WALTCO EM25 Capacity Flipaway Liftgates

Important Information

Last Change

Waltco Lift Corp. Corporate Office United State
285 Northeast Ave.| Waltco Lift Corp. United States
620 S Hambledon Ave.| Waltco Lift Inc. Canada
90 North Queen St.
---|---|---
Tallmadge, OH 44278| City of Industry, CA 91744| Etobicoke, ON M8Z 2C5
P: 330.633.9191
F: 330.633.1418| P: 626.964.0990
F: 626.964.0149| P: 888.343.4550
EO:7915 Rev 13
4-2016| | 80126402

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.

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 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.

• 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.

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 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.

WALTCO warrants its products free of defects in materials and workmanship.
WALTCO will replace components found defective during the warranty period. Labor will be reimbursed according to our flat rate labor schedule at the prevailing shop rate.
Contact our Sales or Warranty departments for the warranty period of your model or for information regarding our flat rate labor schedule.

WALTCO Warranty Claim Procedure

For consideration, all claims must be received within 30 days of repair and include the following information:

• Liftgate Serial Number
• Description of problem and corrective actions
• Itemization of the labor charge to include the number of hours and labor rate

Replacement warranty parts can be obtained by contacting Waltco’s Parts Department.
Parts must be returned for inspection when requested.

Exclusions:

Waltco’s warranty does not include reimbursement for service calls, vehicle rental, towing, travel time, fabrication of parts available from WALTCO, damage from misuse or abuse, negligence, accidents, alteration, loss of income or overtime expense, oil, or normal wear.
Diagnosis and troubleshooting time are included in the flat rate labor times.
Warranty and technical information is available from WALTCO’s toll free customer service lines from 8:00 a.m. to 5:00 p.m. EST.

Waltco Lift Corp

285 Northeast Ave, Box 354, Tallmadge, OH 44278 1-800-211-3074, 330-633-9191
Please visit our websites: http://www.waltco.com or http://www.hiab.com We’re behind you all the way!

Chapter 2 Liftgate Terminology

1. Hydraulic Cylinder

2. Flow Control Valve

3. Return Line Barbed Fitting (Gravity Down)

4. Return Line (Gravity Down)

5. Raise Hose Assembly

6. Breather Cap

7. Pump Unit Starter Solenoid

8. Motor

9. Reservoir

10. Lowering Valve Coil

11. Ground Cable
    

12. Mount Tube Assembly

13. Parting Bar Assembly

14. Deck Assembly

15. Torsion Bar

16. Deck Extension Assembly

17. Lift Arm Assembly

18. Folding Assist Springs

19. Parallel Arm

20. Pump Cover

21. Mount Plate

22. Spec Tag (see following page)

23. Bed Extension

24. Transit Chain

25. Dock Bumper
    

Explanation of Specification Tag

Chapter 3 Operations Instructions

TO OPEN PLATFORM

Rotate and remove transit chain off of transit chain lug.

Never force Latch Chain if platform weight is on chain.
To slacken chain, push Raise Switch.

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.

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.
To prevent unauthorized use of liftgate, insert a heavy gauge pad lock into first link of latch chain.

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.

Check appropriate box below for each step:

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.
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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”.
15| OK| Repair Required| Corrected| Check operation of cycle counter
12 Month Liftgate PM Procedures (Includes steps 1-14 above)
16| OK| Repair Required| Corrected| Inspect Pump Motor for wear or damage.
17| OK| Repair Required| Corrected| Replace Hydraulic Fluid.

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.
• 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.

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.

To prevent unauthorized use of liftgate, use a heavy gauge pad lock as shown.

ADJUST PLATFORM ANGLE

Lower platform until stop blocks hit ground.
Note:
On higher bed heights stop blocks may not reach ground.
Tip of platform should touch ground without platform breaking (starting to fold) as shown in top drawing.
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.
Always secure jam nuts after any adjustment is made.

Platform off ground adjust platform down.

Platform breaking adjust platform up.

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.
For additional assistance contact Waltco Tech Support.

Inspect fold over assist springs and related hardware.
Check that bolts and sleeves contact and hold torsion springs when platform is unfolded to the open position.
NOTE:
Some platforms have two (2) springs, others have only one (1) spring.

CHECK RUBBER SNUBBERS

Raise platform to fully closed position. Pull and/or push on deck extension to verify it is held tight.
Platform end tube should compress rubber snubber. If not, add shims or large washers under snubber pads to obtain this compression.

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

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.

LIFTGATE POSITION FOR OIL LEVEL CHECK

Deck should be in this position:| Gravity Down Pump:| Power Down Pump:
Ground Level| Bed Level
Recommended Fluids

Temperature Range| Acceptable Fluids
0° to 120° F| Waltco Biodegradable LiftlubeTM part #85803860
Shell Tellus S2 V 32
Chevron Rando HDZ 32
-20° to 90° F| Waltco Biodegradable
LiftLube Arctic part #85803866
Waltco All Season Hyd Oil Part 85803867
Shell Tellus S2 V 15
Mobil DTE 10 Excell 15

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.
• Fluids are available from the Waltco parts Dept. 1-800-411-5685 www.waltco.com

NOTE:

NOTE:
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 at the cylinder.
Regardless of weight on platform, liftgate should lower at approximately six (6) inches per second.
Bed Height (inches) = Lowering Time (seconds) 6

This liftgate must have the correct pressure compensative valve install: 7010001-19

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.

CHECK CYCLE COUNTER

Cycle counter should register a cycle every time the lowering switch is activated and held on for a minimum of four (4) seconds.
Refer to wiring schematics in this manual.

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.
  

BLEEDING HYDRAULIC SYSTEM

GRAVITY and POWER DOWN LIFTGATES

Note : Fluid level in reservoir will need to be checked before and after bleeding system.
Check fluid level, to be 1/2″ from top of reservoir with platform at ground for gravity down units, platform at bed height for power down units.
Lower platform to ground, place a bucket or pan under the raise line and cylinder to catch hydraulic fluid.
Disconnect raise line at the flow control valve.
With someone holding the raise line in the bucket/pan, press the raise switch and activate the pump. Do this until a steady, air free, stream of fluid flows from the hose.
Reconnect hose to cylinder. Again, check fluid level of reservoir and fill as may be required.

POWER DOWN LIFTGATES ONLY

On power down liftgates the upper hose (lowering) will also have to be bled of air.
Again, check fluid level with platform at bed level.
Lower platform to ground.
Disconnect upper lowering line.

CAUTION as hydraulic line may be pressurized

With someone holding the lowering line in the bucket/pan, press the lower switch and activate the pump. Do this until a steady, air free, stream of fluid flows from the hose.
Reconnect hose to cylinder. Again, check fluid level and fill as may be required.

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 dual controls, an additional Safety Instruction decal (80100850) is to be placed in a conspicuous place near the second set of controls.
Refer to the following diagram showing decal locations.
Operation| 1| 80101528
Hazard Decal| 1| 80101370
Important Decal| 1| 80100828
Stand Clear Decal| 1| 75089296
 |  |
2| Capacity Decal – 2500 lb| 1| 80100255| Locate on curbside of platform
(Position so as to be read when platform is open)
Capacity Decal – 3300 lb| 1| 80100585
3| 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
Capacity Decal – 2500 lb| 1| 80100255
Capacity Decal – 3300 lb| 1| 80100585
4| Transit Chain Decal| 1| 80101517| Locate on back of deck on curbside
(Visible when platform is stored)
5| Circuit Breaker Decal| 1| 80100829| Locate next to liftgate circuit breaker.
In applications where more than one circuit breaker is used, this decal must be placed in both locations
6| Stand Clear Decal| 1| 75089296| 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.
  

Chapter 6 Lubrication Instructions

The liftgate should be lubricated every 120 days.

1 – Grease all grease fittings in pins, arms, and cylinder with grease gun.

2 – Oil with a light weight machine oil (do not use on bearings in platform).

a Included in Switch Hand Held Remote Kit 80000430.

ELECTRIC CONTROL OPTIONS – Gravity Down

• a Included in Switch Kit 80000436.
• b Included in Switch Dual Control Kit 80000437.
• c Included in Switch Hand Held Remote Kit 80000430.
  

ELECTRIC CONTROL OPTIONS – Power Down

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 Lift Corp
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.

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 LIFT CORP.

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

Customer Support

www.waltco.com Phone: 800.211.3074
sales@waltco.com Fax: 800.211.3075

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