Maxon Tuk-A-Way GPT Series User manual

M-17-06
REV. E
NOVEMBER 2021
© MAXON Lift Corp. 2021
To fi nd 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 REVISION E ............................................................. 4
WARNINGS ........................................................................................................................... 5
SAFETY INSTRUCTIONS .................................................................................................... 6
NOTICE ................................................................................................................................. 6
STANDARD LIFTGATE COMPONENTS .............................................................................. 7
GPT INSTALLATION PARTS BOXES ................................................................................... 8
GPTWR-SERIES MANUALS & DECALS.............................................................................. 9
VEHICLE REQUIREMENTS ............................................................................................... 10
CENTER OF MASS ............................................................................................................. 13
STEP 1 - ATTACH EXTENSION PLATE TO VEHICLE ....................................................... 14
BOLT EXTENSION PLATE .................................................................................. 14
WELD EXTENSION PLATE (ALTERNATE METHOD) ........................................ 17
STEP 2 - WELD LIFTGATE TO VEHICLE .......................................................................... 19
STEP 3 - ATTACH OPTIONAL BATTERY BOX & FRAME TO VEHICLE (IF EQUIPPED) . 23
STEP 4 - RUN POWER & GROUND CABLES ................................................................... 31
STEP 5 - CONNECT POWER CABLE ................................................................................ 33
STEP 6 - CONNECT GROUND CABLE ............................................................................. 36
STEP 7 - INSTALL CONTROL SWITCH ............................................................................. 38
STEP 8 - CHECKING HYDRAULIC FLUID ......................................................................... 40
STEP 9 - CONNECT POWER & GROUND CABLES TO BATTERY .................................. 42
STEP 10 - REMOVE LOCKING ANGLES & KNUCKLE BOLTS, CHECK
FOR INTERFERENCE ........................................................................................................ 43
STEP 11 - INSTALL OPENER & LICENSE PLATE BRACKET WITH ICC BUMPER
OR UNDERRIDE ................................................................................................................. 48
INSTALLATION WITH ICC BUMPER ................................................................ 48
INSTALLATION WITH UNDERRIDE ................................................................. 50
STEP 12 - ADJUST PLATFORM (IF REQUIRED) .............................................................. 52
STEP 13 - FINISH WELDING LIFTGATE TO VEHICLE ..................................................... 54
STEP 14 - BOLT STEPS TO EXTENSION PLATE ............................................................ 55
STEP 15 - ADJUST WALK RAMP PADS ............................................................................ 59
STEP 16 - VEHICLE TAILLIGHT POSITIONING ............................................................... 60

STEP 17 - LUBE GREASE FITTINGS AS NEEDED ........................................................... 61
APPLY DECALS ................................................................................................................. 62
DECALS & PLATES ........................................................................................................... 64
TOUCH-UP PAINTED OR GALVANIZED FINISH .............................................................. 65
SYSTEM DIAGRAMS ......................................................................................................... 66
PUMP MOTOR & SOLENOID SWITCH OPERATION - SINGLE PUMP ............................ 66
PUMP MOTOR & SOLENOID SWITCH OPERATION - DUAL PUMPS ............................. 67
HYDRAULIC SCHEMATIC (POWER DOWN) .................................................................... 68
HYDRAULIC SCHEMATIC (POWER DOWN) - DUAL PUMPS .......................................... 69
ELECTRICAL SCHEMATIC (POWER DOWN) ................................................................... 70
ELECTRICAL SCHEMATIC (POWER DOWN) - DUAL PUMPS ......................................... 71
GPTWR ELECTRICAL VALUES & TORQUE SPECIFICATIONS ....................................... 72
OPTIONS ............................................................................................................................ 73
OPTIONAL LIFTGATE COMPONENTS .............................................................................. 73
PRE-DELIVERY INSPECTION FORM ................................................................................ 75

11921 Slauson Ave. Santa Fe Springs, CA. 90670 [phone] FAX [phone]
4
SUMMARY OF CHANGES: M-17-06 REVISION E
PAGE DESCRIPTION OF CHANGE
COVER Updated REV and date of release.
8
Updated ground cable to 57.75” long cable in Parts Box A. Added new cap screw,
fl atwasher and lock nut to Parts Boxes A and C. Removed plastic ties (items for
packaging) from Parts Boxes A and C. Added 1/4” fl at in Parts Box B to use for shim.
16 Updated weld specifi cations in FIG. 16-1 for LH and RH ends of the extension
plate.
25 Added weld-on option for frame hanger brackets.
26 Combined instructions from paragraph 4 with paragraph 3 on page 25. Renum-
bered paragraphs after page 26.
27 Updated battery positve (+) to positive (+) red cable and negative (-) to negative (-)
black cable from 8” to 10” LG.
30 Updated battery box asembly illustration to identify ground cable from vehicle bat-
tery.
31, 32 Added instructions to install 38 ft dedicated ground cable, and a NOTE about the
electrical cables in Parts Boxes A & C.
36-37
Updated instructions to connect ground cable to pump manifold instead of pump
mounting bracket, and connect ground cable to vehicle chassis with fasteners from
Parts Box A. Added note to connect dedicated ground cable to vehicle battery.
41 Updated tables of recommended hydraulic oils.
42, 48,
49, 50,
51, 55, 58
Added instructions to connect/disconnect dedicated ground cable (if installed) to
battery negative terminal.
52 Added note about making a 3/16” shim.

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 fi ngers, 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.
• 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 modifi cations on the Liftgate. Modifi cations 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.
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while installing
Liftgates. See Operation Manual for operating safety requirements.
Installing and maintaining a liftgate can expose you to chemicals, including lead, which are known
to the State of California to cause cancer and birth defects or other reproductive harm. To mini-
mize exposure, install and maintain liftgate in a well-ventilated area and wear proper Personal
protective equipment (PPE). For more information go to www.P65Warnings.ca.gov.
WARNING
!

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 fl ames 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 fi rst 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]
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GPTWR INSTALLATION PARTS BOXES
PARTS BOX A
TABLE 8-1
PARTS BOX C
TABLE 8-3
PARTS BOX B
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
2#10 RUBBER LOOM CLAMP 2 801681
3CABLE ASSEMBLY, 175 AMPS, 38 FT LG. 1 264422
4SELF-TAPPING SCREW, 10 X 1/2” LG. 2 030458
5CABLE ASSEMBLY, 2 GA, BLACK, 57-3/4” LG. 1 268226-13
6CAP SCREW, 3/8”-16 X 1-1/2”, GR8 1 900014-6
7FLAT WASHER, 3/8” 2 902001-2
8LOCKNUT, 3/8”-16 1 901002
9PLASTIC TIE WRAP 2 206864
ITEM NOMENCLATURE OR DESCRIPTION QTY. PART NUMBER
REF PARTS BOX C 1 297502-02
1SPRING CLIP 20 050079
2CABLE ASSY, 175 AMP 38 FT LG. 1 264422
3GROUND CABLE ASSY, 2 GA X 38 FT LG. 1 269191-01
4#10 LOOM CLAMP 2 801681
5SELF-TAPPING SCREW, 10 X 1/2” LG. 2 030458
6CAP SCREW, 3/8”-16 X 1-1/2”, GR8 1 900014-6
7FLAT WASHER, 3/8” 2 902001-2
8LOCKNUT, 3/8”-16 1 901002
9PLASTIC TIE WRAP 2 206864
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
3HEX NUT, 1/2”-13 2 901011-9
4CAP SCREW, 1/2’’-13 X 1-1/2” LG. 2 900035-3
5INSTALLATION BRACKET 2 269462-01
6LUG, 2 GAUGE, COPPER, 5/16” 1 906497-02
7SCREW, SELF TAPPING, #10-24 X 1-1/2” LG. 2 900057-7
8HEAT SHRINK TUBING, 3/4” X 1-1/12” LG. 1 253316-04
9FLAT, 2-1/2” X 1” X 1/8” THICK 2 201999
10 FLAT, 2-1/2” X 1” X 1/4” THICK 2 090144-38
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
298125-11 (GPTWR-25)
298125-12 (GPTWR-3)
298125-13 (GPTWR-4)
298125-14 (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 fi nd 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
modifi ed to install this Liftgate.
NOTE: Dimensions are provided as reference for fi tting 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”