Maxon GPC Parts Manual

Type
Parts Manual

This manual is also suitable for

M-09-26
REV. D
AUGUST 2016
© MAXON Lift Corp. 2016
MAINTENANCE MANUAL
LIFT CORP.
11921 Slauson Ave.
Santa Fe Springs, CA. 90670
CUSTOMER SERVICE:
TELEPHONE (562) 464-0099 TOLL FREE (800) 227-4116
FAX: (888) 771-7713
WARRANTY/ RMA POLICY & PROCEDURE
NOTE: For latest version of all Manuals (and replacements), download the
Manuals from Maxon’s website at www.maxonlift.com.
LIFTGATE WARRANTY
Type of Warranty: Full Parts and Labor
Term of Warranty: Standard Liftgates - 2 years from ship date or 6,000 cycles
Premium Liftgates - 2 years from ship date or 10,000 cycles
This warranty shall not apply unless the product is installed, operated and maintained in accordance with MAXON Lift’s speci cations as set forth in
MAXON Lift’s Installation, Operation and Maintenance manuals. This warranty does not cover normal wear, maintenance or adjustments, damage or
malfunction caused by improper handling, installation, abuse, misuse, negligence, or carelessness of operation. In addition, this warranty does not
cover equipment that has had unauthorized modi cations or alterations made to the product.
MAXON agrees to replace any components which are found to be defective during the rst 2 years of service, and will reimburse for labor based on
MAXON’s Liftgate Warranty Flat Rate Schedule. (Copy of the Flat Rate is available at www.maxonlift.com.)
All warranty repairs must be performed by an authorized MAXON warranty facility. For any repairs that may exceed $500, including parts and labor,
MAXON’s Technical Service Department must be noti ed and an “Authorization Number” obtained.
All claims for warranty must be received within 30 Days of the repair date, and include the following information:
1. Liftgate Model Number and Serial Number
2. The End User must be referenced on the claim
3. Detailed Description of Problem
4. Corrective Action Taken, and Date of Repair
5. Parts used for Repair, Including MAXON Part Number(s)
6. MAXON R.M.A. # and/or Authorization # if applicable (see below)
7. Person contacted at MAXON if applicable
8. Claim must show detailed information i.e. Labor rate and hours of work performed
Warranty claims can also be placed online at www.maxonlift.com. Online claims will be given priority processing.
All claims for warranty will be denied if paperwork has not been received or claim submitted via Maxon website for processing by MAXON’s Warranty
Department within 30 days of repair date.
All components may be subject to return for inspection, prior to the claim being processed. MAXON products may not be returned without prior written
approval from MAXON’s Technical Service Department. Returns must be accompanied by a copy of the original invoice or reference with original
invoice number and are subject to a credit deduction to cover handling charges and any necessary reconditioning costs. Unauthorized returns will be
refused and will become the responsibility of the returnee.
Any goods being returned to MAXON Lift must be pre-approved for return, and have the R.M.A. number written on the outside of the package in plain
view, and returned freight prepaid. All returns are subject to a 15% handling charge if not accompanied by a detailed packing list. Returned parts
are subject to no credit and returned back to the customer. Defective parts requested for return must be returned within 30 days of the claim date for
consideration to:
MAXON Lift Corp.
10321 Greenleaf Ave., Santa Fe Springs, CA 90670
Attn: RMA#__
MAXON’s warranty policy does not include the reimbursement for travel time, towing, vehicle rental, service calls, oil, batteries or loss of income due to
downtime. Fabrication or use of non Maxon parts, which are available from MAXON, are also not covered.
MAXON’s Flat Rate Labor Schedule takes into consideration the time required for diagnosis of a problem.
All Liftgates returned are subject to inspection and a 15% restocking fee. Any returned Liftgates or components that have been installed or not returned
in new condition will be subject to an additional reworking charge, which will be based upon the labor and material cost required to return the Liftgate or
component to new condition.
PURCHASE PART WARRANTY
Term of Warranty: 1 Year from Date of Purchase.
Type of Warranty: Part replacement only. MAXON will guarantee all returned genuine MAXON replacement parts upon receipt and inspection of parts
and original invoice.
All warranty replacements parts will be sent out via ground freight. If a rush shipment is requested, all freight charges will be billed to the requesting
party.
TABLE OF CONTENTS
SUMMARY OF CHANGES: M-09-26, REVISION D ............................................................. 6
WARNINGS ........................................................................................................................... 8
SAFETY INSTRUCTIONS .................................................................................................... 8
LIFTGATE TERMINOLOGY .................................................................................................11
PERIODIC MAINTENANCE ................................................................................................ 12
PERIODIC MAINTENANCE CHECKS ................................................................................12
PERIODIC MAINTENANCE CHECKLIST ........................................................................... 13
CHECKING HYDRAULIC FLUID ........................................................................................ 15
CHANGING HYDRAULIC FLUID ........................................................................................16
PARTS BREAKDOWN .......................................................................................................18
MAIN ASSEMBLY WITH STANDARD UNDERRUN BUMPER ...........................................18
MAIN ASSEMBLY WITH LONG UNDERRUN BUMPER .................................................... 20
MAIN ASSEMBLY: GPC-22 & GPC-33 ............................................................................... 22
MAIN ASSEMBLY: GPC-44 ................................................................................................. 24
ALUMINUM PLATFORM ASSEMBLY .................................................................................26
ALUMINUM CART STOPS (94-1/2” PLATFORM) .............................................................. 32
ALUMINUM CART STOPS (98-1/2” PLATFORM) .............................................................. 33
STEEL PLATFORM ASSEMBLY ......................................................................................... 34
STEEL CART STOP (700MM FLAP)................................................................................... 38
STEEL CART STOP (900MM FLAP)................................................................................... 39
HYDRAULIC COMPONENTS - WITHOUT AUTO TILT ...................................................... 40
HYDRAULIC COMPONENTS - WITH AUTO TILT ..............................................................42
12V POWER PACK - WITHOUT AUTO TILT ...................................................................... 44
12V POWER PACK - WITH AUTO TILT ..............................................................................46
PUMP ASSEMBLY ............................................................................................................. 48
ELECTRICAL COMPONENTS ............................................................................................52
CONTROLS, SENSORS & INTERCONNECTING WIRING ...............................................52
ELECTRICAL JUNCTION BOX ...........................................................................................53
POWER & GROUND CABLES ........................................................................................... 54
EXTERNAL CONTROL BRACKET (KIT) ............................................................................ 55
INTERNAL CONTROL BRACKET (KIT) ............................................................................. 56
FLOOR SEAL, DOOR SEALS & BUMPERS ...................................................................... 58
MARKER FLAGS KIT .......................................................................................................... 60
DECALS ..............................................................................................................................62
SYSTEM DIAGRAMS .........................................................................................................64
PUMP & MOTOR SOLENOID OPERATION (WITHOUT AUTO TILT) ................................ 64
PUMP & MOTOR SOLENOID OPERATION (WITH AUTO TILT) ........................................65
HYDRAULIC SCHEMATIC (WITHOUT AUTO TILT) ........................................................... 66
HYDRAULIC SCHEMATIC (WITH AUTO TILT) .................................................................. 67
ELECTRICAL SCHEMATIC, 12V (WITHOUT AUTO TILT) ................................................. 68
ELECTRICAL SCHEMATIC, 12V (WITH AUTO TILT) ......................................................... 69
TROUBLESHOOTING ........................................................................................................ 70
PAGE DESCRIPTION OF CHANGE
COVER Updated REV and date of release.
15-17 Updated pump reservoir and uid check/ ll instructions.
32-33 Updated parts explosions for redesigned cart stops.
40-42 Updated hose routing for lift cylinders on GD & PD hydraulic parts diagrams.
65 Updated Power Unit Motor & Solenoid Operation chart.
48-51 Updated pump assembly illustrations and tables to show new reservoir .
56
Updated Internal Control Bracket illustration to show socket connector and hard-
ware.
68-69 Added diodes and updated wiring to controls on electrical schematics.
SUMMARY OF CHANGES: M-09-26, REVISION D
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
8
WARNINGS
SAFETY INSTRUCTIONS
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
Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your
feet are clear of the Liftgate.
• Keep ngers, hands, arms, legs, and feet clear of moving Liftgate parts (and platform
edges) when 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.
Disconnect Liftgate power cable from battery before repairing or servicing Liftgate.
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 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 rst aid. If acid gets on your
skin, immediately wash it off with soap and water.
Comply with the following WARNINGS and SAFETY INSTRUCTIONS while maintaining
Liftgates. See Operation Manual for operating safety requirements.
Read and understand the instructions in this Maintenance Manual before performing mainte-
nance on the Liftgate.
Before operating the Liftgate, read and understand the operating instructions in Operation
Manual.
Comply with all WARNING and instruction decals attached to the Liftgate.
If it is necessary to stand on the platform while maintaining 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 vehicle body.
WARNING
!
• Correctly stow platform when not in use. Extended platforms could create a hazard for
people and vehicles passing by.
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 could result from welds that are done incorrectly.
Recommended practices for welding on aluminum parts are contained in the current AWS
(American Welding Society) D1.2 Structural Welding Code - Aluminum. Damage to Liftgate
and/or vehicle, and personal injury could result from welds that are done incorrectly.
SAFETY INSTRUCTIONS
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
9
If an emergency situation arises (vehicle or Liftgate) while operating the Liftgate, release the con-
trol switch to stop the Liftgate.
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. Listen for scraping, grat-
ing and binding noises and correct the problem before continuing to operate Liftgate.
Use only Maxon Authorized Parts for replacement parts. Provide Liftgate model and serial num-
ber information with your parts order. Order replacement parts from:
MAXON LIFT CORP. Customer Service
11921 Slauson Ave., Santa Fe Springs, CA 90670
Online: www.maxonlift.com
Express Parts Ordering: Phone (800) 227-4116 ext. 4345
Email: Ask your Customer Service representative
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
10
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11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
11
LIFTGATE TERMINOLOGY
POWER
PACK
MAIN FRAME
BUMPER
PLATFORM
(ALUMINUM SHOWN)
CART STOPS
TILT
CYLINDER
LIFT
CYLINDER
LIFT FRAME
LOGIC VALVE &
HYDRAULIC LOCK
EXTERNAL
CONTROL
AUTO TILT
INTENSIFIER
(IF EQUIPPED)
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
12
PERIODIC MAINTENANCE CHECKS
Never operate the Liftgate if parts are loose or missing.
WARNING
NOTE: Make sure vehicle is parked on level ground while performing the
maintenance checks.
Quarterly or 1250 Cycles (whichever occurs rst)
Semi-annually or 2500 Cycles (whichever occurs rst)
Visually check the platform hinge pins for excessive wear and broken welds. See PARTS
BREAKDOWN section for replacement parts. Also, do the Quarterly or 1250 Cycles
maintenance checks.
Check the hydraulic uid level in the pump reservoir. Refer to the CHECKING HYDRAULIC
FLUID procedure in the PERIODIC MAINTENANCE section.
If hydraulic uid appears contaminated, refer to the CHANGING HYDRAULIC FLUID
procedure in the PERIODIC MAINTENANCE section.
Keep track of the grade of hydraulic uid in the pump reservoir and never mix two different
grades of uid.
Check all hoses and ttings for cha ng and uid leaks. Tighten loose ttings or replace
parts as required.
Check electrical wiring for cha ng and make sure wiring connections are tight and free of
corrosion. Use dielectric grease to protect electrical connections.
Check that all WARNING and instruction decals are in place. Also, make sure decals are
legible, clean and undamaged.
Check that all bolts, nuts, and roll pins are in place. Replace fasteners and roll pins if
necessary.
PERIODIC MAINTENANCE
!
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate, clean it off.
Touch up the paint where bare metal is showing. MAXON recommends using the zinc
primer touchup paint kit, P/N 908134-01.
Damaged cylinder seals and contaminated hydraulic uid can result from paint-
ing the polished portion of the cylinder rod. To prevent damage, protect the
exposed polished portion of the cylinder rod while painting.
CAUTION
Pump multi-purpose lithium grease in each lube tting on the cylinders and arms until
grease starts oozing from ends of the bearings. The lubrication diagram on the PERIODIC
MAINTENANCE CHECKLIST shows where to nd the lube ttings. Wipe off excess grease
with a clean lint-free cloth.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
13
PERIODIC MAINTENANCE CHECKLIST
Quarterly or 1250 Cycles (whichever occurs rst)
Semi-annually or 2500 Cycles (whichever occurs rst)
NOTE: Make sure vehicle is parked on level ground while performing maintenance
checks.
Do the Quarterly or 1250 Cycles Checks on this checklist.
Check the level and condition of the hydraulic uid.
Visually check all hoses and ttings for cha ng and uid leaks. Tighten loose ttings or
replace parts as required.
Check electrical wiring for cha ng and make sure wiring connections are tight and free
of corrosion. Use dielectric grease to protect electrical connections.
Check that all WARNING and instruction decals are in place. Also, make sure decals
are legible, clean, and undamaged.
Check that all bolts, nuts, and roll pins are in place. Replace fasteners and roll pins if
necessary.
Check for rust and oily surfaces on Liftgate. If there is rust or oil on Liftgate or if the
Liftgate is dirty, clean it off. Touch up the paint where bare metal is showing. Refer to
the paint system CAUTION and recommended touchup kit on the preceding page.
Pump multi-purpose lithium grease in each lube tting on the cylinders and arms until
grease starts oozing from ends of the bearings. Refer to lubrication diagram on the next
page. Wipe off excess grease with a clean lint-free cloth.
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
14
NOTE: Lube ttings are shown for the RH tilt cylinder, RH lift cylinder, and RH
arm of the lift frame. There are also lube ttings at the same places on the
LH tilt cylinder, LH lift cylinder, and LH arm of the lift frame. Refer to the
PERIODIC MAINTENANCE CHECKS and PERIODIC MAINTENANCE
CHECKLIST for the recommended grease and maintenance interval.
PERIODIC MAINTENANCE
GPC LUBRICATION DIAGRAM
FIG. 14-1
LH TILT CYLINDER,
LIFT CYLINDER &
LIFT ARM
RH TILT CYLINDER,
LIFT CYLINDER &
LIFT ARM
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15
CHECKING HYDRAULIC FLUID
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic uid reservoir ller cap, drain plug and hydrau-
lic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.
1. Tilt platform down to bed level. Then,
lower platform to the ground and tilt
the tip down.
UNLATCH/LATCH PUMP COVER
FIG. 15-1
POWER UNIT FLUID LEVEL
FIG. 15-2
5. Close and latch the pump cover (FIG.
15-1).
3. Check the hydraulic uid level in
reservoir as follows. With platform on
ground, level should be as shown in
FIG. 15-2.
NOTE: If the hydraulic uid in the
reservoir is contaminated, do
the CHANGING HYDRAULIC
FLUID procedure in this section.
PUMP COVER
LATCHES
(2 PLACES)
PUMP UNIT
(REF)
2. Unlatch and open pump cover (FIG.
15-1).
CAUTION
Pump cover must be correctly
secured to prevent it from becom-
ing a hazard. Ensure pump cover
is latched to pump box.
4. If needed, add ISO 22 hydraulic uid
to the reservoir as follows. Remove-
ller cap (FIG. 15-2). Fill the reser-
voir with hydraulic uid to the FULL
mark (FIG. 15-2). Reinstall ller cap
(FIG. 15-2).
CAUTION
Do not ll reservoir to the FULL
mark on the dipstick. Hydraulic
uid can over ow from the reser-
voir.
FILLER/BREATHER
CAP
RESERVOIR
DRAIN PLUG
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16
CHANGING HYDRAULIC FLUID
CAUTION
Keep dirt, water and other contaminants from entering the hydraulic system.
Before opening the hydraulic uid reservoir ller cap, drain plug and hydrau-
lic lines, clean up contaminants that can get in the openings. Also, protect the
openings from accidental contamination.
PERIODIC MAINTENANCE
2. Unlatch and open the pump cover
(FIG. 16-1).
3. Place empty 3 gallon bucket under drain
plug (FIG. 16-2). Remove drain plug
(FIG. 16-2) to drain hydraulic uid.
UNLATCH PUMP COVER
FIG. 16-1
POWER UNIT
FIG. 16-2
DRAIN PLUG
1. Raise the platform. Then tilt platform
up to stowed position.
4.
Tilt platform down to bed level.
Then, lower platform to the ground
and tilt the tip down.
PUMP COVER
LATCHES
(2 PLACES)
PUMP UNIT
(REF)
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17
POWER UNIT
FIG. 17-1
5. When oil stops draining, reinstall drain
plug (FIG. 17-1).
CAUTION
Pump cover must be correctly
secured to prevent it from becom-
ing a hazard. Ensure pump cover
is latched to pump box.
11. Close and latch the pump cover (FIG.
17-2).
7. Tilt tip of platform up and raise platform
to bed level. Then, tilt platform up to
stowed position.
8. Tilt platform down to bed level. Then,
lower platform to the ground and
tilt the tip down.
9. Check the hydraulic uid level in pump
reservoir. Level should be at the FULL
markas shown in FIG. 17-1.
10. If needed, add uid to the reservoir as
follows. Remove ller/breather cap (FIG.
17-1). Fill the reservoir with fresh ISO
VG22 hydraulic uid up to FULL mark
(FIG. 17-1). Reinstall cap (FIG. 17-1).
LATCH PUMP COVER
FIG. 17-2
PUMP COVER
LATCHES
(2 PLACES)
PUMP UNIT
(REF)
6. Remove ller cap (FIG. 17-1). Add
7-1/2 quarts of ISO 22 hydraulic uid
to the reservoir. Hydraulic uid level
should be at THE full mark (FIG.
17-1). Reinstall ller cap (FIG. 17-1).
FILLER/BREATHER
CAP
RESERVOIR
DRAIN PLUG
11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713
18
PARTS BREAKDOWN
MAIN ASSEMBLY WITH STANDARD UNDERRUN BUMPER
1
1A
1B
1C
2
(2 PLACES)
4
(4 PLACES)
3
(4 PLACES)
REFER TO
ALUMINUM OR STEEL
PLATFORM ASSEMBLIES
REFER TO
12V POWER
PACK
REFER TO
CONTROLS &
SENSORS
REFER TO
GPC-22 & GPC 33 OR
GPC-44 MAIN
ASSEMBLIES
REFER TO
HYDRAULIC
ASSEMBLY
5A
(6 PLACES)
5B
(4 PLACES)
6
(2 PLACES)
7
(12 PLACES)
8
(12 PLACES)
9
(12 PLACES)
BUMPER
(4 PLACES)
10
(3 PLACES)
1D
(2 PLACES)
1F
(4 PLACES)
1E
(2 PLACES)
12
(4 PLACES)
11
(2 PLACES)
4
(2 PLACES)
REFER TO
HYDRAULIC
COMPONENTS
WITH AUTO TILT
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19
ITEM QTY. PART NO. DESCRIPTION
1 REF 3-100866-02
STD
UNDERRUN BUMPER KIT
(GPC-22/-33 AUTOTILT, 750MM LEGS)
1A 1 4-100867 UNDERRUN WLDMT (STD, CENTER)
1B 1 4-100870-02 UNDERRUN WLDMT (RH, 2400 MM)
1C 1
4-
100869-02 UNDERRUN WLDMT (LH, 2400 MM)
1D 8 NB13512-100 M12 X 100 HEX HEAD BOLT
1E 8 NB13512-P M12 PLAIN TYPE NYLON LOCK NUT (GR 8.8)
1F 16 NB13512-WB M12 PLAIN WASHER
1 REF 3-100866-03
STD
UNDERRUN BUMPER KIT
(GPC-44 AUTOTILT &
GPC-22/-33/-44 NON-AUTOTILT, 750MM LEGS )
1A 1 4-100867-01 UNDERRUN WLDMT (STD, CENTER)
1B 1 4-100870-03 UNDERRUN WLDMT (RH, 2400 MM)
1C 1
4-
100869-03 UNDERRUN WLDMT (LH, 2400 MM)
1D 8 NB13512-100 M12 X 100 HEX HEAD BOLT
1E 8 NB13512-P M12 PLAIN TYPE NYLON LOCK NUT (GR 8.8)
1F 16 NB13512-WB M12 PLAIN WASHER
2 2 NB13510-30SH
M10 X 30MM LG. SOCKET HEAD CAP SCREW
3 4 903435-06
WASHER, NORD-LOCK, 3/8”/M10
4 6 NB13510-P
M10 PLAIN TYPE NYLON LOCK NUT (AUTO TILT ONLY)
5 REF
PL00394
UNDERRUN END CAPS (KIT)
5A 6
5-13024
PLASTIC END CAPS, 100MM X 50MM
5B 4
5-13090
PLASTIC END CAPS, 60MM X 60MM
6 2
NB13510-30S M10 X 30MM LG. HT SET SCREW
7 12
NB13514-50 M14 X 50MM LG. HEX HEAD BOLT (GR 8.8)
8 12
NB13514-W M14 PLAIN WASHER
9 12
NB13514-P M14 PLAIN TYPE NYLON LOCK NUT (GR 8.8)
10 3
EH13176 CHASSIS CABLE TIE, 14-3/4” LG.
11 2
NB13510-25S HEX HEAD SET SCREW, M10 X 25MM LG. ( AUTO TILT ONLY)
12 4
NB13510-WB PLAIN WASHER, M10 (AUTO TILT ONLY)
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20
PARTS BREAKDOWN
MAIN ASSEMBLY WITH LONG UNDERRUN BUMPER
1
1A
1B
1C
2
(2 PLACES)
4
(4 PLACES)
3
(4 PLACES)
REFER TO
ALUMINUM OR STEEL
PLATFORM ASSEMBLIES
REFER TO
12V POWER
PACK
REFER TO
CONTROLS &
SENSORS
REFER TO
GPC-22 & GPC 33 OR
GPC-44 MAIN
ASSEMBLIES
REFER TO
HYDRAULIC
ASSEMBLY
5A
(6 PLACES)
5B
(4 PLACES)
6
(2 PLACES)
7
(12 PLACES)
8
(12 PLACES)
9
(12 PLACES)
BUMPER
(4 PLACES)
10
(3 PLACES)
1D
(2 PLACES)
1F
(4 PLACES)
1E
(2 PLACES)
12
(4 PLACES)
11
(2 PLACES)
4
(2 PLACES)
REFER TO
HYDRAULIC
COMPONENTS
WITH AUTO TILT
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Maxon GPC Parts Manual

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