emtc_series_om

E.O. 6309RR Rev. 07 80126502

EM-25 TC / EM-30 TC SERIES

TWIN CYLINDER

Visit us at www.waltco.com Owner’s Manual 2500/3000 lb. Capacity, Flipaway Liftgate

3-2011

OHIO 285 Northeast Avenue Tallmadge, OH 44278 (330) 633-9191 FAX – (330) 633-1418

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.

http://www.waltco.com/

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

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

Page 1 - 1 80101253 Rev 04 EO 6309JJ

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.

Chapter 1 Safety Information

Page 1 - 2 80101253 Rev 04 EO 6309JJ

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.

NOTICE

WARNING

CAUTION

Chapter 2 Liftgate Terminology

Page 2-1

1. Hydraulic Cylinder 2. Hose Assembly 3. Male-Female Adapter 4. Return Line Barbed Fitting 5. Return Line 6. Breather Cap 7. Pump Unit Starter Solenoid 8. Lowering Valve Coil

9. 90 Deg. Hose Fitting 10. Tee, Hose Fitting 11. Drain Plug 12. Pump 13. Thermal Switch (Inside Motor) 14. Ground Cable 15. Pump Unit Motor 16. Pump Unit Reservoir

GR02641

2

8

67

13

5

1

9

2

4

3

543

15

1216

11

14

10


Page 2-2

17. Mount Tube Assembly

18. Parting Bar Assembly

19. Deck Assembly

20. Torsion Bar

21. Deck Extension Assembly

22. Lift Arm Assembly

23. Folding Assist Springs

24. 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 2-3

Explanation of Specification Tag

Model Name Description Capacity

EMTC Twin Cylinder 2500 lb.

EMTC Twin Cylinder 3000 lb.

GR00241

GR02777

Specification Tag

MODEL NAME 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

Chapter 3 Operations Instructions

Page 3-1

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.

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.

To prevent unauthorized use of liftgate,

insert a heavy gauge pad lock into first link

of latch chain.

GR02568

8010151

S T CHA N

015 7

Lug

Chapter 4 Preventive Maintenance

Page 4-1

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 4-2

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.

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.

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

GR02568

A

7

Lug


Page 4-3

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.

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.

GR02816 GR02817

Kick-up of platform

Stop Block Platform off ground adjust platform down

Properly adjusted platform

Platform breaking adjust platform up

Platform Adjusting Bolt


Page 4-4

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.

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

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.

Plug

GR00159

End Tube

Rubber Snubber


Page 4-5

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.

-10 to 195 F Shell Tellus 32T Mobil DTE 13M

Fill the reservoir to within 1/2” from the top.

-25 to 140 F Shell Tellus 15T Liftgate filled at factory with Shell Tellus 15T

Mobil DTE 11M

-40 to 145 F AeroShell Fluid 4 NOTICE:

Exxon Univis HVI 13 Do not use the following fluids:

-45 to 200 F Shell Tellus Arctic (Tellus S4 VX 32)

Brake Fluid Power steering fluid

A good quality SAE 10W motor oil may also be used in Automatic Transmission Fluid (ATF) temperatures above 32 F.

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) = Lowering Time (seconds)

6

This liftgate must have the pressure compensative valve installed in the cylinder.

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.

Pressure Compensative Flow Control Valve inside Port


Page 4-6

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.

GR02100

Remove cover to check brushes and clean out motor

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

Motor Thermal Switch 1 80101480

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 – 3000 lb

1 80100257

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 – 3000 lb

1 80100257

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

Page 5-1

A

GR02655

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

Page 6-1

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.

GR02656

1

1

2

2

2

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

LIFT CORP.

EM-25 TC & EM-30 TC

REVISED: 3-18-11 E.O. 6309RR REV. 06

PM-781

ITEM PART NUMBER QTY DESCRIPTION

1 26520001 1 Mount Frame Weldment

2 75089334 1 Grommet, 1/2” ID

3 75090310 1 Grommet, Multi-Split

4 26470101 2 Mount Plate

5 70401408 1A Grommet, 7/16” ID

6 70401409 1B Grommet, 1/4” ID

7 10090450 1 Pump Cover

8 7500010-21 3 Hex Screw, ¼-20 x 1”, Gr 8

9 75088079 3 Lock Washer, ¼”

10 70430550

1 Hydraulic Pump, Gravity Down

70430560 Hydraulic Pump, Power Down

11 26455001 2 Parallel Arm Assembly

12 10010188C 6 Bearing, 1” ID x 1” Lg

13 10010187C 8 Bearing, 1” ID x 3/4” Lg

14 1000022-01D 4 Pin Assembly, 1-1/4” x 2-1/8”

15 75088055D 10 Hex Bolt, 3/8-16 x 3/4” Grade 5

16 10010189C 4 Bearing, 1-1/4” ID x 1” Lg

17 26530001

1 Lift Arm Weldment

26530002 Lift Arm Weldment, Under-ride

18 1000021-03D 2 Pin, 1” x 3-1/4”

19 1000022-02D 2 Pin Assembly, 1-1/4” x 3”

20 1000021-06D 2 Pin, 1” x 5-7/8”

21 26580010 2 Hydraulic Cylinder

22 CS Stop Block 1 See PM-798

23 DS Stop Block 1 See PM-798

24 75089307 12 Grease Zerk Fitting

25 26492001 1 Parting Bar Assembly

26 75086236 1 Hex Bolt, 5/8-18 x 2-1/2” Lg

27 75085111 1 Nut, 5/8-18

28 75088064 2 Washer, 5/8”

32 10010186C 2 Bearing, 1-1/4” ID x 1-5/8” Lg

33 75088081D 10 Lock Washer, 3/8”

34 75088053D 10 Flat Washer, 3/8”

35 7500045-2 4 Grease Zerk, ¼ Straight

A QTY of 2 with Power Down Pump, QTY of 1 with Gravity Down Pump

B 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

IMPORTANT:Parts shown may not match yourliftgate. See PARTS NAVIGATOR orcontact Waltco Parts to confirmcorrect part numbers.

LIFT CORP.

EM-25 TC & EM-30 TC

REVISED: 3-18-11 E.O. 6309RR REV. 06

PM-781

MOUNT FRAME ASSEMBLY


PM-798 Stop Block Assemblies

Page 1-1

Stop Blocks shipped with liftgate are based on the depth and style of platform.

26450001 CS 26450003 CS 26450004 CS 26450005 CS 26450002 CS 26450051 DS 26450053 DS 26450054 DS 26450055 DS 26450052 DS 26451001 Kit 26451003 Kit 26451004 Kit 26451005 Kit 26451002 Kit Kits include both stop blocks. 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

Bed Height Range

A-Dim Recommend Stop Blocks

56 - 55 26 26450003 & 26450053

54 - 42 24 26450004 & 26450054

41 - 36 19 26450002 & 26450052

40 + 4” Deep Platform

Bed Height Range


56 - 55 26 26450001 & 26450051

54 - 42 24 26450003 & 26450053

41 - 36 19 26450005 & 26450055

50” Deep Wedge Platform

Bed Height Range


56 - 55 26 26450001 & 26450051

54 - 42 24 26450003 & 26450053

41 - 39 19 26450005 & 26450055

46+4” Deep Platform

Bed Height Range


56 - 55 26

26450001 & 26450051

54 - 42 24

41 - 39 19 26450003 & 26450053

GR02815

REVISED 3-17-11

E.O. 6309RR REV 02


This page intentionally left blank.


LIFT CORP.

EM, EM TC

REVISED: 9-20-10 E.O. 6309JJ REV. 04

PM-782

ITEM PART NUMBER 44” WEDGE 26410012

50” WEDGE 26410011

40”+4” 26410002

46”+4” 26410001

DESCRIPTION

1 26411001 1 1 Deck Weldment, 50”

26411002 1 1 Deck Weldment, 44”

2 26413011 1 Deck Extension Weldment, 50” Wedge

26413012 1 Deck Extension Weldment, 44” Wedge

3 26413001 1 Deck Extension Weldment, 46+4

26413002 1 Deck Extension Weldment, 40+4

4 22114300 2 1 2 1 Torsion Spring, Red End

5 21514301 1 1 Torsion Spring, Green End

6 10010187 A 2 2 2 2 Bearing, 1” ID x 3/4” Lg.

7 7500019-3 1 1 1 1 Socket Head Shoulder Bolt, 1/2” x 1/2”

8 26412001 B 2 2 2 2 Pin, Deck Spring w/ Grease Fitting

9 75089542 4 4 4 4 Coil Spring, 1/2” Dia. x 2” Lg.

10 26417301 1 1 1 1 Torsion Bar Anchor

11 22517100 1 1 1 1 Torsion Bar, 1/2”

12 1000101-6 2 2 2 2 Pin Weldment, 1” x 1-1/4”

13 75086053 2 2 2 2 Hex Bolt, w/ Vibraseal Thread Locking

14 7500010-30 2 2 2 2 Hex Bolt, 3/4-10 x 2” Lg. Grade 5

15 75085015 2 2 2 2 Hex Jam Nut, 3/4-10

A Included in Bearing Replacement Kits 80001283 (EM) & 80001284 (EM TC)

D Included in Pin Replacement Kits 80001285 (EM) & 80001286 (EM TC)


LIFT CORP.

EM, EM TC

REVISED: 9-20-10 E.O. 6309JJ REV. 04

PM-782

STEEL PLATFORM ASSEMBLY


LIFT CORP.

EM, EM TC

REVISED: 9-20-10 E.O. 6309JJ REV. 03

PM-791

ITEM PART NUMBER

44” ALUM

WEDGE

26410014

50” ALUM

WEDGE

26410013

44” ALUM/STEEL

WEDGE 26410016

50” ALUM/STEEL

WEDGE 26410015

DESCRIPTION

1

26411012 1 Deck, 50” Alum

26411011 1 Deck, 44” Alum

26411001 1 Deck, 50” Steel

26411002 1 Deck, 44” Steel

2 26413014 1 1 Deck Extension Assy, 50” Alum Wedge

26413013 1 1 Deck Extension Assy, 44” Alum Wedge

3 1000101-6 2 2 2 2 Pin Assy

4 75086053 2 2 2 2 Hex Bolt, w/Vibraseal Thread Locking

5 26317100 1 Torsion Bar, 3/8”

26417702 1 Torsion Bar, 3/8”

6 26417301 1 1 Torsion Bar Anchor

7 7500019-3 1 1 Socket Head Shoulder Bolt, 1/2” x 1/2”

8 42668440 4 4 4 4 Spring, Cart Stop

9 26414801

A 1 1 1 1 Cart Stop Assy Complete, Curbside

26414851 A 1 1 1 1 Cart Stop Assy Complete, Street Side

10 42669012 1 1 1 1 Cart Stop, Curbside

42669011 1 1 1 1 Cart Stop, Street Side

11 75089591 2 2 2 2 Spring Pin, 3/16” Dia x 7/8” Lg.

12 7500019-4 2 2 2 2 Socket Head Shoulder Bolt, 3/8” x 3/8”

13 42669299 2 2 2 2 Roll Stop

14 42669286 6 6 6 6 Shim

15 75088268 2 2 2 2 Spring, Cart Stop

16 42669014 2 2 2 2 Locking Pin, Cart Stop

17 26412001 C 2 2 2 2 Pin, Deck Spring w/ Grease Fitting

18 75089542 C 4 4 4 4 Coil Spring, 1/2” Dia x 2” Lg.

19 75085015 2 2 2 2 Hex Jam Nut, 3/4-10

20 7500010-30 2 2 2 2 Hex Bolt, 3/4-10 x 2” Lg. Grade 5

21 21514301 1 1 1 Torsion Spring, Green End

22 22114300 2 1 Torsion Spring, Red End

23 10010187 B 4 4 4 4 Bearing, 1” Dia x 3/4” Lg.

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

REVISED: 9-20-10 E.O. 6309JJ REV. 03

PM-791

ALUMINUM PLATFORM ASSEMBLIES ALUM DECK EXTENSION + STEEL DECK ASSEMBLIES


REVISED: 12-20-10 E.O. 6309NN REV. 02

PM-799

LIFT CORP.

EM, EMTC


1

26460005

1

Bed Extension 96” Vehicles

26460006 Bed Extension, 102” Vehicles

26460013 Bed Extension, Walk Ramp Ready, 96”

26460014 Bed Extension, Walk Ramp Ready, 102”

26460020 Bed Extension, 3/8” Skin, 96”

26460021 Bed Extension, 3/8” Skin, 102”

2 26497001 1 Dock Bumper, CS For Lights (Option)

3 26497051 1 Dock Bumper, DS For Lights (Option)

4 26497002 1 Dock Bumper, CS (Option)

5 26497052 1 Dock Bumper, DS (Option)

6 26498501 1 Stir-Up Assembly (Option)

7 26297604B 2 24” Rubber Bumper, Long (Option)

8 26297603A 2 6” Rubber Bumper, Short (Option)

9 75088067AB

6 Washer, 1/2” (Option)

10 75088085C 8 Lock Washer, 5/8” (Option)

11 75086110B 6 Hex Bolt, ½”-13 x 2-1/2” Lg. (Option)

12 75086154C 8 Hex Bolt, 5/8”-11 x 1-3/4” Lg. (Option)

13 75088064C 12 Washer, 5/8” (Option)

14 26498101C 1 Angle Support, CS (Option)

15 26498151C 1 Angle Support, DS (Option)

16 26498301C 2 Angle, 3” x 3” x ¼” x 24” Lg. (Option)

17 75086218 8 Hex Bolt, 3/8”-16 x 1-1/4” (Option)

18 75088081 8 Lock Washer, 3/8” (Option)

19 75088053 17 Washer, 3/8” (Option)

20 75085096 8 Hex Nut, 3/8”-16 (Option)

21 26498201 4 Light Bracket (Option)

22 75089334 2 Grommet, ½” ID (Option)

23 75086732 12 Round Head Screw, #10-32 (Option)

24 75085000 12 Hex Nut, #10-32 (Option)

25 22575200 2 Harness, 2 Lamps (Option)

26 75089376 4 Light Grommet (Option)

27 75089373 2 Tail Light ST & T (Option)

28 75089374 2 Backup Light (Option)

29 7500010-26 1 Hex Bolt, 3/8”-16 x 2-1/2” Lg.

30 22598100 1 Transit Chain


31 75085193 1 Hex Lock Nut, 3/8”-16

32 7500010-23A 4 Hex Bolt, ½”-13 x 3” Lg. (Option)

33 75085012C 4 Hex Nut, 5/8”-11 (Option)

34 75088083AB

6 Lock Washer, ½” (Option)

35 26497003 1 Dock Bumper, CS, Short

36 26497053 1 Dock Bumper, DS, Short

37 75085008 6 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

B Included in 24” Rubber Bumper Kit 26496012

C Included in Dock Bumper Brace (bolt-on) Kit 26496010


LIFT CORP.

EM, EMTC

REVISED: 12-2010 E.O. 6309NN REV. 02

PM-799

BED EXTENSION AND LIGHT KIT OPTIONS

3

4

1

6

5

7

9

34

11

2

33 10

10

12

13 13

13

12

14

16

15

18 17

19

20

19

23

21

25

26

22

27

28

24

19 31

8 32

35

36

34 37

37


LIFT CORP.

EM TC

REVISED: 3-1-11 E.O. 6469 REV. 02

PM-784


1 70430550 1 Hydraulic Pump Unit

A 70400001 B

1 Hydraulic Reservoir

B 70400004 B

1 Breather

C 7043001 1 A,B

1 Motor

D 75089833 A,B

1 Sta ter Solenoid

E 70092503 B

1 Valve Assembly, 2-way, 2 pos w/ Coil

F 75089853 B

1 Fuse

G 10099309 B

1 Inline Fuse Assembly (Includes Fuse 75089853)

H 75089834 A,B

1 Bus Bar

J 10098425 B

1 Ground Cable

K 70091291 B

1 Steel Plug

L 70402303 1 Coil, 10V, 25W


3 75083111 1 Hose, 3/8” ID x 1/4” JIC x 3/8” JIC

4 7500077-11 1 Hose, 1/4” ID x 3/8” JIC x 3/8” JIC

5 75083023 1 Tube, ¼” ID

6 7500092-1 2 Adapter, 3/8” ORB x ¼” NPT

7 75082747 1 Tee Barbed Fitting, ¼” NPT x ¼” Tube

8 75083133 1 Tube, ¼” ID

9 75082745 1 Elbow Barbed Fitting, ¼” NPT x ¼” Tube

10 75082887 1 Tee, 3/8” ORB x 3/8” JIC

11 75082869 1 Elbow, 3/8” ORB x 3/8” JIC

A Included in Motor Assembly 70400854.

B Included in Pump Assembly 70430550.


LIFT CORP.

EM TC

REVISED: 3-1-11 E.O. 6469 REV. 02

PM-784

HYDRAULIC LAYOUT, GRAVITY DOWN

3

E

BD

5

2

11

4

7

6

896

C

1A

J

10

H

F

G

K

L


LIFT CORP.

EM TC

REVISED: 3-1-11 E.O. 6469 REV. 02

PM-785


1 70430560 1 Hydraulic Pump Unit

A 70400828 A

1 Hydraulic Reservoir

B 70400004 A

1 Breather

C 7043001 1 A

1 Motor

D 75089833 A

2 Sta ter Solenoid

E 70092503 A


F 75089853 A

1 Fuse

G 10099309 A

1 Inline Fuse Assembly (Includes Fuse 75089853)

H 70400014 A


J 10098425 A

1 Ground Cable

K 70091291 A

1 Steel Plug

L 70091779 A

1 Connecting Strap

M 70091778 A

2 Solenoid Cable

N 70402303 A

2 Coil, 10V, 25W


3 75083111 1 Hose, 3/8” ID x 1/4” JIC x 3/8” JIC

4 7500077-11 1 Hose, 1/4” ID x 3/8” JIC x 3/8” JIC

5 7500077-13 1 Hose, 1/4” ID x 1/4” JIC x 3/8” JIC

6 75082890 1 Elbow, 45, 3/8” ORB x 1/4” JIC

7 75083132 1 Tee, 3/8” ORB x 3/8” JIC

8 7500077-12 1 Hose, 1/4” ID x 1/4” JIC x 3/8” JIC

9 75082887 1 Tee, 3/8” ORB x 3/8” JIC

10 75082869 1 Elbow, 3/8” ORB x 3/8” JIC

A Included in Pump Assembly 70430560.


LIFT CORP.

EM TC

REVISED: 3-1-11 E.O. 6469 REV. 02

PM-785

HYDRAULIC LAYOUT, POWER DOWN

3

E

B

D

5

2

10

4

7

86

C

1A

J

9

H

FG

K

L

M

N

N


LIFT CORP.

EM, EM TC

REVISED: 9-20-10 E.O. 6309JJ REV. 02

PM-786


1

10099330 a 1 Switch w/10ft Cord (for curb side)

10099331 b 1 Switch w/15ft Cord (for Dual Control)

2 10099325 c 1 Switch (Hand Held Remote)

3 75082038 1 Trailer Socket

4 75082037 1 Tra ler Plug

5 75089854 1 15 Amp Fuse

6 10099309 1 Fuse Holder

7 10098413 1 Dual Control Harness

8 75089243 1 150 Amp Circuit Breaker (Manual Reset)

a Included in Switch Kit 80000436.

b Included in Switch Dual Control Kit 80000437.

c Included in Switch Hand Held Remote Kit 80000430.

GR02671


LIFT CORP.

EM, EM TC

REVISED: 9-20-10 E.O. 6309JJ REV. 02

PM-786

ELECTRIC CONTROL OPTIONS – Gravity Down

GREEN POWER

WHITE RAISE

BLACK LOWER


LIFT CORP.

EM, EM TC

REVISED: 9-20-10 E.O. 6309JJ REV. 02

PM-787


1

10099330 a 1 Switch w/10ft Cord (for curb side)

10099331 b 1 Switch w/15ft Cord (for Dual Control)

2 10099325 c 1 Switch (Hand Held Remote)

3 75082038 1 Trailer Socket

4 75082037 1 Tra ler Plug

5 75089854 1 15 Amp Fuse

6 10099309 1 Fuse Holder

7 10098413 1 Dual Control Harness

8 75089243 1 150 Amp Circuit Breaker

a Included in Switch Kit 80000436.

b Included in Switch Dual Control Kit 80000437.

c Included in Switch Hand Held Remote Kit 80000430.

LOWER PORT

Lowering Solenoid Valve

Raise Solenoid Valve

RAISE PORT

GR02675


LIFT CORP.

EM, EM TC

REVISED: 9-20-10 E.O. 6309JJ REV. 02

PM-787

ELECTRIC CONTROL OPTIONS – Power Down

GREEN POWER

WHITE RAISE

BLACK LOWER


80101389 Page 8-1 EO 5534A

Rev 02

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: [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

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 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

emtc_series_om

Documents

operation instructions

improper installation

lubrication instructions

improper operation

installation waltco

flipaway liftgate

liftgate terminology

owners manual