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em-25 em-30 series visit us at www.waltco.com installation instructions 2500/3000 lb capacity flipaway liftgate warning improper installation of this liftgate could result in severe personal injury or death read and understand the contents of these instructions before proceeding when installed this liftgate must not alter or prevent vehicle compliance to any existing state or federal standards each chassis manufacturer s recommendations should be consulted for compliance gr02693 12-2010 ohio 285 northeast avenue tallmadge oh 44278 330 633-9191 fax ­ 330 633-1418 e.o 6309jj rev 07 80126401

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table of contents chapter introduction safety information 1 liftgate terminology 2 basic mounting requirements 3 installation 4 placement of decals 5 lubrication instructions 6 final inspection 7 how to order parts 8 optional kit instructions hand held remote kit 80101485 kit #80000430 aux battery kit truck 80101387 kit #80001066 aux battery kit trailer 80101387 kit #80001069 tractor wiring kit 80100822 kit #80000618 dual control kit 80101550 kit #80000437 theft deterrent kit tt100006 kit #80001313 cab shutoff kit 80101363 kit #80000827 remote pump mount kit 80101284 kit #80000979 underride kit 80101565 kits #26495001 26495102 e.o 6309jj rev 07 80126401

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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

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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

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chapter 1 liftgates with tilt function safety information 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

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chapter 2 1 2 3 4 5 6 7 liftgate terminology 8 9 10 11 12 13 thermal switch inside motor pump unit motor reservoir lowering valve coil ground cable drain plug hydraulic cylinder flow control valve return line barbed fitting gravity down return line gravity down raise hose assembly breather cap pump unit starter solenoid gr02636 page 2-1

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chapter 2 14 15 16 17 18 19 mount tube assembly parting bar assembly deck assembly torsion bar deck extension assembly lift arm assembly liftgate terminology 20 21 22 23 24 25 26 27 folding assist springs parallel arm pump cover mount plate spec tag see following page bed extension transit chain dock bumper gr02637 page 2-2

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chapter 2 liftgate terminology explanation of specification tag model name em em model name description single cylinder single cylinder capacity 2500 lb 3000 lb rated capacity based on an evenly distributed load on the platform flat surface 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 gr02773 page 2-3

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chapter 3 determine basic mounting requirements measure distance from ground to floor level this is the bed height refer to bed height dimension on mounting chart to determine basic mounting dimension a and minimum mount frame clearance required note max bed height dimensions for unloaded vehicle min bed height dimensions for fully loaded vehicle note tire clearance should be 6 minimum between tire and mount frame gr00139 bed height ground to floor mounting chart bed height 36 43 44 54 55 56 a dimension 19 24 26 mount frame clearance 34-1/2 30-1/2 28-3/8 important minimum bed height for 50 wedge or 46 4 deep platforms is 39 important read following page to determine if you will need to change stop blocks shipped with liftgate note a dimension is from top of floor bed to top of mount tube gr02638 page 3-1

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chapter 3 determine basic mounting requirements stop blocks shipped with liftgate are based on the depth and style of platform 26450001 26450051 26450003 26450053 26450004 26450054 26450005 26450055 26450002 26450052 below in bold indicates which stop blocks 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 bed height range 56 55 54 44 44 36 a-dim recommend stop blocks 40 4 deep platform bed height range 56 55 54 44 44 36 a-dim recommend stop blocks 26 24 19 26450003 26450053 26450004 26450054 26450002 26450052 26 24 19 26450001 26450051 26450003 26450053 26450005 26450055 50 deep wedge platform bed height range 56 55 54 44 44 39 a-dim recommend stop blocks 46+4 deep platform bed height range 56 55 54 44 44 39 a-dim recommend stop blocks 26 24 19 26450001 26450051 26450003 26450053 26450005 26450055 26 26450001 26450051 24 19 26450003 26450053 gr02815 page 3-2

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chapter 4 preparation of body sill installation x remove all obstructions that would interfere with operation of liftgate such as dock bumpers trailer hitches projections etc locate and mark the center of body sill note all mounting measurements for centering liftgate will come from centerline mark body sill must have clearances indicated cut or notch rear sill to obtain these clearances refer to chart p 3-1 platform width 2 hold x as follows a dimension x max 19 4 24 5-1/2 26 6 gr02184 note for aluminum platforms only on units that have aluminum platforms additional notching of the rear sill will be necessary notches not required for 26 a-dimension gr02184 cut away vehicle frame as required to obtain the minimum clearance indicated 36 to 43 bed height 19 a dimension gr01896 page 4-1

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chapter 4 cut away vehicle frame as required to obtain the minimum clearance indicated installation 44 to 56 bed height 24 and 26 a dimensions gr02079 cap vehicle frame using a 3/16 or 1/4 x 2 steel strap body crossmember vehicle frame 3/16 or 1/4 x 2 steel strap gr00625 installation of bed extension if bed extension is to be bolted on use pattern at right for drilling holes twelve 12 9/16 diameter holes required gr02760 page 4-2

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chapter 4 installation of bed extension installation position bed extension up to rear sill using a forklift or crane make certain bed extension is centered on vehicle body and level with bed other means may be used to support bed extension in position always verify the safety of your supporting method before proceeding bed extension gr02647 if bolting bed extension to sill use twelve 12 1/2 bolts nuts and washers provided with kit torque bolts to 90 ft lbs if welding note to help protect vehicle paint notches have been provided so top of bed extension does not have to be welded note if corner posts of vehicle body extend beyond rear sill of body shims may be added behind bed extension to prevent bowing of bed extension weld underside of bed extension weld all notches 100 with 1/8 weld to rear sill of vehicle body weld inside bottom of both side bars with 1/8 weld to protect paint do not weld outside weld both sides of all gusset bottoms where gussets contact the rear sill weld with 1/8 weld gr02648 notches bottom of gussets bottom of side bar page 4-3

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chapter 4 installation 1/8 weld x 2 long above each of the notches alternative welding of bed extension weld top side of bed extension 1/8 x 2 welds over each of the notches on underside of extension weld inside bottom of both side bars with 1/8 weld to protect paint do not weld outside weld both sides of all gusset bottoms where gussets contact the rear sill weld with 1/8 weld bottom of gussets bottom of side bar gr02647 48 remove liftgate from shipping pallet and all banding do not unfold platform until instructed to do so upper hole 19 a-dim lower hole 24 a-dim from factory mounting bar platform folded stop before proceeding verify vehicle bed height and a-dimension to be used set mounting bar for proper a-dimension refer to chapter 3 of this manual mounting bar must be set to correct a-dimension for vehicle bed height mount bar is set for 24 a-dimension when shipped from factory as shown to change hole remove cotter pin from upper cylinder pin pull mounting bar off pin and rotate cylinder tower push mounting back onto pin and reinsert cotter pin gr02732 page 4-4

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chapter 4 installation do not remove mounting bar until instructed to do so note if mounting to 26 a-dimension the mounting bar will need to be removed before proceeding unfold platform to open position mounting bar mounting bar retaining bolt gr02650 page 4-5

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