Maxon GPC 22 X1 User manual

GPC 22 X-1 liftgate
Installation Manual
LIFT CORP.
11921 Slauson Avenue
Santa Fe Springs, CA 90670-2221
P 800.227.4116 / 562.464.0099
F 888.771.7713
Date 03.2021
Part-no. S 20 912 436

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 3 Version 2021
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

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 4 Version 2021
Safety
Intended use
These installation directions contain the instructions necessary to install the liftgate and adjust it
to those vehicles for which the liftgate was designed. To determine whether the device may be
installed on a certain vehicle, please contact us. We will provide the required information.
If the liftgate needs to be modified or if it is necessary to differ from these installation directions, a
written approval from Maxon Lift CORP. needs to be obtained first. Unapproved modifications
and amendments from these installation directions may lead to failure and to operating
interruptions as well as to hazards for the operator.
The warranty for the device will be voided by "unapproved modifications" and "deviations
from the installation directions."
The installations guidelines of the chassis manufacturer need to be complied with!
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.
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.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 5 Version 2021
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 are prohibited.
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).
Check for damages after arrival
For damages on the liftgate which occurred during transportation, the shipping/forwarding
company will be responsible. The lift needs to be checked for damages upon arrival. If any
damages occurred during transportation, they need to be recorded on the waybill, so that claims
can be raised. Insurance claims can be settled only by Maxon Lift CORP. and the
shipping/forwarding company or its insurance.
Trailer hitch
If the vehicle has a trailer hitch, the clearance of the shaft axle to the liftgate and the overall
length need to be guaranteed by the installer.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 6 Version 2021
Presentation of warning notices
The following types of notices are used in this manual to identify hazards and complications:
DANGER
Failure to heed this notice can result in death or serious injury.
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.
IMPORTANT
Important information or useful tip for correct use.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 7 Version 2021
Fundamental hazards
DANGER
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.
Fire and explosion hazard. Excessive current may damage the battery or cable harness. To
prevent this, visually inspect the electrical system (maintenance schedule).
DANGER
High-pressure hydraulic system:
The liftgate’s hydraulic system operates at high pressure max. 3200 PSI (max. 220 bar). The
hydraulic system is designed using state-of-the-art technology.
 Do not damage or modify hydraulic components or hoses.
Danger from pressurized liquids and gases.
Hydraulic components/lines can burst and cause injury.
 Inspect hydraulic components/lines at regular intervals (maintenance schedule).
 Install only state-of-the-art hydraulic components/lines.
DANGER
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.
DANGER
Moving parts with points where objects can be pulled in and/or trapped:
Parts of the body, long hair, and clothing are at risk of being caught and pulled in by moving
parts. This can result in fatal injuries.
 Always secure long hair
 Do not wear loose-fitting clothing

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 8 Version 2021
Installation Directions GPC 22 X-1
Installation-Safety Precautions
 Before installing, the battery of the vehicle needs to be disconnected.
 The vehicle needs to be secured against all unintentional shifting.
 The plugs for electronic systems as for example ABS needs to be pulled before welding.
Fuel lines, air hoses of the brake system, and cables in the installation area need to be
protected against damages.
 Any special safety regulations (if applicable) need to be complied with.
 Safety gear, like protective goggles, work gloves and work boots, need to be made
available before installing and are to be used if necessary.
 Safety devices on cranes, forklifts, and other lifting gear necessary for installing are to be
checked to see if they are in proper working condition before they are used.
CAUTION
Unsuitable transport equipment
When transporting and lifting heavy parts, use transport equipment (e.g. cranes,
pallet trucks, or other lifting gear) with a sufficient load carrying capacity.
 Verify the correct and reliable functioning of the transport equipment.
Unpacking the lifting gear, installation adapters, and accessories kit
CAUTION
Unsecured, heavy parts
When transport locks are removed, parts may fall or tip over and the platform may tip
over. Risk of injury.
 Secure loose parts. Remove transport locks carefully.
 After disposing of packing materials, store all parts in a secured manner.
NOTICE
Oil leakage
Incorrect positioning of the lifting gear can result in oil leakage. Risk of environmental
damage.
 Always transport the lifting gear in an upright position using suitable lifting
points.
IMPORTANT
Dispose of all packing materials in accordance with environmental regulations.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 9 Version 2021
IMPORTANT
Please follow these important steps before starting installation.
1. Read and fully understand complete installation manual.
2. Check and verify that your vehicle dimensions are
correct for the model of liftgate that you are installing.
Vehicle mounting data is found on page 20 of the
installation manual.
3. The Stabilizer bar
must be mounted before
liftgate is installed on the
truck body lnstall the 1/2"
spacer on the body. This spacer bar is always used with
exception of liftgate behind swing doors. See page 12 for
further instructions.
The power pack was already filled
with oil in the factory. If oil is required, use recommended oil
type found in the chart on page 36 to fill the reservoir.
CAUTION
Caution with transport. Failure can result in injury.
do not lift at the power pack
no pressure or shocks
do not use pry bars
Caution!

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 10 Version 2021
Install the sub frame according to
instructions and manuals of the
chassis manufacturer.
Preparation of the Vehicle
Dismantle the synchronizer bar and the tail lights. If there are any U-shaped mounting brackets
with threads on both sides, brackets, rivets, spare wheels, or couplings in the installation area of
the mounting brackets, they need to
be removed. If necessary, remove hinges and locks at the rear end plate of the body floor.
IMPORTANT
Be careful not to damage the vehicle. We recommend using appropriate coverings.
CAUTION
Secure the vehicle in place to prevent unintentional movement.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 11 Version 2021
Cutouts in Rear Sill
If the dimension of the rear sill (H2) in the area of the lift arms is more than H2, then openings
need to be cut out according to our recommendations. The min. demission for the rear sill is
1 4/7”. H3 is the max. sill height. If the rear sill is cut out, proper reinforcement should be put
back in to maintain structural integrity of the rear sill.
Recommendations for the rear sill cutouts to install the models GPC 22 X-1
Dimensions GPC 22 X-1
Platform min. / max.
M1
centre / centre
29”1/2 - 34”5/8 inch
750 - 880 mm
M3
M5
M4
Model inch/
Platform
max/min
Lift Arm
Center/Center M1 max M3 max M4 M5
GPC 22 X-1 inch 98/92 41 51 48 35 84,5
wei
g
hts Platform wei
g
hts total
GPC 22 X-1 width x height
92 and 98 x 48, 60, 72 inch Platform 290 pounds 670
pounds
inch H1 H2 H3 H4
GPC
22 X-1 8,5 3 1/8 5 35
Table
H3
29”1/2 - 34”5/8 inch
750 - 880 mm
H4
H2
H1 H1

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 12 Version 2021
Instruction, GPC-X spacer kit installation,
Kit p/n 211915-01 (a spacing dampers between GPC-X platform and truck body)
1. Kit components:
2. Steel bar installation (before lift-gate installation)
• for 102" wide truck, use full length of the 98" length spacer bar.
• for 96" width truck, shorten spacer bar by 3" equally from two ends.
• place and clamp the spacer bar horizontally at level with bed height.
• use the bar as a template to transfer holes locations on truck rear sill.
• drill 5x 17/32" diameter holes; remove burrs and sharp edges.
• use provided nuts and screws to mount the spacer bar as shown.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 13 Version 2021
3. Bumpers installation
• with platform stowed, mark lines 5.0" platform tip (as shown), both sides.
• with platform unstowed, place bumpers top on lines, 1.75" away from in inside post, both
sides.
• use bumper as templates, transfer holes location onto truck sill.
• use the bar as a template to transfer holes locations on truck body.
• drill 4x .26" +/- .005" diameter holes; remove burrs and sharp edges.
• use proper rivet tool to install provided rivet with washers between rivet head and bumper.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 14 Version 2021
Placement of GPC 22 X-1 mount fixture
IMPORTANT
Measure body opening and mark center line
Mark center line on GPC mounting fixture
IMPORTANT
Place the mount fixture tight against the 1/2” spacer before welding or clamping it in place.
Use platform pins to center liftgate on truck body

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 15 Version 2021
Assembly of the lifting gear and the synchronizer bar
WARNING
Installation at crushing and shearing points
Fingers are at risk of being crushed or sheared when the lifting gear is installed on the vehicle.
 Be careful at the connecting points between the lifting gear and vehicle.
Install the mounting brackets loose, secure lifting machanism with Bolt clamp, and connect the
positive and ground cables at the battery.
Lift up the Lift arms in order and to assemble the synchronizer bar (see drawings at page 17).
Measure the frame width of the vehicle.
Adjust the
positions of the brackets
to the frame and hand
tighten the bolts
The brackets GPC positioned on the frame width
max. 34“ 2/3 inch
min. 29“ ½ inch
lift the arm
to assembly
the synchronizer
bar
IMPORTANT
after assembly
check and readjust
if necessary.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 16 Version 2021
IMPORTANT
Before assembling the lifting gear, it is imperative that the bolt (A) is loose. It will be tightened
after adjusting the lifting gear. (Please refer to page 26)
NOTICE
 Do not damage cables.
A

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 17 Version 2021
Assembly drawing of lifting mechanism with synchronizer bar

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 18 Version 2021
Place the lifting gear of the GPC on a pallet
and put it in fitting position under the vehicle
with a forklift truck.
Put the GPC in the correct fitting position
and align it.
IMPORTANT
You will find all needed measurements on page 20 of these
instructions.

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 19 Version 2021
Position and pin both liftgate arms into the assembly brackets.
Press the lifting arms against the rear frame of the vehicle and
secure them against unintentional movement.
Secure the mounting fixture with clamps / weights
or by welding it to the rear sill.
Weld on the brackets at the vehicle frame, according to table
at page 21.
Secure the main beam by tightening the 4 bolts according to
the tightening torque table on
page 39.
IMPORTANT
Tighten the bolts according to the torque table on page 39

Installation manual Liftgate GPC 22 X-1, Series 11
Document no.: S 20 912 436 20 Version 2021
Assembly measurements
Liftinga
r
m
Free space W
Floor level
Stay always close to the measurement
under the vehicle frame
Ground
Chassis
Measurement always as close as possible to the chassis, without exceeding the max. D.
Please refer to page 11 and 20 in the installation manual for correct mounting dimensions.
Installation Chart GPC 22 X-1
If there is not enough space, please contact the sales / customer service by calling 800-227-4116
department. The sales / customer service will contact the technical department to check whether
the installation, considering the dimensions of the vehicle, is possible. If the installation is possible,
you will get a special drawing in which the installation situation is shown.
Find technical information online at https://www.maxonlift.com/support. For additional technical
information, visit https://www.maxonlift.com/support/technical-service or you can send
an e-mail to: [email protected].
Model

inch

Lengthof
theliftarm
(inch)
Liftgate
R
max
(inch)
Vehicle
R
min
(inch)
Vehicle
D
from - to
(inch)
Top of
main beam
E
from - to
(inch)
Top of
main beam
W
from - to
(inch)
Space
GPC 22 X-1 inch 26,5 46,5 34 19 - 26,5 15 - 20 28,5 - 33
GPC 22 X-1 inch 29,5 51 39,5 19,5 - 28 20 – 23,5 30 - 34
*