EM-25 TC / EM-30 TC SERIES TWIN CYLINDER Owner’s Manual
Visit us at www.waltco.com
2500/3000 lb. Capacity, Flipaway Liftgate
WARNING THE SUCCESS OR FAILURE OF THIS EQUIPMENT COULD VERY WELL DEPEND ON THOROUGH AND PROPER OPERATION AND MAINTENANCE OF THIS EQUIPMENT. READ AND UNDERSTAND THE CONTENTS OF THIS MANUAL BEFORE OPERATING THE EQUIPMENT.
3-2011
OHIO 285 Northeast Avenue Tallmadge, OH 44278 (330) 633-9191 FAX – (330) 633-1418 E.O. 6309RR Rev. 07
80126502
Table of Contents Chapter INTRODUCTION....................................................................................................................................................... SAFETY INFORMATION ........................................................................................................................................ 1 LIFTGATE TERMINOLOGY ................................................................................................................................... 2 OPERATION INSTRUCTIONS ............................................................................................................................... 3 INSPECTION .......................................................................................................................................................... 4 PLACEMENT OF DECALS ..................................................................................................................................... 5 LUBRICATION INSTRUCTIONS ............................................................................................................................ 6 PMs & SCHEMATICS ............................................................................................................................................. 7 HOW TO ORDER PARTS ...................................................................................................................................... 8
E.O. 6309RR Rev. 07
80126502
INTRODUCTION If anyone observes improper installation, improper operation, or damage, they should immediately contact a qualified person for assistance and correction. We strongly urge anyone that has any questions or doubts as to the installation, condition, use, operation, maintenance or repair of the liftgate to contact us at Waltco where we have qualified personnel that will be happy to assist you. Telephone numbers and addresses of these locations are listed in the Owner’s Manual and Installation Instructions. INSTALLATION Waltco liftgates should only be installed by those with sufficient basic skills to understand the installation and operation of the liftgate, along with the equipment on which the liftgate is being installed. Waltco’s installation instructions are not intended to give rationale for all the instructions that are given; however, it is the intent of these instructions to give the installer both the operations and what we believe to be the most desirable sequence of implementing these operations. These instructions can in no way expand into an area where they will replace a qualified person, or clear thinking and a basic knowledge that must be possessed by the installer. It has been our experience that a knowledgeable journeyman following these instructions and observing the operation of the liftgate will have a sufficient comprehension of the liftgate to enable this person to troubleshoot and correct all normal problems that may be encountered. Failure to follow the installation instructions, adjustments and mounting dimensions may result in improper and unsafe operation of the liftgate. Unauthorized alterations of the liftgate can cause an undesirable and dangerous condition. OWNER’S MANUAL The Waltco Owner’s Manual is intended to act as a guide for operation and routine maintenance but is no way intended to encourage usage or repair of the liftgate by those who are not qualified to do so. The contents of the owner’s manual include, but are not limited to general operation instructions, routine lubrication, parts lists, and an outline of things that should be checked but may not be obvious to those not technically qualified. This manual assumes the liftgate is properly installed, undamaged and operates correctly. Improper installation, improper operation, or damage should be immediately corrected by a qualified person. INSPECTION As part of the regular inspection of a liftgate and after damage or suspicion of an overload, inspect for wear or structural damage and make necessary repairs or replacements. Check all structural components and their attachment to the liftgate for cracked welds, loose fasteners, wear and part deformation. Check cylinder and hose for leaks. Inspections and repairs should be made by a qualified mechanic. REPLACEMENT PARTS Use only Waltco original equipment replacement parts. Components of other liftgate manufacturers may outwardly appear to be the same but are not interchangeable with Waltco products. Waltco components are specifically designed for safety requirements, reliability and compatibility with our products. Refer to your Waltco parts manual when ordering parts. NOTE: When ordering, give model and serial number of liftgate. DECALS It is important that every vehicle that has a WALTCO Liftgate have legible DECALS clearly posted on the vehicle and an OWNER’S MANUAL in the vehicle at all times as a guide for proper operation and maintenance. Additional DECALS and OWNER’S MANUALS can be obtained from WALTCO TRUCK EQUIPMENT COMPANY 80101388 Rev 02 EO 6156
Chapter 1
Safety Information WARNING
Read, understand, and follow all of the warning listed below. Failure to follow these warning could result in severe personal injury or death. Read and understand the Owner’s Manual, all decals and warning on liftgate before operating liftgate. Do not operate liftgate without a thorough knowledge and understanding of the operation of the liftgate. Liftgate hazards can result in crushing or falling. This liftgate is designed for loading and unloading of cargo. If personnel are required to ride liftgate, observe and familiarize yourself with the liftgate operation, decals and manuals. Ensure stable footing at all times. Do not ride liftgate with unstable loads. Wheeled loads must be properly retained from rolling. Tall, high center of gravity loads must be retained from falling over. Never overload liftgate: Load platform as close to the vehicle, and towards the middle of the platform as possible. Refer to owner’s manual and capacity decal of liftgate for maximum load and load placement. Keep hands and feet clear of all potential pinch points. Never use liftgate if it makes any unusual noise, has unusual vibration, raises or lowers unevenly, or fails to operate smoothly. Never use liftgate if it shows any signs of structural damage such as cracked welds, bent or distorted members. Do not attempt any repairs unless you are qualified to do so. Care should be taken when work is performed on a disabled liftgate located near moving traffic. When possible the vehicle should be moved away from traffic areas for repair. Precautionary measures should be taken to ensure personal safety including those recommended in Federal Motor Vehicle Safety Standards 571.125. When welding to liftgate, or liftgate components, take all necessary safety precautions, including using respiratory protection and other pertinent personal protective gear when welding harmful materials. All protective covers, guards, and safety devices must be in place and access doors closed before operating liftgate. Do not allow anyone to stand in, or near area, in which Platform will open and close before opening or closing Platform. Do not allow anyone to stand near the Platform where a falling load could land on them. Platform is always to be properly stored and secured for transit. See the Owner’s Manual for details. Take care to retain cargo during transit for liftgate Platforms which function as the tailgate or door of the cargo area. Small objects can fall through the space between the vehicle and the folded Platform. A Lock-Out device or Shut-Off Switch should always be used to prevent unauthorized use of liftgate. For liftgates with Runners, never use liftgate if Runners do not travel freely and smoothly. For liftgates with Roller Lifting Chain, the Chain should be replaced every (5) five years or 15,000 cycles, whichever comes first. Replace only with Waltco approved Roller Chain. Never transfer loads which exceed lifting capacity on or over any part of the Platform unless the liftgate is equipped with a special reinforced Platform and Platform Support Bars for use when the Platform is used as loading ramp (dock board). Refer to the “Using Platform as a loading ramp” Chapter in the Operation Instructions of the BZ/RZ series Owner’s Manual. For liftgates equipped with Trailer Hitches, never exceed the rated capacity of the hitch. Do not exceed the vehicle’s weight rating. Refer to the vehicle’s Owner’s Manual. Vehicle must comply with all state and federal standards. Follow the “Maintenance Guide” chapter in the Owner’s Manual.
Page 1 - 1 80101253 Rev 04 EO 6309JJ
Chapter 1
Safety Information
Liftgates with Tilt Function Proper use of the Control Switches is of extreme importance. Improper use of Tilt Switch could cause load to fall from the Platform or damage the liftgate. Platform should be in a generally horizontal position when raising or lowering with a load. In any tilt position, the Platform may vary from level while raising or lowering the Platform. Liftgates equipped with spring operated Cam Closer Replace Cam Release Spring every five (5) years or 15,000 cycles, whichever comes first. RGL-Series Liftgates Make certain Platform Brake mechanisms are operating properly. The Runners are always to remain powered up against the Upstops Pins when in transit. Inspect Cables every three (3) months or 750 cycles, whichever comes first. Cables must be replaced if they show signs of wear, distortion, kinking or if any broken wires are visible Replace cables every five (5) years or 10,000 cycles, whichever comes first.
This is the safety alert symbol. This manual uses this symbol to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid personal injury or death.
SIGNAL WORDS WARNING Indicates a potentially hazardous situation, which if not avoided, could result in death or serious injury. Black letters on an orange background CAUTION Indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury. May also be used to alert against unsafe practices. Black letters on a yellow background. NOTICE Indicates a potentially hazardous situation, which if not avoided, may result in property damage.
WARNING CAUTION NOTICE
Page 1 - 2 80101253 Rev 04 EO 6309JJ
Chapter 2 1. 2. 3. 4. 5. 6. 7. 8.
Liftgate Terminology
Hydraulic Cylinder Hose Assembly Male-Female Adapter Return Line Barbed Fitting Return Line Breather Cap Pump Unit Starter Solenoid Lowering Valve Coil
9. 10. 11. 12. 13. 14. 15. 16.
90 Deg. Hose Fitting Tee, Hose Fitting Drain Plug Pump Thermal Switch (Inside Motor) Ground Cable Pump Unit Motor Pump Unit Reservoir
7
6 8
13 15
2 16
12
5
11 1 9
14
10
2
3 4
3
5
4
GR02641
Page 2-1
Chapter 2 17. 18. 19. 20. 21. 22. 23. 24.
Liftgate Terminology
Mount Tube Assembly Parting Bar Assembly Deck Assembly Torsion Bar Deck Extension Assembly Lift Arm Assembly Folding Assist Springs Parallel Arm
25. Pump Cover 26. Mount Plate 27. Spec Tag (inside pump cover) 28. Bed Extension 29. Transit Chain 30. Dock Bumper
GR02643
Page 2-2
Chapter 2
Liftgate Terminology Explanation of Specification Tag
Model Name Description EMTC Twin Cylinder EMTC Twin Cylinder
Capacity 2500 lb. 3000 lb. RATED CAPACITY Based on an evenly distributed load on the platform flat surface.
MODEL NAME
SERIAL NUMBER of liftgate. To be used when ordering parts or when contacting Waltco for service or warranty questions
DATE OF MANUFACTURE Month / Year
GR00241
Specification Tag
GR02777
Page 2-3
Chapter 3
Operations Instructions
TO OPEN PLATFORM Rotate and remove transit chain off of transit chain lug.
Lug
015 7
Never force Latch Chain if platform weight is on chain. To slacken chain, push Raise Switch.
GR02567
TO OPERATE LIFTGATE Use Raise and Lower Toggle Switch to raise and lower platform. Load platform as close to vehicle and towards middle of platform as possible. Maximum rated capacity is based on an evenly distributed load on platform flat surface.
GR02680
TO STORE LIFTGATE FOR TRANSIT Lower platform to ground. Fold platform. Raise platform to transit position. Power platform snugly to underside of bed extension. Hook transit chain onto chain lug.
S T CHA N
To prevent unauthorized use of liftgate, insert a heavy gauge pad lock into first link of latch chain.
8010151
GR02568
Page 3-1
Chapter 4
Preventive Maintenance
Waltco recommends that the EM-Series liftgate be inspected at 6 month or 3000 cycle intervals to help assure proper function and operation of the liftgate. Note: Photocopy the following PM Checklist to help keep track of periodic maintenance on the liftgate. Keep completed form with maintenance records. For more detailed instructions on the following checklist items, refer to the appropriate sections in this Owner’s Manual. Do not continue to use liftgate if any points of inspection listed at left, or below, may cause you to think the liftgate is unsafe. Repair immediately. If liftgate is found to be in need of repair or adjustment not covered in this manual, contact your nearest Waltco Distributor.
WALTCO EM-SERIES LIFTGATE PREVENTIVE MAINTENANCE CHECKLIST PM Interval: 6 Months or 3000 Cycles
Date: ______________
Vehicle No.__________
Mechanic:_________________
Liftgate S/N:____________
Model:______________
Check appropriate box below for each step: 6 Month Liftgate PM Procedures 1
OK
Repair Required
Corrected
Check for apparent damage to the lifting structure, such as bent or distorted members or cracked welds, which may have resulted from overloading or abuse.
2
OK
Repair Required
Corrected
Check that all pins, bolts and fasteners are tight and secure.
3
OK
Repair Required
Corrected
Check for worn or damaged bearings.
4
OK
Repair Required
Corrected
Check that controls operate properly.
5
OK
Repair Required
Corrected
Check all battery cables and connections (both positive and ground cables) to be sure they are tight and free of corrosion.
6
OK
Repair Required
Corrected
Check that transit chain properly hooks onto transit chain lug.
7
OK
Repair Required
Corrected
Check operation of lockout device.
8
OK
Repair Required
Corrected
Check fold over assist spring and related hardware.
9
OK
Repair Required
Corrected
Check platform tilt is adjusted correctly.
10
OK
Repair Required
Corrected
Check for hydraulic leaks in hydraulic cylinder(s), hoses, fittings, and valves.
11
OK
Repair Required
Corrected
Check oil level in reservoir.
12
OK
Repair Required
Corrected
Check lowering speed of platform.
13
OK
Repair Required
Corrected
Check that all decals are in place and legible.
14
OK
Repair Required
Corrected
Lubricate the liftgate per the “Lubrication Instructions”.
12 Month Liftgate PM Procedures (Includes steps 1-14 above) 15
OK
Repair Required
Corrected
Inspect Pump Motor for wear or damage.
16
OK
Repair Required
Corrected
Replace Hydraulic Fluid.
Page 4-1
Chapter 4
Preventive Maintenance
MONTHLY INSPECTION Operate the liftgate throughout its entire operational cycle. Check for:
Damage to lifting structure such as bent or distorted members or cracked welds. Bent or distorted cylinder pins or damaged cylinder. All pivot and cylinder pins are securely in place, undamaged and retained by their proper fasteners (refer to parts drawings in chapter 7, “PMs and Schematics”). Damaged or worn bearings that pivot and cylinder pins rest in. Controls operate correctly (refer to chapter 3, “Operations Instructions”)
Check all power cables, ground cables, and connections.
Clean and tighten all loose connections. Replace any damaged or corroded wires or connectors.
Do not continue to use liftgate if any points of inspection listed at left, or below, may cause you to think the liftgate is unsafe. Repair immediately. If liftgate is found to be in need of repair or adjustment not covered in this manual, contact your nearest Waltco Distributor.
Inspect transit chain. Chain must hook on lug freely.
Lug
7
GR02567
Check proper operation of lockout device. Hook transit chain unto transit chain lug and insert a heavy gauge padlock into the last chain link to ensure chain cannot be removed from lug.
A
To prevent unauthorized use of liftgate, use a heavy gauge pad lock as shown.
GR02568
Page 4-2
Chapter 4
Preventive Maintenance
ADJUST PLATFORM ANGLE Lower platform until stop blocks hit ground. Note: On higher bed heights stop blocks may not reach ground.
Properly adjusted platform
Tip of platform should touch ground without platform breaking (starting to fold) as shown in top drawing. Stop Block Platform off ground adjust platform down
If platform tip is off the ground, adjust platform down until it reaches ground.
If platform tip reaches ground before stop blocks, and platform starts to fold, adjust platform up. Be sure both adjusting bolts are adjusted the same.
Platform breaking adjust platform up
Always secure jam nuts after any adjustment is made.
Platform Adjusting Bolt
Raise platform back to bed level to check kick-up of platform. Note: If kick-up is too little, or too great, it may be due to bed height of vehicle. Different stop blocks may be required to achieve desired kick-up. Larger the stop block hole spacing, the more tilt-up the platform will achieve at bed height. See PM-798 in this manual for stop block recommendations for varying platforms and bed heights.
Kick-up of platform
For additional assistance contact Waltco Tech Support.
GR02816 GR02817
Page 4-3
Chapter 4
Preventive Maintenance
Inspect fold over assist spring and related hardware. Check that coiled pin (A) contacts and holds torsion spring when platform is unfolded open.
GR02191
CHECK RUBBER SNUBBERS Raise platform to fully closed position. Pull and/or push on deck extension to verify it is held tight.
Rubber Snubber End Tube
Platform end tube should compress rubber snubber. If not, add shims or large washers under snubber pads to obtain this compression.
GR02690
HYDRAULICS Inspect for oil leaks in: Hydraulic cylinder(s) Hydraulic hoses - Replace hoses if they show signs of excessive abrasion Hydraulic fittings and valves Tighten or replace all hydraulic components as may be required to stop oil leakage
CHECK AND FILL HYDRAULIC RESERVOIR
Plug
Position liftgate deck per chart below. Remove Reservoir Plug. Oil level should be 1/2� from top of reservoir. If low, fill as required. Use appropriate fluid per chart. Replace Plug.
GR00159
Page 4-4
Chapter 4
Preventive Maintenance LIFTGATE POSITION FOR OIL LEVEL CHECK
Gravity Down Pump:
Power Down Pump:
Ground Level
Bed Level
Deck should be in this position:
Recommended Fluids Temperature Range Acceptable Fluids Shell Tellus 32T -10 to 195 F Mobil DTE 13M Shell Tellus 15T -25 to 140 F Mobil DTE 11M AeroShell Fluid 4 -40 to 145 F Exxon Univis HVI 13 Shell Tellus Arctic -45 to 200 F (Tellus S4 VX 32) A good quality SAE 10W motor oil may also be used in temperatures above 32 F.
Fill reservoir Fill with recommended fluid or equivalent. Fill the reservoir to within 1/2” from the top. Liftgate filled at factory with Shell Tellus 15T NOTICE: Do not use the following fluids: Brake Fluid Power steering fluid Automatic Transmission Fluid (ATF)
There is no speed adjustment on this liftgate. Lowering speed is controlled by the pressure compensative valve plumbed into the cylinder. Regardless of weight on platform, liftgate should lower at approximately six (6) inches per second. Bed Height (inches) 6
= Lowering Time (seconds)
This liftgate must have the pressure compensative valve installed in the cylinder.
Pressure Compensative Flow Control Valve inside Port GR02695
INSPECT DECALS AND LUBRICATE LIFTGATE Inspect all decals per Chapter 5 of this manual. Replace any that are missing or damaged.
Lubricate liftgate per Chapter 6 of this manual.
Page 4-5
Chapter 4
Preventive Maintenance
SEMI ANNUAL INSPECTION
Inspect power motor: Disconnect battery cable. Remove end cover. Examine armature brushes for wear (Motor should be replaced if less than 1/8" long). Clean out all residue from inside of motor housing. Apply several drops of light weight machine oil to armature shaft bearing in motor end cover. Reassemble motor.
Remove cover to check brushes and clean out motor
GR02100
Page 4-6
Chapter 5
Placement of Decals
All decals must be in place and legible or all warranties are void. ITEM
DECAL
QTY
PART NO.
Safety Instructions
1
80100850
Operation
1
80101528
Hazard Decal
1
80101370
Important Decal
1
80100828
Motor Thermal Switch
1
80101480
Stand Clear Decal
1
75089296
Refer to the following diagram showing decal locations.
Capacity Decal – 2500 lb
1
80100255
Capacity Decal – 3000 lb
Locate on curbside of platform (Position so as to be read when platform is open)
1
80100257
Use Handle Decal
1
75089295
Stand Clear Decal Capacity Decal – 2500 lb
1
75089296
1
80100255
Capacity Decal – 3000 lb
1
80100257
4
Transit Chain Decal
1
80101517
5
Circuit Breaker Decal
1
80100829
6
Stand Clear Decal
1
75089296
1
2
3
LOCATION Locate in a conspicuous place near controls. If your liftgate is equipped with dual controls, an additional Safety Instruction decal (80100850) is to be placed in a conspicuous place near the second set of controls.
Locate near platform handle (Positioned so as to be read when platform is being unfolded into loading position)
Locate on back of deck on curbside (Visible when platform is stored) Locate next to liftgate circuit breaker. In applications where more than one circuit breaker is used, this decal must be placed in both locations Locate on driver’s side of vehicle body near liftgate
To maximize decal adhesion to surfaces: Surface must be dry and clean Firm pressure must be applied to decal Minimum surface temperature 65º Heat gun may be used to heat surface
A
GR02655
Page 5-1
Chapter 6
Lubrication Instructions
The liftgate should be lubricated every 120 days. #1 - Oil with a light weight machine oil (do not use on bearings in arms, platform, pivot blocks, or cylinders). #2 - These are bearings that do not require grease, however, bearings may be greased through pins to prevent corrosion of pins, reduce friction, and increase life of bearings.
1
2
2
2
1
GR02656
Page 6-1
This page intentionally left blank.
Ch. 7
PARTS MANUAL SHEETS PM Number
MOUNT FRAME ASSEMBLY ...................................................................................... PM-781 STOP BLOCK ASSEMBLIES ...................................................................................... PM-798 STEEL PLATFORM ASSEMBLY ................................................................................ PM-782 ALUMINUM PLATFORM ASSEMBLY ........................................................................PM-791 BED EXTENSION and DOCK BUMPERS................................................................... PM-799 HYDRAULIC LAYOUT, GRAVITY DOWN................................................................... PM-784 HYDRAULIC LAYOUT, POWER DOWN ..................................................................... PM-785 ELECTRIC CONTROL OPTIONS, GRAVITY DOWN .................................................. PM-786 ELECTRIC CONTROL OPTIONS, POWER DOWN .................................................... PM-787
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 32 33 34 35
PART NUMBER 26520001 75089334 75090310 26470101 70401408 70401409 10090450 7500010-21 75088079 70430550 70430560 26455001 C 10010188 C 10010187 D 1000022-01 D 75088055 C 10010189 26530001 26530002 D 1000021-03 D 1000022-02 D 1000021-06 26580010 CS Stop Block
QTY DESCRIPTION IMPORTANT: 1 Mount Frame Weldment Parts shown1 may not match your Grommet, 1/2” ID liftgate. See 1PARTS NAVIGATOR or Grommet, Multi-Split contact Waltco Parts to confirm 2 Mount Plate A 1 Grommet, 7/16” ID correct part numbers. B
DS Stop Block 75089307 26492001 75086236 75085111 75088064 C 10010186 D 75088081 D 75088053 7500045-2
1 1 3 3 1
2 6 8 4 10 4 1 2 2 2 2 1 1 12 1 1 1 2 2 10 10 4
LIFT CORP. EM-25 TC & EM-30 TC
Grommet, 1/4” ID Pump Cover Hex Screw, ¼-20 x 1”, Gr 8 Lock Washer, ¼” Hydraulic Pump, Gravity Down Hydraulic Pump, Power Down Parallel Arm Assembly Bearing, 1” ID x 1” Lg Bearing, 1” ID x 3/4” Lg Pin Assembly, 1-1/4” x 2-1/8” Hex Bolt, 3/8-16 x 3/4” Grade 5 Bearing, 1-1/4” ID x 1” Lg Lift Arm Weldment Lift Arm Weldment, Under-ride Pin, 1” x 3-1/4” Pin Assembly, 1-1/4” x 3” Pin, 1” x 5-7/8” Hydraulic Cylinder See PM-798
A
QTY of 2 with Power Down Pump, QTY of 1 with Gravity Down Pump QTY of 0 with Power Down Pump, QTY of 1 with Gravity Down Pump C Included in Bearing Replacement Kit 80001284 D Included in Pin Replacement Kit 80001286 B
See PM-798 Grease Zerk Fitting Parting Bar Assembly Hex Bolt, 5/8-18 x 2-1/2” Lg Nut, 5/8-18 Washer, 5/8” Bearing, 1-1/4” ID x 1-5/8” Lg Lock Washer, 3/8” Flat Washer, 3/8” Grease Zerk, ¼ Straight REVISED: E.O. REV.
3-18-11 6309RR 06
PM-781
IMPORTANT: shown may not match your MOUNTParts FRAME ASSEMBLY liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.
LIFT CORP. EM-25 TC & EM-30 TC
REVISED: E.O. REV.
3-18-11 6309RR 06
PM-781
IMPORTANT: PM-798 Stopyour Block Assemblies Parts shown may not match liftgate. See PARTS NAVIGATOR or Stop Blocks shipped with liftgate are based on the depth and style of platform. contact Waltco Parts to confirm correct part numbers.
26450001 CS 26450003 CS 26450051 DS 26450053 DS 26451001 Kit 26451003 Kit Kits include both stop blocks.
26450004 CS 26450054 DS 26451004 Kit
26450005 CS 26450055 DS 26451005 Kit
26450002 CS 26450052 DS 26451002 Kit
Below in bold indicates which stop blocks that are shipped with different platforms. Below are stop block recommendations for different bed height ranges. Note: The larger the stop block hole spacing, the more tilt up the platform will achieve at bed height. 44” Deep Wedge Platform
40 + 4” Deep Platform
Bed Height Range
A-Dim
Recommend Stop Blocks
Bed Height Range
A-Dim
Recommend Stop Blocks
56 - 55
26
26450003 & 26450053
56 - 55
26
26450001 & 26450051
54 - 42
24
26450004 & 26450054
54 - 42
24
26450003 & 26450053
41 - 36
19
26450002 & 26450052
41 - 36
19
26450005 & 26450055
50” Deep Wedge Platform
46+4” Deep Platform
Bed Height Range
A-Dim
Recommend Stop Blocks
Bed Height Range
A-Dim
56 - 55
26
26450001 & 26450051
56 - 55
26
54 - 42
24
26450003 & 26450053
54 - 42
24
41 - 39
19
26450005 & 26450055
41 - 39
19
Recommend Stop Blocks
26450001 & 26450051
26450003 & 26450053
GR02815 REVISED 3-17-11 E.O. 6309RR REV 02
Page 1-1
IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.
This page intentionally left blank.
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A D
PART NUMBER
44” WEDGE
50” WEDGE
40”+4”
IMPORTANT:26410012 26410011 26410002 Parts your 26411001shown may not match 1 26411002 1 1 liftgate. See PARTS NAVIGATOR or 26413011 1 contact Waltco 1Parts to confirm 26413012 correct 26413001 part numbers. 26413002 22114300 21514301 A 10010187 7500019-3 B 26412001 75089542 26417301 22517100 1000101-6 75086053 7500010-30 75085015
2 2 1 2 4 1 1 2 2 2 2
1 1 2 1 2 4 1 1 2 2 2 2
1 2 2 1 2 4 1 1 2 2 2 2
46”+4” 26410001 1
1 1 1 2 1 2 4 1 1 2 2 2 2
DESCRIPTION Deck Weldment, 50” Deck Weldment, 44” Deck Extension Weldment, 50” Wedge Deck Extension Weldment, 44” Wedge Deck Extension Weldment, 46+4 Deck Extension Weldment, 40+4 Torsion Spring, Red End Torsion Spring, Green End Bearing, 1” ID x 3/4” Lg. Socket Head Shoulder Bolt, 1/2” x 1/2” Pin, Deck Spring w/ Grease Fitting Coil Spring, 1/2” Dia. x 2” Lg. Torsion Bar Anchor Torsion Bar, 1/2” Pin Weldment, 1” x 1-1/4” Hex Bolt, w/ Vibraseal Thread Locking Hex Bolt, 3/4-10 x 2” Lg. Grade 5 Hex Jam Nut, 3/4-10
Included in Bearing Replacement Kits 80001283 (EM) & 80001284 (EM TC) Included in Pin Replacement Kits 80001285 (EM) & 80001286 (EM TC)
LIFT CORP. EM, EM TC
REVISED: E.O. REV.
9-20-10 6309JJ 04
PM-782
IMPORTANT: shown may not match your STEELParts PLATFORM ASSEMBLY liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.
LIFT CORP. EM, EM TC
REVISED: E.O. REV.
9-20-10 6309JJ 04
PM-782
44” ALUM
ITEM
1
50” ALUM
44”
IMPORTANT:WEDGE ALUM/STEEL WEDGE WEDGE Parts shown26410014 may not 26410013 match your 26410016 liftgate. See PARTS NAVIGATOR or 26411012 1 contact Waltco1Parts to confirm 26411011 correct part numbers. 26411001 PART NUMBER
26411002 1 26413014 1 2 26413013 1 1 3 1000101-6 2 2 2 4 75086053 2 2 2 26317100 5 26417702 1 6 26417301 1 7 7500019-3 1 8 42668440 4 4 4 A 26414801 1 1 1 9 A 26414851 1 1 1 42669012 1 1 1 10 42669011 1 1 1 11 75089591 2 2 2 12 7500019-4 2 2 2 13 42669299 2 2 2 14 42669286 6 6 6 15 75088268 2 2 2 16 42669014 2 2 2 C 17 26412001 2 2 2 C 18 75089542 4 4 4 19 75085015 2 2 2 20 7500010-30 2 2 2 21 21514301 1 1 22 22114300 2 B 23 10010187 4 4 4 A Includes items 10 thru 14. B. Included in Bearing Replacement Kits 80001283 (EM) & 80001284 (EM TC) C Included in Pin Replacement Kits 80001285 (EM) & 80001286 (EM TC)
LIFT CORP. EM, EM TC
50” ALUM/STEEL WEDGE 26410015
1 1 2 2 1 1 1 4 1 1 1 1 2 2 2 6 2 2 2 4 2 2 1 1 4
DESCRIPTION Deck, 50” Alum Deck, 44” Alum Deck, 50” Steel Deck, 44” Steel Deck Extension Assy, 50” Alum Wedge Deck Extension Assy, 44” Alum Wedge Pin Assy Hex Bolt, w/Vibraseal Thread Locking Torsion Bar, 3/8” Torsion Bar, 3/8” Torsion Bar Anchor Socket Head Shoulder Bolt, 1/2” x 1/2” Spring, Cart Stop Cart Stop Assy Complete, Curbside Cart Stop Assy Complete, Street Side Cart Stop, Curbside Cart Stop, Street Side Spring Pin, 3/16” Dia x 7/8” Lg. Socket Head Shoulder Bolt, 3/8” x 3/8” Roll Stop Shim Spring, Cart Stop Locking Pin, Cart Stop Pin, Deck Spring w/ Grease Fitting Coil Spring, 1/2” Dia x 2” Lg. Hex Jam Nut, 3/4-10 Hex Bolt, 3/4-10 x 2” Lg. Grade 5 Torsion Spring, Green End Torsion Spring, Red End Bearing, 1” Dia x 3/4” Lg.
REVISED: E.O. REV.
9-20-10 6309JJ 03
PM-791
IMPORTANT: PartsPLATFORM shown may not match your ALUMINUM ASSEMBLIES liftgate. See PARTS NAVIGATOR or ALUM DECK EXTENSION + STEEL DECK ASSEMBLIES contact Waltco Parts to confirm correct part numbers.
LIFT CORP. EM, EM TC
REVISED: E.O. REV.
9-20-10 6309JJ 03
PM-791
ITEM
1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
PART NUMBER 26460005 26460006 26460013 26460014 26460020 26460021 26497001 26497051 26497002 26497052 26498501 B 26297604 A 26297603 AB 75088067 C 75088085 B 75086110 C 75086154 C 75088064 C 26498101 C 26498151 C 26498301 75086218 75088081 75088053 75085096 26498201 75089334 75086732 75085000 22575200 75089376 75089373 75089374 7500010-26 22598100
QTY DESCRIPTION IMPORTANT: Bed Extension 96” Vehicles Parts shown may not match your Bed Extension, 102” Vehicles liftgate. See PARTS NAVIGATOR or 96” Bed Extension, Walk Ramp Ready, 1 contact Waltco Bed Parts to confirm Extension, Walk Ramp Ready, 102” Bed Extension, correct part numbers. 3/8” Skin, 96”
LIFT CORP. EM, EMTC
1 1 1 1 1 2 2 6 8 6 8 12 1 1 2 8 8 17 8 4 2 12 12 2 4 2 2 1 1
Bed Extension, 3/8” Skin, 102” Dock Bumper, CS For Lights (Option) Dock Bumper, DS For Lights (Option) Dock Bumper, CS (Option) Dock Bumper, DS (Option) Stir-Up Assembly (Option) 24” Rubber Bumper, Long (Option) 6” Rubber Bumper, Short (Option) Washer, 1/2” (Option) Lock Washer, 5/8” (Option) Hex Bolt, ½”-13 x 2-1/2” Lg. (Option) Hex Bolt, 5/8”-11 x 1-3/4” Lg. (Option) Washer, 5/8” (Option) Angle Support, CS (Option) Angle Support, DS (Option) Angle, 3” x 3” x ¼” x 24” Lg. (Option) Hex Bolt, 3/8”-16 x 1-1/4” (Option) Lock Washer, 3/8” (Option) Washer, 3/8” (Option) Hex Nut, 3/8”-16 (Option) Light Bracket (Option) Grommet, ½” ID (Option) Round Head Screw, #10-32 (Option) Hex Nut, #10-32 (Option) Harness, 2 Lamps (Option) Light Grommet (Option) Tail Light ST & T (Option) Backup Light (Option) Hex Bolt, 3/8”-16 x 2-1/2” Lg. Transit Chain
ITEM 31 32 33 34 35 36 37
PART NUMBER 75085193 A 7500010-23 C 75085012 AB 75088083 26497003 26497053 75085008
QTY 1 4 4 6 1 1 6
DESCRIPTION Hex Lock Nut, 3/8”-16 Hex Bolt, ½”-13 x 3” Lg. (Option) Hex Nut, 5/8”-11 (Option) Lock Washer, ½” (Option) Dock Bumper, CS, Short Dock Bumper, DS, Short Hex Nut, ½”-13
Dock Bumpers complete w/ Stirrups and Truck Lights and mounting hardware: 2649801 CS and 26498051 DS Dock Bumpers complete w/ Stirrups and Trailer Lights and mounting hardware: 26498006 CS and 26498056 DS Dock Bumpers complete w/ Stirrups and mounting hardware: 26498002 CS and 26498052 DS Short Dock Bumpers complete w/ Stirrups and mounting hardware: 26498003 CS and 26498053 DS A
Included in 6” Rubber Bumper Kit 26496011 Included in 24” Rubber Bumper Kit 26496012 C Included in Dock Bumper Brace (bolt-on) Kit 26496010 B
REVISED: E.O. REV.
12-20-10 6309NN 02
PM-799
IMPORTANT: Parts shown notKIT match your BED EXTENSION ANDmay LIGHT OPTIONS liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers. 36 37 34 9 13
15
11
10 12 16
1 7
20 5
3
14
19
19
17 18
23 19
31 33
13
13 10
22
21
12
35
25 28 27
24 26
2 32
8 34
6
4
37
LIFT CORP. EM, EMTC
REVISED: E.O. REV.
12-2010 6309NN 02
PM-799
A B
ITEM 1 A B C D E F G
PART NUMBER 70430550 B 70400001 B 70400004 A,B 7043001 1 A,B 75089833 B 70092503 B 75089853 B 10099309
QTY DESCRIPTION IMPORTANT: 1 Hydraulic Pump Unit Parts shown1 may not match your Hydraulic Reservoir liftgate. See 1PARTS BreatherNAVIGATOR or contact Waltco Parts to confirm 1 Motor 1 Sta ter Solenoid correct part numbers.
H J K L 2 3 4 5 6 7 8 9 10 11
75089834 B 10098425 B 70091291 70402303 26580010 75083111 7500077-11 75083023 7500092-1 75082747 75083133 75082745 75082887 75082869
A,B
1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1
Valve Assembly, 2-way, 2 pos w/ Coil Fuse Inline Fuse Assembly (Includes Fuse 75089853) Bus Bar Ground Cable Steel Plug Coil, 10V, 25W Hydraulic Cylinder Hose, 3/8” ID x 1/4” JIC x 3/8” JIC Hose, 1/4” ID x 3/8” JIC x 3/8” JIC Tube, ¼” ID Adapter, 3/8” ORB x ¼” NPT Tee Barbed Fitting, ¼” NPT x ¼” Tube Tube, ¼” ID Elbow Barbed Fitting, ¼” NPT x ¼” Tube Tee, 3/8” ORB x 3/8” JIC Elbow, 3/8” ORB x 3/8” JIC
Included in Motor Assembly 70400854. Included in Pump Assembly 70430550.
LIFT CORP. EM TC
REVISED: E.O. REV.
3-1-11 6469 02
PM-784
IMPORTANT: Parts LAYOUT, shown may not match HYDRAULIC GRAVITY DOWNyour liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.
D
B L
F
E
G
K
C
3 1
A H 5
2 11
J
10
4
6 7
LIFT CORP. EM TC
6
9
8
REVISED: E.O. REV.
3-1-11 6469 02
PM-784
A
ITEM 1 A B C D E F G
PART NUMBER 70430560 A 70400828 A 70400004 A 7043001 1 A 75089833 A 70092503 A 75089853 A 10099309
QTY DESCRIPTION IMPORTANT: 1 Hydraulic Pump Unit Parts shown1 may not match your Hydraulic Reservoir liftgate. See 1PARTS BreatherNAVIGATOR or contact Waltco Parts to confirm 1 Motor 2 Sta ter Solenoid correct part numbers.
H J K L M N 2 3 4 5 6 7 8 9 10
70400014 A 10098425 A 70091291 A 70091779 A 70091778 A 70402303 26580010 75083111 7500077-11 7500077-13 75082890 75083132 7500077-12 75082887 75082869
A
1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1
Valve Assembly, 2-way, 2 pos w/ Coil Fuse Inline Fuse Assembly (Includes Fuse 75089853) Valve Assembly, 4-way, 2 pos w/ Coil Ground Cable Steel Plug Connecting Strap Solenoid Cable Coil, 10V, 25W Hydraulic Cylinder Hose, 3/8” ID x 1/4” JIC x 3/8” JIC Hose, 1/4” ID x 3/8” JIC x 3/8” JIC Hose, 1/4” ID x 1/4” JIC x 3/8” JIC Elbow, 45, 3/8” ORB x 1/4” JIC Tee, 3/8” ORB x 3/8” JIC Hose, 1/4” ID x 1/4” JIC x 3/8” JIC Tee, 3/8” ORB x 3/8” JIC Elbow, 3/8” ORB x 3/8” JIC
Included in Pump Assembly 70430560.
LIFT CORP. EM TC
REVISED: E.O. REV.
3-1-11 6469 02
PM-785
D
IMPORTANT: Parts LAYOUT, shown may not DOWN match your HYDRAULIC POWER liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.
N
B
E
L
F
G
K
C
3 N
1
A
H
M 5
2 10
J
9
4
7
LIFT CORP. EM TC
6
8
REVISED: E.O. REV.
3-1-11 6469 02
PM-785
ITEM 1
PART NUMBER a 10099330 b 10099331 c 10099325 75082038 75082037 75089854 10099309 10098413 75089243
QTY DESCRIPTION IMPORTANT: 1 Switch w/10ft Cord (for curb side) Parts shown1 may not match your Switch w/15ft Cord (for Dual Control) liftgate. See 1PARTS NAVIGATOR Switch (Hand Held Remote) or contact Waltco Parts to confirm 1 Trailer Socket 1 Tra ler Plug correct part numbers.
2 3 4 5 6 7 8
1 1 1 1
15 Amp Fuse Fuse Holder Dual Control Harness 150 Amp Circuit Breaker (Manual Reset)
a
Included in Switch Kit 80000436. Included in Switch Dual Control Kit 80000437. c Included in Switch Hand Held Remote Kit 80000430. b
GR02671
LIFT CORP. EM, EM TC
REVISED: E.O. REV.
9-20-10 6309JJ 02
PM-786
IMPORTANT: Parts shown may not match your ELECTRIC CONTROL OPTIONS – Gravity Down liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers. GREEN POWER
WHITE RAISE
LIFT CORP. EM, EM TC
BLACK LOWER
REVISED: E.O. REV.
9-20-10 6309JJ 02
PM-786
ITEM 1
PART NUMBER a 10099330 b 10099331 c 10099325 75082038 75082037 75089854 10099309 10098413 75089243
QTY DESCRIPTION IMPORTANT: 1 Switch w/10ft Cord (for curb side) Parts shown1 may not match your Switch w/15ft Cord (for Dual Control) liftgate. See 1PARTS NAVIGATOR Switch (Hand Held Remote) or contact Waltco Parts to confirm 1 Trailer Socket 1 Tra ler Plug correct part numbers.
2 3 4 5 6 7 8
1 1 1 1
15 Amp Fuse Fuse Holder Dual Control Harness 150 Amp Circuit Breaker
RAISE PORT
LOWER PORT
Lowering Solenoid Valve
a
Included in Switch Kit 80000436. Included in Switch Dual Control Kit 80000437. c Included in Switch Hand Held Remote Kit 80000430. b
Raise Solenoid Valve
LIFT CORP. EM, EM TC
REVISED: E.O. REV. GR02675
9-20-10 6309JJ 02
PM-787
IMPORTANT: Parts shown may not match ELECTRIC CONTROL OPTIONS – Poweryour Down liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.
GREEN POWER
WHITE RAISE
LIFT CORP. EM, EM TC
BLACK LOWER
REVISED: E.O. REV.
9-20-10 6309JJ 02
PM-787
Chapter 8 How To Order Parts Repairs should be made only by authorized mechanics using WALTCO Replacement parts. When ordering repair or replacement parts, please include all the information asked for below. If this information is not available, a complete written description or sketch of the required part will help WALTCO identify and deliver the needed part to you. ________________________________________________________________ THE FOLLOWING INFORMATION MUST BE INCLUDED: 1. SERIAL NUMBER - [WALTCO liftgate serial numbers can be found on the Specification Tag attached to the mount frame. (On older units the Specification Tag is located on the side or bottom of the platform.)] 2. MODEL NUMBER - [Or capacity] 3. PLATFORM SIZE ________________________________________________________________ THEN INCLUDE THE FOLLOWING INFORMATION: 4. PART NUMBERS 5. DESCRIPTION 6. QUANTITY REQUIRED ________________________________________________________________ MAIL, E-MAIL OR PHONE YOUR REQUEST TO: Waltco Truck Equipment Co. 285 Northeast Avenue Tallmadge, OH 44278 1-800-411-5685 FAX: 1-800-411-5684 E-MAIL: parts@waltco.com ALL PARTS ARE F.O.B. FROM THE SHIPPING FACTORY ________________________________________________________________ PLEASE NOTE: To assure you of continuing and effective quality control, our warranty policy permits replacement of hydraulic cylinders, valves and motor pump units when their factory seals are intact. Parts under warranty will be exchanged promptly after careful inspection of the returned assemblies.
________________________________________________ 80101389
Page 8-1
EO 5534A Rev 02
Every vehicle that has a WALTCO Liftgate must have legible WARNING AND OPERATION DECALS clearly posted on the vehicle and an OWNER’S MANUAL in the vehicle at all times as a guide for proper operation and maintenance.
Additional WARNING DECALS, OPERATION DECALS and OWNER’S MANUALS can be obtained from WALTCO TRUCK EQUIPMENT COMPANY.
____________________ NOTE: When ordering, give model and serial number of the liftgate. ____________________
IMPORTANT KEEP THIS OWNER’S MANUAL IN THE VEHICLE
WARNING Improper operation and maintenance of this liftgate could result in severe personal injury or death. Read and understand the contents of this manual and all warning and operation decals before operating and/or performing maintenance on this liftgate.
For SAFETY information on this liftgate see Chapter 1 of this manual
80101519
EO6156 Rev 01