Installation Manual C15, C20, C25 - QTE · Installation Manual C15, C20, C25 1600, 2000, 2500 lb....

EO:6823 Rev 16

5-2012 80122201

Installation Manual

C15, C20, C251600, 2000, 2500 lb. Capacity Flipaway Liftgates

Waltco Lift Corp. Waltco Lift Corp. Waltco Lift Inc.Corporate Office United State United States Canada285 Northeast Ave. 620 S Hambledon Ave. 90 North Queen St.Tallmadge, OH 44278 City of Industry, CA 91744 Etobicoke, ON M8Z 2C5P: 330.633.9191 P: 626.964.0990 P: 888-343.4550F: 330.633.1418 F: 626.964.0149

www.waltco.com Phone: [email protected] Fax: 800.411.5684

Table of Contents

Introduction .....................................................................................................................3

1. Safety Information................................................................................................................ 42. Liftgate Terminology ............................................................................................................ 63. Basic Mounting Requirements ............................................................................................. 94. Installation ..........................................................................................................................115. Placement of Decals...........................................................................................................296. Lubrication Instructions.......................................................................................................307. Final Inspection...................................................................................................................318. How to Order Parts .............................................................................................................329. Optional Kit Instructions:

Hand Held Remote Kit.............................................................................................33Kit #80000430

Aux Battery Kit (Truck) ............................................................................................34Kit #80001066

Aux Battery Kit (Trailer) ...........................................................................................34Kit #80001069

Tractor Wiring Kit ....................................................................................................39Kit #80000618

Dual Control Kit .......................................................................................................40Kit #80000431

Anti Theft Kit............................................................................................................41Kit #80001313

Cab Shut-Off Kit ......................................................................................................42Kit #80000827

Rubber Snubber Kit.................................................................................................43Kit #80000421

Remote Pump Mount Kit .........................................................................................44Kit #80000979

Walk Ramp Install Kit ..............................................................................................45Kit #80000432

Improper installation of this liftgate could result in severe personal injury ordeath.

Read and understand the contents of these instructions before proceeding.

When installed, this liftgate must not alter or prevent vehicle compliance to anyexisting state or federal standards.

ommendations should be consulted forcompliance.

IntroductionIf 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 anyquestions or doubts as to the installation, condition, use, operation, maintenance or repair of the liftgateto contact us at Waltco where we have qualified personnel that will be happy to assist you. Telephone

Instructions.

INSTALLATIONWaltco 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

are given; however, it is the intent of these instructions to give the installer both the operations andwhat we believe to be the most desirable sequence of implementing these operations. Theseinstructions can in no way expand into an area where they will replace a qualified person, or clearthinking and a basic knowledge that must be possessed by the installer.

It has been our experience that a knowledgeable journeyman following these instructions andobserving the operation of the liftgate will have a sufficient comprehension of the liftgate to enable thisperson to troubleshoot and correct all normal problems that may be encountered.

Failure to follow the installation instructions, adjustments and mounting dimensions may result inimproper and unsafe operation of the liftgate. Unauthorized alterations of the liftgate can cause anundesirable and dangerous condition.

is no way intended to encourage usage or repair of the liftgate by those who are not qualified to do so.

routine lubrication, parts lists, and an outline of things that should be checked but may not be obviousto those not technically qualified. This manual assumes the liftgate is properly installed, undamagedand operates correctly. Improper installation, improper operation, or damage should be immediatelycorrected by a qualified person.

INSPECTIONAs 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 structuralcomponents and their attachment to the liftgate for cracked welds, loose fasteners, wear and partdeformation. Check cylinder and hose for leaks. Inspections and repairs should be made by a qualifiedmechanic.

REPLACEMENT PARTSUse 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. Waltcocomponents are specifically designed for safety requirements, reliability and compatibility with ourproducts. Refer to your Waltco parts manual when ordering parts. NOTE: When ordering, give modeland serial number of liftgate.

DECALSIt is important that every vehicle that has a WALTCO Liftgate have legible DECALS clearly posted on

dmaintenance.

an be obtained from WALTCO LIFT CORP.

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.

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, observeand 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 themanual 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 tooperate smoothly.Never use liftgate if it shows any signs of structural damage such as cracked welds, bent or distortedmembers.

Do not attempt any repairs unless you are qualified to do so. Care should be taken when work is performedon a disabled liftgate located near moving traffic. When possible the vehicle should be moved away fromtraffic areas for repair. Precautionary measures should be taken to ensure personal safety including thoserecommended in Federal Motor Vehicle Safety Standards 571.125.

When welding to liftgate, or liftgate components, take all necessary safety precautions, including usingrespiratory 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 operatingliftgate.

Do not allow anyone to stand in, or near area, in which Platform will open and close before opening or closingPlatform.

Do not allow anyone to stand near the Platform where a falling load could land on them.

Take care to retain cargo during transit for liftgate Platforms which function as the tailgate or door of the cargoarea. 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 isequipped with a special reinforced Platform and Platform Support Bars for use when the Platform is used asloading ramp (dock board). Refer to th

For liftgates equipped with Trailer Hitches, never exceed the rated capacity of the hitch. Do not exceed the

Vehicle must comply with all state and federal standards.

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 Up-stops Pins when in transit.Inspect Cables every three (3) months or 750 cycles, whichever comes first. Cables must be replaced if theyshow signs of wear, distortion, kinking or if any broken wires are visibleReplace 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 injuryhazards.Obey all safety messages that follow this symbol to avoid personal injury or death.

SIGNAL WORDS

WARNINGIndicates a potentially hazardous situation, which if notavoided, could result in death or serious injury.Black letters on an orange background

CAUTIONIndicates a potentially hazardous situation, which if notavoided, may result in minor or moderate injury. Mayalso be used to alert against unsafe practices.Black letters on a yellow background.

NOTICEIndicates a potentially hazardous situation, which if notavoided, may result in property damage.

WARNING

CAUTION

NOTICE

Chapter 2 Liftgate Terminology

1. Hydraulic Cylinder

2. Hose Assembly

3. Return Line Barbed Fitting

4. Return Line

5. Breather

6. Lowering Solenoid

7. Pump Unit Starter Solenoid

8. Pump Unit Motor

9. Pump Unit Reservoir

10. Hose fitting

11. Pressure Compensative Flow Control Valve

12. Drain Plug

GR02594

Gravity Down

Power Down(optional)


15. Transit Chain

16. Pump Unit Cover

17. Dock Bumper

18. Mount Tube Assembly

19. Parallel Arm Assembly

20. Lift Arm Assembly

21. Platform Deck Assembly

22. Platform Extension Assembly

23. Parting Bar

24. Specification Tag

25. Transit Chain Lug

26. Bed Extension

27. Hydraulic Pump Unit

GR02557


Explanation of Specification Tag

Model Description CapacityC15 SB Standard Bed Height 1600 lbs.C15 HB High Bed Height 1600 lbs.C20 SB Standard Bed Height 2000 lbs.C20 HB High Bed Height 2000 lbs.C25 HB High Bed Height (Only) 2500 lbs.

GR00241

GR02558

MODEL NUMBERRATED CAPACITYBased on an evenlydistributed load on theplatform flat surface.

SERIAL NUMBERof liftgate. To be usedwhen ordering parts orwhen contacting Waltcofor service or warrantyquestions

DATE OFMANUFACTUREMonth / Year

Chapter 3 BASIC MOUNTING REQUIREMENTS

Measure distance from ground to floor level. This isthe bed height.

Refer to bed height dimension on mounting chart

minimum mount frame clearance required.

NOTE:Max bed height dimensions for unloaded vehicle.Min bed height dimensions for fully loaded vehicle

NOTE:

and mount frame.GR00139

C-15 SB & C-20 SBSTANDARD BED HEIGHT MODELS

GR02529

BedHeight

GroundClearance Dimension

MountFrame

Clearance

NotchHeightMax.

SillHeightMax.

Dimension Dimension

- 16

-

-

- 12

C-15 HB & C-20 HBHIGH BED HEIGHT MODELS

GR02829

BedHeight


MountFrame

Clearance

NotchHeightMax.

SillHeightMax.

Dimension Dimension

-

-

C-25 HBHIGH BED HEIGHT MODELS

GR02829

BedHeight


MountFrame

Clearance

NotchHeightMax.

SillHeightMax.

Dimension Dimension

- 16 16

42 -47 21 33¾ ---- 4½ 18 12

Bed Height(Ground to Floor)

Chapter 3 BASIC MOUNTING REQUIREMENTS

26-1/8

23-7/8 37-1/8

46-1/2

72-5/8

13-1/8

7

8-3/8

7-1/4

Mount frameClearance (Ref.)

GroundClearance

A

22-1/8

Chapter 4 Installation

Cut away vehicle frame as required to obtain theminimum clearance indicated.

GR02127

strap. Body Crossmember

steel strap

Vehicle Frame

GR00625

PREPARATION OF BODY SILL

Remove all obstructions that would interfere withoperation of Liftgate; such as dock bumpers, trailerhitches, projections, etc.

Locate and mark the center of body sill.

NOTE:

All mounting measurements for centering liftgatewill come from centerline mark.

Body sill must have clearances indicated. Cut or notchRear Sill to obtain these clearances.

Refer to chart p. 3-1

GR02126

MaximumSill Height

Floor Level

X

Y

MaximumSill Height

45 deg TYP

MaximumNotchHeight

Chapter 4 InstallationINSTALLATION OF BED EXTENSION

Place two Support Gussets on rear sill as shown.

Tack weld Gussets to sill.

NOTE:Do not weld hanger tabs to sill!

Break off Hanger Tabs

GR00144

Place Bed Extension on Gussets and center BedExtension with sill.(Two raised round spots on surface of diamondplate indicate centerline.)

Weld Bed Extension to sill as shown.

NOTE:Be certain centerline of body sill and centerline ofbed extension are in line.

GR02559

Weld the two Support Gussets to Bed Extension andweld all gussets to sill as shown.

NOTE:

When irregular sill exists, cut or shim gussetsto maintain a level attitude of bed extensionwith floor of body.

GR02560

Bolt Transit Chain to Bed Extension with 3/8-16 x 1-1/4Grade 8 bolt, Washer and Hex Locknut as shown.

GR02569

Hanger TabsGusset

Approx.

gusset and end bar.

Approx.

Weld two support gussets

of each.around threesides ofeach bar.

of every gusset.

Chapter 4 InstallationPosition liftgate up under vehicle.

Using a forklift or crane, raise platform up to bedextension.

Butt platform and bed extension skins together.

Platform to be centered on vehicle.

A jack, or come-a-long, can be used to position mounttube to proper A-Dimension.

Be sure platform is centered on vehicle body and bedextension.

Other means may be used to supportLiftgate in position. ALWAYS verify thesafety of your supporting method beforeproceeding.

GR02659A & 2651A

Platform

Bed Extension

Dimension

Bed Extension

Centerline of body, bedextension and platform

Chapter 4 InstallationFor C-15 and C-20 Only

Assemble supports, using channels or tubes assupports, and rest them on 1" spacers as shown.

Position deck centrally to and tight against bedextension and clamp securely to supports.RaiseRotate mount tu ilhinge assembly and platform stops are snug

Other means may be used to supportMount Frame in position. ALWAYS verifythe safety of your supporting methodbefore proceeding.

NOTE:Pump box end cover orientation may vary fromhorizontal up to 3 degrees rotation in eitherdirection. This is normal. Amount of rotation willvary with bed height and mounting dimensions.

GR01901A

For C-25 Only

The C-25 liftgate has platform adjusting bolts as shown.

Installation is different, see below.

Never get under platform to adjust bolts..

GR02906

For C-25 Only

Assemble supports, using channels or tubes assupports, do not use spacers.

Position deck centrally to and tight against bedextension as shown and clamp securely to supports.

Raise mount tube into position to holdRotate mount tube so pump bracket and cover areparallel to the ground.

Other means may be used to supportMount Frame in position. ALWAYS verifythe safety of your supporting methodbefore proceeding.

NOTE:Platform angle will be adjusted later.

GR01901B

Supports

HingeAssembly

No Spacers

lbs.

PlatformAdjusting Bolt

Mount Tube

Dimension

Pump CoverParallelw/Ground

Platform Adjustment Bolts

Mount Tube

Supports

HingeAssembly

Platform StopDimension

lbs.

Chapter 4 InstallationMOUNT PLATE INSTALLATION

Locate mount plates on mount tube. Mount platesshould be approximately 90° to vehicle frame.

Check that mount plates extend a minimum of 5-1/4"above bottom of vehicle frame. If dimension cannot beheld, refer to the optional installation.

See below for additionaA-Dimension on C-25 liftgates.

Shield all wires and hoses from heat andweld splatter.

plates 100% to vehicle frame with 1/4

Weld mount tube to the mount plates. Weld all around,both sides of the mount plates, and ends, with 1/4" weld.

To avoid injury or property damage, do notremoveclamps from deck. Use forklift, crane, orother safemeans to support deck and then removeclamps.

GR00472A

MOUNT PLATE INSTALLATIONC- -DIMENSION

Note how chassis frame cutout falls in relation to mountplate.

Weld back side of mount plate

GR00472B

Chassis framecutout falls behindmount plate

weld x 100%

sides of mount plates

both sides and ends of mountplates

5-

Mount Tube

MountPlate

Chapter 4 InstallationOPTIONAL INSTALLATION

If the 5-plate must be added.

Shield all wires and hoses from heat andweld splatter.

1/4

Weld mount tube to mount plates. Weld all around, bothsides of mount plates, and ends, with 1/4" weld.

To avoid injury or property damage, do notremoveclamps from deck. Use forklift, crane, orother safemeans to support deck and then removeclamps.

1/4sides of mount plates andadapter plates as shown.

1/4around both sides andends of mount plates.

5-Min.

5-Min.

adapterplate

GR00473

NOTE:If necessary, liftgate may be mounted to inside offrame as shown.

GR01713

3

Truck Frame

Weld channelto Truck Framewith weld.Weld 100% allaround asshown.

Weld Mount Plate tochannel with 1/4after channel is weldedto the Truck Frame.

5-

Chapter 4 InstallationINSTALLATION OF CONTROLS

Locate Switch such that, when operating liftgate,operator will have clear view of entire platform areaand will not be in area that liftgate will pass through.

Install Switch Mounting Template Decal (or use thisdiagram). Locate screw holes. Drill four (4) holes witha #26 (0.147"dia.) drill bit.

GR02181

If Control Cord will be run through a hole in rear of body,remove all sharp edges from hole and insert a grommet.

Use #8 Self-tapping Screws to secure switch.

GR02561

Route Control Cord from Switch to Pump Plate.

Install grommets (supplied) as shown on Control Cordand Battery Cable. Secure cables to vehicle with cableties provided.

Connect Control Cord and Battery Cable to pump asshown. Connectors are gendered to allow only correctconnections.

Add generous amount of dielectric grease to allelectrical terminals and connections.

NOTE:Do not connect battery cable to battery at this time.

GR02000

BLACKLOWERWHITE

RAISEGREENPOWER

1.75

Dia. HoleHole forControl Cord(optional)

NOT ACTUAL SIZE

#8 Self-TappingScrews

Chapter 4 InstallationINSTALLATION OF POWER CABLE

Locate and mount 150 Amp circuit breaker directly tobatteries using copper terminal link supplied.

Circuit breaker must be mounted to give good protectionagainst any objects coming into contact with circuitbreaker terminals and causing a short. Position mustalso be readily accessible to reset breaker.

NOTE:Circuit Breaker is to rest solidly on batteryto prevent vibration during transit.

If unable to connect circuit breaker direct to batteries,

may be used.

Connect end of battery cable from liftgate to TerminalLink attached to circuit breaker.

Apply a generous amount of Dielectric Grease to allBattery terminals and Circuit Breaker terminals.

Secure all battery cables to chassis frame with cableties provided.

IMPORTANT:Original equipment ground cable furnished onvehicle should be at least a number 2 ga. to insureproper operation of pump unit. An auxiliary groundcable should be added between engine block andchassis frame if engine is not adequately groundedto chassis frame. When there are two or morebatteries, all cables connecting batteries togethermust be 2 ga. or heavier. This includes all originalequipment batteries on vehicle.

Protect wires from any sharp edges orholes that may abrade insulated coveringof wires.

Secure battery cable so it does not comenear, or in contact with, other vehiclewiring, fuel lines, brake lines, air hoses,exhaust system, etc.

Copper Terminal Link

150 Amp Circuit Breaker

Battery CableFrom Liftgate

GR00080

Chapter 4 InstallationDIVERT WATER FROM ENCLOSURE

To help prevent channeling water into pump or batteryenclosures:

Secure hoses, cables and cords downward asthey exit the enclosure.

If a downward exit is impractical, a Zip Tie canbe installed around hose or cable to helpinterrupt the flow of water as shown.

GR02460

Basic gravity down liftgate wiring

GR01994

Hydraulic Schematic Gravity Down

GR02595

Hydraulic Cylinder

Lowering Speed FlowControl Valve (pressurecompensative, non-adjustable)

LoweringSolenoidValve

Pump/Reservoir

Zip Tie

Pump or BatteryEnclosure

Flow of water

Chapter 4 InstallationBasic power down liftgate wiring

GR02904

Hydraulic Schematic Power Down

GR02596

RaiseSolenoidValve

Lowering SolenoidValve

Pump/Reservoir

Lowering Speed FlowControl Valve (pressurecompensated)

Hydraulic Cylinder

Chapter 4 InstallationHOSE INSTALLATION

Avoid twisting of hoses.

Avoid sharp bends when routing hoses

Hoses will contract under pressure. Allow plenty ofslack between connecting points.

Do not clamp hoses at bends to allow for lengthchanges when hose is pressurized.

No Pressure

High Pressure

GR00717

FILLING HYDRAULIC RESERVOIR

Position liftgate deck per chart below (use forklift,crane, or other safe device).

Remove Reservoir Plug.

of reservoir.

If low, fill as required. Use appropriate fluid per chart.

Replace Plug.

Run liftgate full cycle several times to release trappedair from system.

GR02130

LIFTGATE POSITION FOR OIL LEVEL CHECK

Deck should be in this position:

Gravity Down Pump: Power Down Pump:

Ground Level Bed Level

Recommended Fluids Fill reservoir

Temperature Range Acceptable Fluids Fill with recommended fluid or equivalent.

0 to 120 F Waltco BiodegradableLiftlube

TMpart #85803860

FFluids are available from the Waltco parts

Shell Tellus S2 V 32 Dept. 1-800-411-5685 www.waltco.com

Chevron AW32

-20 to 90 F Waltco BiodegradableLiftLube Arctic part#85803866

NOTE:Do not use the following fluids:

Shell Tellus S2 V 15Mobil DTE 13MIL H - 5606

Brake FluidPower steering fluidAutomatic Transmission Fluid (ATF)

A good quality SAE 10W motor oil may also be used intemperatures above 32 F.

Plug

Chapter 4 InstallationThere is no speed adjustment on this liftgate.

Lowering speed is controlled by the pressurecompensative valve plumbed at the cylinder.

Regardless of weight on platform, liftgate should lowerat approximately six (6) inches per second.

Bed Height (inches)= Lowering Time (seconds)

6

This liftgate must have the correctpressure compensative valve installed:

7010001-12

GR02597

Pressure CompensativeFlow Control Valve

Chapter 4 InstallationFor C-25 Only

ADJUST PLATFORM ANGLE

Lower platform until stop blocks hit ground.

Tip of platform should touch ground without platformbreaking (starting to fold) as shown in top drawing.

If platform tip is off the ground, adjust platform downuntil it reaches ground.

If platform tip reaches ground before stop blocks, andplatform starts to fold, adjust platform up.

Be sure both adjusting bolts are adjusted the same.

Never get under platform to adjust bolts.

Always secure jam nuts after anyadjustment is made.

Raise platform back to bed level to check kick-up ofplatform.

Initial kick-4- er bed heights.

If kick-up is too little, or too great for specificapplication, adjust angle of platform as required.

For additional assistance contact Waltco Tech Support.

GR02816 GR02817

Kick-up of platform

Stop BlockPlatform off groundadjust platform down

Properly adjustedplatform

Platform breakingadjust platform up

Platform Adjusting Bolt

Chapter 4 InstallationINSTALLATION OF PARTING BAR

To assist the opening of the platform:

Locate and position the parting bar using the appropriate diagram below.

Tack weld in place.

Check the opening and closing operation of the platform.

Weld the parting bar to the mount tube 100% at all points of contact with 1/4

C-15 & C-20 Only

GR01789

C-25 Only

For -Dimension

For: 21- -Dimension

GR01791

C-25 Only

For -Dimension

For: 21- -Dimension

42

GR01792

Note positionof flat bar


Parting Bar


Parting Bar

Chapter 4 InstallationNOTE:If properly installed, skid plate will ride onparting bar when platform is opening.

GR01906

ACTIVATION OF FOLD OVER ASSIST SPRING

With hinge (1) half way to ground and platform (4)resting on parting bar, drive coiled pin (2) throughhinge pin (3).

Check to ensure that torsion spring contacts coiledpin (2) when platform is rotated to vertical position.

GR01725

INSTALLATION OF UPSTOPS

Purpose of up-stops is to prevent excessive bowing ofbed extension when platform is powered up againstextension.

Stored position up-stop

Fold platform to stored position and using Raise Switch,

bed extension as shown.

Position up-stop along outside of truck frame as shown.Only one up-stop is required.

NOTE:Use up-stop supplied in parts box or use a pieceof channel, angle, or bar stock. Up-stop should

Tack weld up-stop in place. Check to make sureUp-stop does not interfere with opening or foldingof platform before finish welding.

GR02132

Platform Deck

SkidPlate

Platform Extension

Weld upstop to truck frame only.

Bed Extension

Upstop

Upstop should be locatedabove deck tube.

Hinge Assembly

Chapter 4 InstallationOpen position up-stop

NOTE:

This up-stop is optional and only required if bedextension bows when platform is powered upagainst it while in the open (loading) position.

With platform in the open position and usingRaise Switch, raise platform to within 1/16"of bed extension as shown below.

GR01732

NOTE:

Up-stock.

Locate and weld up-stops to underside of bedextension. Up-stops are to contact the platform sidebars on each side of platform.

GR02562

INSTALLATION OF DOCK BUMPERS

Grind corners of bed extension as required for properfit of dock bumper angles.

Locate and weld dock bumper angles against outeredge of bed extension and snug up against undersideof bed extension, 3/16" weld 100% as shown below.

Position support bar as shown holding bar tightagainst sill. Weld 3/16" welds as shown to crossmembers and sill.

Position support channel as shown holding channeltight against bumper angle and support bar.Weld 3/16" welds as shown.

Install optional rubber bumper if ordered. Install optionalstep if desired by welding a 3/8" x 3" x 9-1/2"lg. barbetween support channel and bumper angle as shown.

GR02563

3/16" weld

Optional Step(not included in kit)

SupportChannel

3/16" weld

CrossMember

Support Bar

3/16" weld

3/16" weld

RubberBumper

Bumper Angle

3/16" weld

BedExtension

Up-stop

(approx.)

PlatformSide Bar

Up-stop tocontact SideBars

Bed Extension

PlatformSide Bar

Upstop

Chapter 4 InstallationOPTIONAL SUPER DUTY DOCK BUMPERINSTALLATION.

Position bumper assemblies as shown. Top of bumperassemblies to be flush with top of bed extensions.

Weld into place with 3/16" weld as shown.

Weld support gussets to bumper assembly and tocross members as shown below.

GR02564

OPTIONAL DOCK BUMPER AND TAILLIGHTINSTALLATION

Position bumper assemblies as shown.

Weld into place with 3/16" fillet weld as shown.

Weld support gussets to bumper assembly and tocross members as shown.

GR01339

100%

Sill Cross Member

SupportGusset

weld 100%both sides

SupportGusset

welds asshown

Chapter 4 InstallationLIGHT INSTALLATION

Install lights and rubber bumpers (if ordered) usingparts and fasteners provided.

GR02089

Waltco offers three suggestions for the installation of thevehicle taillights. We believe these suggested locationsmeet D.O.T. regulations but do not warrant that they do.Your installation of the vehicle taillights should meet allapplicable regulations and requirements. This is in noway to infer that these suggestions are the only correctmethod of installing taillights.

skin, if there is sufficient room.

the body rear corner posts.bumpers available that

have lights included as part of the dock bumper.

NOTE:

Original equipment lights may not provide sufficientclearance at this location so a narrower light may berequired.

All lights must be installed in accordancewith all applicable D.O.T. regulations.

GR02503

Taillight,

Taillight,

Light grommet

Harness, 2 lamps

Taillight Bracket

Machine Screw

Hex NutDock Bumper Assembly

Rubber Bumper

White back-up

Red S, T&T

inside dock bumperHex Nut welded

Chapter 5 Placement of Decals

All decals must be in place and legible or all warranties are void.

ITEM DECAL QTY PART NO. LOCATION

1

Safety Instructions 1 80100850 Locate in a conspicuous place near controls.

If your liftgate is equipped with dualcontrols, an additional Safety Instructiondecal (80100850) is to be placed in aconspicuous place near the second set ofcontrols.

Refer to the following diagram showing decal locations.

Operation 1 80101528

Hazard Decal 1 80101370

Important Decal 1 80100828

Motor Thermal Switch 1 80101480

Stand Clear Decal 1 75089296

C15 1600 lb 1 80100252

C20 2000 lb 1 80100253

C25 2500 lb 1 80100255

2

Use Handle Decal 1 75089295

Locate near platform handle

(positioned so as to be read when platform

is being unfolded into loading position)

Stand Clear Decal 1 75089296

C15 1600 lb 1 80100252

C20 2000 lb 1 80100253

C25 2500 lb 1 80100255

3 Store Tight Decal 1 80101517Locate on back of deck on curb side

(visible when platform is stored)

4 Circuit Breaker Decal 1 80100829

Locate next to liftgate circuit breaker.In applications where more than one circuit breakeris used, this decal must be placed in both locations

5 Stand Clear Decal 1 75089296 Locate

02-098010151

7

TRANS ITCHAIN

To maximize decal adhesion to surfaces:Surface must be dry and cleanFirm pressure must be applied to decalMinimum surface temperature 65ºHeat gun may be used to heat surface

GR02565

Chapter 6 Lubrication InstructionsThe liftgate should be lubricated every 120 days.

There are no grease fittings provided on the liftgate.

#1 Oil with a light weight machine oil (do not use oil on bearings in arms or cylinder).

#2 These are bearings that do not require grease, however, bearing can be sprayed with a non-petroleum

based lubricant such as Zep-45 to retard corrosion of pins, reduce friction, and increase life of bearings

GR02566

Ch 7. FINAL INSPECTION SHEETIMPORTANT:

All of the following are to be checked and verifiedbefore installation is complete.

A. Is grade 8 bolt installed through collar andlower cylinder pin and retained with self-locking nut?

B. Are all roll pins securely in place?

C. Are all fasteners tight?

D. Does liftgate fold and unfold properly?

E. Does the platform meet the bed extensionproperly?

F. Does transit chain properly hook onto transitchain lug?

G. Do controls operate properly?

H. Are bed extension, mount frame, mountplates, up-stops, dock bumpers, bumperbraces, taillight guards and taillights allfinish welded?

I. Are hydraulic hoses and fittings properlyconnected with no leaks?

J. Verified correct pressure compensativevalve is installed?

K. Is battery cable attached and clampedtight?

L. Is 150 amp circuit breaker installed atbattery?

M. Are all electrical connections coated withdielectric grease?

N. Has hydraulic system been properly bledof all air?

O. Is pump reservoir full of oil?

P. Are all parts properly lubricated accordingto the lubrication instructions?

Q. Do lights operate properly(Note: Lights must be installed inaccordance with all applicable stateand federal D.O.T. regulations)

R. Is license plate properly installed?

S. Are all decals properly in place and legibleaccording to the decal placement drawings?

T. Is pump cover installed and securelylatched?

U.

Do not use liftgate if any of the above are notchecked and verified. If you have any questionsnot covered in this manual, contact your nearestWaltco distributor, or the nearest Waltcofactory.

How To Order PartsRepairs should be made only by authorized mechanics using WALTCOReplacement parts.

When ordering repair or replacement parts, please include all the informationasked for below. If this information is not available, a complete written descriptionor sketch of the required part will help WALTCO identify and deliver the neededpart to you.________________________________________________________________

THE FOLLOWING INFORMATION MUST BE INCLUDED:

1. SERIAL NUMBER - [WALTCO liftgate serial numbers can be found on theSpecification Tag attached to the mount frame.]

2. MODEL NUMBER

3. CAPACITY

4. PLATFORM SIZE________________________________________________________________

THEN INCLUDE THE FOLLOWING INFORMATION:

5. PART NUMBERS

6. DESCRIPTION

7. QUANTITY REQUIRED________________________________________________________________

MAIL, E-MAIL OR PHONE YOUR REQUEST TO:

Waltco Lift Corp285 Northeast AvenueTallmadge, OH 442781-800-411-5685FAX: 1-800-411-5684E-MAIL: [email protected]

ALL PARTS ARE F.O.B. FROM THE SHIPPING FACTORY________________________________________________________________

PLEASE NOTE:

To assure you of continuing and effective quality control, our warranty policypermits replacement of hydraulic cylinders, valves and motor pump units whentheir factory seals are intact. Parts under warranty will be exchanged promptlyafter careful inspection of the returned assemblies.

________________________________________________

Hand Held Remote Installation

80101485 EO6447 Rev.04

DRILL SOCKET HOLES

Using dimension shown, drill mountingholes in desired location for socket.

GR00036

INSTALL SOCKET

Assemble socket as shown.

Install wires according to colors:W = White (Raise)B or BK = Black (Lower)G = Green (Power)

GR02240

CONNECT WIRES TO PUMP UNIT

This step is for most liftgates, see nextpage for MDL series liftgate instructions.

Route Control Cord into pump enclosure.

First connect Pump wires to Dual ControlAdapter Harness as shown.

Connect both Control Cords to other ends ofAdapter Harness as shown.

Note!Match wire connections male to female. Colorof wire may vary.

GR02082

CONTROLCORD

ADAPTORHARNESS

CONTROLCORD

1-

SOCKET

BATTERY KIT INSTALLATIONS 80101387

EO6410 Rev 047-22-10

DETERMINE BATTERY AND PUMP LOCATION, ANDCABLE ROUTING

Determine where pump unit and battery box will belocated. Make certain hydraulic hoses supplied willreach pump.Your installation may use only one cable supplied withliftgate, or, it may also use a cable supplied with thetrailer kit.

Truck with auxiliary batteries:Cable supplied with liftgate will be cut into two lengths toreach from pump to auxiliary batteries and to vehiclebatteries.

Trailer with auxiliary batteries:Use cable supplied with liftgate from pump to auxiliarybatteries.Use cable supplied with trailer kit from auxiliary batteriesto nose of trailer.

Note: Auxiliary batteries on trailers are to be-

GR01389

PUMP VEHICLEBATTERY

AUXILIARYBATTERY


EO6410 Rev 047-22-10

BATTERY AND PUMP BOX INSTALLATION

Locate battery box and pump box in a suitable locationunder the vehicle body (refer to previous page.)

Weld hanger channels to body crossmembers.

Hint:To save space, hanger channels can be cut down andboxes moved closer together as shown.

Install batteries.

GR01390

INSTALLATION OF BATTERY CABLE

Install battery cable supplied with liftgate to the pumpstarter solenoid.

For trucks:

Route cable to vehicle batteries, cut to desired length.

Cut cable to reach auxiliary batteries, and cut remainingpiece to reach from auxiliary batteries to vehiclebatteries.

For trailers:

Route cable to auxiliary batteries, cut to desired length.

Use cable supplied with trailer kit and route fromauxiliary batteries to nose of trailer.

NOTE: Do not connect cables to any batteries at thistime.

GR01391

BODYCROSSMEMBERS

PUMP BOXBATTERY BOX

HANGERCHANNELS

Cable runs tovehicle batteries ornose of trailer


EO6410 Rev 047-22-10

INSTALLATION OF TERMINAL LUG

of cable.

Slide heat shrinkable tubing onto cable.

Insert bare wire into compression nut until it seats.

NOTE: Be sure to use correct compression nut, use2 gauge nut for 2 gauge cable, use 0gauge nut for 0 gauge cable.

Note: Copper wire should be flush with, or slightlypast nut

Heat shrinkable tubingbefore installation

GR00299

Grip nut with wrench and turn terminal until nut seats

GR00300

Position heat shrinkable tubing over terminal and end ofcable

Shrink tubing using electric heat gun or torch.

Note: To reduce chance of damaging tube andcable, a heat gun is recommended

Apply sufficient heat to produce thin bead of sealant allaround tube edges Heat Shrinkable

Tubing

Beads of Sealant

GR00301

Compression Nut


EO6410 Rev 047-22-10

INSTALLATION OF SOCKET

Drill 1- e of trailer for trailer socket.

Mount socket to trailer with bolts and nuts provided.

Attach cable to back of socket with bolt provided.

Apply a generous amount of Dielectric Grease overcable terminal.

GR02739

Ground trailer socket to main structure of trailer.

trailer socket and suitable structure on the nose of thetrailer.

An angle has been provided, it can be used by welding itto the crash plate, or other suitable structure.

GR01414

Trailer Socket

Angle

Ground Cable

Battery Cable

Trailer Socket


EO6410 Rev 047-22-10

INSTALLATION OF CIRCUIT BREAKER(S)

Auxiliary batteries on a truck will require circuit breakersat both the auxiliary batteries and the vehicle batteries.

Locate and mount 150 Amp circuit breaker directly tobatteries using copper terminal link supplied.

Circuit breaker must be mounted to give good protectionagainst any objects coming into contact with circuitbreaker terminals and causing a short. Position mustalso be readily accessible to reset breaker.

Note: Circuit Breaker is to rest solidly on battery toprevent vibration during transit.

If unable to connect circuit breaker direct to batteries, an

be used.

Connect end of battery cable from liftgate to TerminalLink attached to circuit breaker.

Apply a generous amount of Dielectric Grease to allPositive (Hot) Battery terminals and Circuit Breakerterminals.

Secure all battery cables to chassis frame with cable tiesprovided.

NOTE: Original equipment ground cable furnishedon vehicle should be at least a number 2 ga. toinsure proper operation of pump unit. An auxiliaryground cable should be added between engineblock and chassis frame if engine is not adequatelygrounded to chassis frame. When there are two ormore batteries, all cables connecting batteriestogether must be 2 ga. or heavier. This includes alloriginal equipment batteries on vehicle.

Protect wires from any sharp edges orholes that may abrade insulated coveringof wires.

Secure battery cable so it does not comenear, or in contact with, other vehiclewiring, fuel lines, brake lines, air hoses,exhaust system, etc.

GR01413

150 AmpCircuit Breaker

Cable suppliedwith Liftgate

See belowFor detail

Cable supplied withLiftgate or with TrailerKit

GroundCable

Cable to Vehicle Batteriesor to Nose of Trailer

Terminal Links

Cable from Liftgate

80101488 EO6187A Rev. 02

Dual Control Switch, Installation InstructionsFor Kit 80000434

Note: Kit may include additional parts not used in all installations

Locating and Mounting Switch

Locate a position for Switch such that operator hasa clear view of entire Platform area and will not bein the area that liftgate passes through.

IMPORTANTVerify that Control Cord is long enough toreach pump unit before advancing to the

next step.

Using Switch Mounting Template or diagram tothe right, drill four fastener holes with a #26

If Control Cord will be run through a hole in theside of the truck, remove all sharp edges fromcenter hole and insert a grommet.

Mount Switch with #8 Self-tapping screwsprovided.

GR00340

GR02080

This step is for most liftgates, see next page forLPF liftgate instructions.Route Control Cord into pump enclosure.

First connect Pump wires to Dual ControlAdapter Harness as shown.

Connect both Control Cords to other endsof Adapter Harness as shown.

NOTE:Match wire connections male to female.Color of wire may vary. GR02081

CONTROLCORD

CONTROLCORD

ADAPTORHARNESS

#8 SELF-TAPPINGSCREWS

2.80

1.75

Date:8-23-2010No. TT100006Model: ManyEO 6393

New Theft Deterrent Pump Cover

Waltco has released a new Theft Deterrent Pump Cover (lockable) for most Flipaway andConventional liftgates. This new cover will allow user to install a simple pad lock to secure thecover in place, thus restricting access to the pump unit.

This new cover will be an option on EM, EMTC, C, K, SL, FSL, 1090, and 1290 liftgates.This option will be available on liftgates October 1, 2010.

Note: Cover can not be used on olderliftgates unless pump bracket is alsoreplaced.

GR02759

New LockablePump Cover

Pad lock notincluded with cover

Lock Bar

Installation of Cab Shut Off Switch

80101363 REV 04 09-08-11

Install cab shut off switch and shut off switchdecal in convenient location in vehicle cab.

GR00379

Remove fuse line from motor solenoid.Unplug fuse line (or cut if required) fromswitch and save for later installation.

Connect green 16 ga. cab shut off wireto switch.

Install supplied bullet connector ontoswitch wire, if required.

GR02087

Run green 16 ga. cab shut off wire to cab shutoff switch.

Cut off excess wire and connect to cab shut offswitch with supplied #10 ring terminal.

Re-using the fuse line, attach supplied bulletconnector if not already equipped. Connect toexcess 16 ga. wire.

Run excess 16 ga. wire from vehicle battery tocab shut off switch. Fuse end to be towardbattery.

Note: Do not connect to battery at this time.

Connect 16 ga. wire to cab shut off switch withsupplied #10 ring terminal.

ring terminal.

Important: Heat shrink all connectors.GR00716

To switchgreen wire

Fuse

ExcessWire

BulletConnector

BatteryCable

Switch

Cab ShutOff Switch

Remove

To Battery

16 Ga. CabShut Off Wire

Decal

Motor Solenoid

Cab Shut Off Switch

NOTE: Circuit Breakerto rest solidly on batteryto prevent vibrationduring transit

Snubber Kit Instructions 80100503

INSTALL RUBBER SNUBBERS

Raise Platform to fully closed position.

NOTE:

On F and FSL Series Liftgates only:

Pull up and rearward on Deck Extension tomake certain Platform is fully in storedposition.

GR00168

selected spot on chassis frame.

Lower platform slowly

GR00168

Position a Snubber Assembly approximately as shownon each Mount Plate and tack weld in place.

Lower, open and re-store Platform a few times to checkoperation of Snubbers.

Check that Snubber Assemblies do not interfere withopening or storing away of deck.

Mount Plate

Snubber Assembly

Pad to touch Platformend tube.

Weld 100%, all around

GR00169

EO6091 Rev 038-08

REMOTE MOUNT BRACKET INSTALLATION INSTRUCTIONS

If welding to crossmembers

Weld top ends of Mount Bracket to acrossmember.Weld both sides of one end of Brace to acrossmember.Weld (3) sides of other end of Brace to theMount Bracket.

If bolting Mount Bracket tovehicle frame

Weld both sides of one end ofBrace to the body longmember.Weld (3) sides of other end ofBrace to the Mount Bracket.

Self-tapping Screw

Hose Clamp

2. Install Remote Bracket on to the vehicle.

If welding Mount Bracket tovehicle frame

Weld the Mount Bracket asshown

Also weld Brace as shown inprevious picture.

3. Add Gasketto MountBracket.

4. Detach hoses and un-fasten (4) hex-screws toremove pump.

6. Connect HoseExtension to HydraulicHose.

5. Replace ventedplug with SquareHead Plug

7. Fasten Pump to Mount Bracket using the (4) hexscrews.

8. Re-attach hoses.

9. Secure hoses to the vehicle using the hoseclamps and self-tapping screws provided.

IMPORTANT:Hydraulic hoses are to be

protected from sharpedges, and never secured

near exhaust system.

80101284 Rev 02 3/16/01

Mounted on crossmembers parallelto the vehicle frame

Mounted on crossmembersperpendicular to the vehicle frame

Bolted or welded to the vehicleframe

1. Locate a position for the pump on the truck frame as near to the rear of the vehicle as practical.Shown below are three possible ways the pump may be mounted.If the p80000429) so that a switch can be mounted on the curb side.

This page left intentionally blank.

Every vehicle that has a WALTCO Liftgate must have legibleWARNING AND OPERATION DECALS clearly posted on the

a guide for proper operation and maintenance.

be obtained from WALTCO LIFT CORP.

____________________NOTE:

When ordering, give modeland serial number of the liftgate.

____________________

IMPORTANT

WARNINGImproper operation and maintenance of thisliftgate could result in severe personal injuryor death.

Read and understand the contents of thismanual and all warning and operation decalsbefore operating and/or performingmaintenance on this liftgate.

For SAFETY information on this liftgate seeChapter 1 of this manual

80101520 EO6156Rev 01

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