
STEP 16 - LUBE GREASE FITTINGS AS NEEDED........................................................... 59

APPLY DECALS................................................................................................................. 60
DECALS & PLATES ........................................................................................................... 62
TOUCH-UP PAINTED OR GALVANIZED FINISH.............................................................. 63
SYSTEM DIAGRAMS......................................................................................................... 64
PUMP & MOTOR SOLENOID OPERATION ....................................................................... 64
HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 65
ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 66
GPTWR ELECTRICAL VALUES ......................................................................................... 67
OPTIONS ............................................................................................................................ 68
OPTIONAL LIFTGATE COMPONENTS.............................................................................. 68

SUMMARY OF CHANGES: M-17-06
PAGE DESCRIPTION OF CHANGE
5 Changed WARNING for welding galvanized steel to reference AWS D19.0.
7 Main assembly shows new bolt-on mounting plates.
8
Added Installation Parts Box Tables A, B & C. Added new molded, toggle switch
assembly, Added new 1/2” X 5/16” flat washer, 1-1/2” long self-tapping screws for
control switch assembly, and 1/2” long self-tapping screws for rubber loom clamp.
Added ground cable assembly, 2 GA X 48’ LG.
9 Updated GPTWR series manuals and decals part numbers.
17 Added welding note and specifications for bolt-on extension plate.
18
Removed WARNING for welding galvanized parts. Added note for recommended
practices for welding galvanized steel to refer to AWS (American Welding Soci-
ety) D19.0 Welding Zinc-Coated Steel.
20 Added illustration and table showing mounting plates for various frame widths.
20-23
Updated Step 2: Weld Liftgate to Vehicle instructions. Bolt-on mounting plates
are not welded to main frame. With bolt-on mounting plates, it’s not necessary to
remove split loom.
23 Added electrical welder Caution for connecting welder.
27 Removed instruction and image regarding welding galvanized decal.
34, 35, 38,
65
Updated power unit has no thermal switch. Fused power connection shows new 10
AMP fuse holder assembly.
36 Added new instructions to connect ground cable supplied with parts Box B.
38 Updated hydraulic fluid reservoir fill level.
40, 47, 49,
10, 55
Added instructions for disconnecting and reconnecting both negative (-) and posi-
tive (+) battery connections.
47-50 Made separate procedures for GPT’s equipped with ICC bumper or underride.
55 Added 1/2”-13 flange lock nuts for mounting steps to extension plate.
62 Removed galvanized warning decal.
63 Updated Platform Warning Decal, P/N 281189-02
66 Updated electrical schematic show cycle counter (if equipped).
67 Added GPTWR electical values.
68, 69
Updated hand-held, street side and dual control kits in the OPTIONS table. Re-
moved cold galvanize spray (16 OZ) and bright zinc spray paint (16 OZ). Removed
painted step kit options.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
5
•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.
•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.
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.
•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 modifications on the Liftgate. Modifications 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.
!
WARNINGS
•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.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
6
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.
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 to operate the Liftgate.
•Be careful working by an automotive type battery. Make sure the work area is well ventilated and
there are no flames 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 first 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.
•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.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
7
STANDARD LIFTGATE COMPONENTS
CAUTION
!
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 [phone] or
Send e-mail to [email protected]
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.
EXTENSION PLATE
MAIN
ASSEMBLY
PARTS
BOXES
OPENER
STEP KIT
ASSEMBLY
(DUAL STEPS
SHOWN)
TYPICAL LIFTGATE COMPONENTS FOR SHIPMENT
(OPTIONAL COMPONENTS NOT SHOWN)
FIG. 7-1

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
8
GPTWR INSTALLATION PARTS BOX
PARTS BOX A WITH POWER CABLE
TABLE 8-1
PARTS BOX C WITH GROUND CABLE
TABLE 8-3
PARTS BOX B WITHOUT POWER CABLE, GROUND CABLE, OR FRAME CLIPS
TABLE 8-2
ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER
REF PARTS BOX A 1 297502-01
1SPRING CLIP, 1/2” x 1-3/8” 10 050079
2PLASTIC TIE 2 206864
3#10 RUBBER LOOM CLAMP 2 801681
4CABLE ASSEMBLY, 175 AMPS, 38 FT LG. 1 264422
5SELF-TAPPING SCREW, 10 X 1/2” LG. 2 030458
6GROUND CABLE ASSEMBLY, 2 GA X 48” LG. 1 251871-26
ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER
REF PARTS BOX C 1 297502-02
1SPRING CLIP 20 050079
2PLASTIC TIE 4 206864
3GROMMET, 1” DIA, 2 HOLES 1 266428-09
4CABLE ASSY, 175 AMP 38 FT LG 1 264422
5GROUND CABLE ASSY, 2 GA X 38FT LG 1 269191-01
6#10 LOOM CLAMP 2 801681
7SELF-TAPPING SCREW, 10 X 1/2” LG. 2 030458
ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER
REF PARTS BOX B 1 297049-02
1SHIM, 2-1/2” X 1” X 16 GAUGE 2 264732
2TOGGLE SWITCH ASSEMBLY 1 296855-01
3FLAT WASHER, 1/2” X 5/16” THICK 2 902000-13
4HEX NUT, 1/2”-13 2 901011-9
5CAP SCREW, 1/2’’-13 X 1-1/2” LG. 2 900035-3
6INSTALLATION BRACKET 2 269462-01
7LUG, 2 GAUGE, COPPER, 5/16” 1 906497-02
8SCREW, SELF TAPPING, #10-24 X 1-1/2” LG 2 900057-7
9HEAT SHRINK TUBING, 3/4” X 1-1/12” LG. 1 253316-04
10 FLAT, 2-1/2” X 1” X 1/8” THICK 2 201999
11 LICENSE PLATE BRACKET KIT 1 287015-01

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
9
GPTWR-SERIES MANUALS & DECALS
ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER
REF DECAL & MANUAL KIT 1
297225-11 (GPTWR-25)
297225-12 (GPTWR-3)
297225-13 (GPTWR-4)
297225-14 (GPTWR-5)
1INSTALLATION MANUAL (GPTWR) 1 M-17-06
2OPERATION MANUAL (GPT & GPTWR) 1 M-17-07
3DECALS (SEE DECAL PAGES IN THIS MANUAL) 1 (ALL GPTWR’S)
TABLE 9-1
NOTE: To find maintenance information for your GPTWR Liftgate, go to www.max-
onlift.com. Click the PRODUCTS, TUK-A-WAY & GPTWR buttons. Open
the Maintenance Manual in the PRODUCT DOCUMENTATION window. For
parts, click on the PARTS PORTAL, TUK-A-WAY & GPTWR buttons.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
10
VEHICLE REQUIREMENTS
1. Check for correct clearances (FIG. 10-1 & 10-2) on
vehicle to prevent interference between vehicle
and Liftgate.
NOTE: Make sure vehicle is parked on level ground while preparing vehicle and
installing Liftgate.
NOTE: BODY maximum and minimum operating bed height, for GPTWR models
with standard platform, are as follows.
Maximum height is 55” (Unloaded). Loaded height is 49”. On vehicle bodies
equipped with swing-open doors, extension plate and vehicle body must be
modified to install this Liftgate.
NOTE: Dimensions are provided as reference for fitting Liftgate to vehicle body.
GPTWR-25 & GPTWR-3 LIFTGATE CLEARANCE DIMENSIONS
FIG. 10-1
15-5/8” TO 21-5/8”
55” MAX. BED HEIGHT
49” LOADED BED HEIGHT
15”
14-3/4”
33”
29-5/8”
22”
12”
GPTWR-4 & GPTWR-5 LIFTGATE CLEARANCE DIMENSIONS
FIG. 10-2
16-3/16” TO 22-3/16”
55” MAX. BED HEIGHT
49” LOADED BED HEIGHT
15”
13-5/16”
35-5/16”
27-7/8”
12”
23-7/8”
22-3/8”
39-1/2”
22”