Parts Manual C15, C20, C , 2000, 2500 lb. Capacity Flipaway Liftgates

Transcription

1 Phone: Fax: Parts Manual C5, C20, C25 600, 2000, 2500 lb. Capacity Flipaway Liftgates This manual identifies parts for Liftgates manufactured: 3/20 to Current Last Change Date Page(s) Description , 0, 3, 4 P8 & 9 Revised to add torsion spring P0 Revised to remove torsion spring P3 & 4 - Revised to remove ground cable Waltco Lift Corp. Waltco Lift Corp. Waltco Lift Inc. Corporate Office United State United States Canada 285 Northeast Ave. 620 S Hambledon Ave. 90 North Queen St. Tallmadge, OH City of Industry, CA 9744 Etobicoke, ON M8Z 2C5 P: P: P: F: F: EO:0289 Rev

2 Table of Contents Improper operation and maintenance of this liftgate could result in severe personal injury or death. Read and understand the contents of the owner s manual and all warning and operation decals before operating and/or performing maintenance on this liftgate. INTRODUCTION... 3 HOW TO ORDER PARTS... 4 MODEL INFORMATION... 5 DECALS... 6 STEEL PLATFORMS, C-5, C ALUMINUM PLATFORMS, C-5, C PLATFORMS, C MOUNT FRAME ASSEMBLY, C-5, C MOUNT FRAME ASSEMBLY, C BED EXTENSION... 3 HYDRAULIC LAYOUT, GRAVITY DOWN... 4 HYDRAULIC LAYOUT, POWER DOWN... 5 ELECTRIC CONTROL OPTIONS, GRAVITY DOWN... 6 ELECTRIC CONTROL OPTIONS, POWER DOWN... 7 Page 2

3 Introduction Each Waltco liftgate is manufactured to stringent quality standards for years of reliable service. To ensure maximum performance of your Waltco liftgate, always specify and use OEM Parts from Waltco. This manual does not provide procedures for the servicing and repair of Waltco liftgates. Service and repair should only be performed by an authorized Waltco distributor. For information on the nearest authorized Waltco distributor contact: Waltco Lift Corp. 285 Northeast Avenue Tallmadge, OH Phone: Fax: The use of non-standard or makeshift parts can be extremely hazardous and result in serious injury or death. 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 EO774 REV 0 Page 3

4 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:. 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, OR PHONE YOUR REQUEST TO: Waltco Lift Corp 285 Northeast Avenue Tallmadge, OH FAX: 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 EO 5534A Rev 02 Page 4

5 Model Information Explanation of Specification Tag Model Description Capacity C5 SB Standard Bed Height 600 lbs. C5 HB High Bed Height 600 lbs. C20 SB Standard Bed Height 2000 lbs. C20 HB High Bed Height 2000 lbs. C25 HB High Bed Height (Only) 2500 lbs. MODEL NUMBER 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 GR0024 Specification Tag (Backside of pump mount plate) GR02558 Page 5

6 Decals To order complete set of C-Series liftgate decals, order kits below: C-5 = Kit part number C-20 = Kit part number C-25 = Kit part number Page 6

7 Decals All decals must be in place and legible or all warranties are void. ITEM DECAL QTY PART NO. LOCATION 2 3 Safety Instructions Locate in a conspicuous place near controls. Operation Hazard Decal Important Decal Stand Clear Decal Use Handle Decal Stand Clear Decal C5 600 lb C lb C lb C5 600 lb C lb C lb Store Tight Decal Circuit Breaker Decal If your liftgate is equipped with dual controls, an additional Safety Instruction decal ( ) is to be placed in a conspicuous place near the second set of controls. Refer to the following diagram showing decal locations. Locate near platform handle (positioned so as to be read when platform is being unfolded into loading position) Locate on side of deck (Same side as controls, position as to be read with platform open) Locate on back of deck on curb side (Visible when platform is stored) Locate next to liftgate circuit breaker. In applications where more than one circuit breaker is used, this decal must be placed in both locations 6 Stand Clear Decal 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 TRANSIT CHAIN GR02565 Page 7

8 ITEM PART NUMBER 32x72+4 High 32x84+4 High 36x72 Wedge High 36x84 Wedge High 32x72+4 Standard 32x84+4 Standard 36x72 Wedge Standard 36x84 Wedge Standard DESCRIPTION 2202 X Steel platform, high bed 2203 X Steel platform, high bed 2204 X Steel platform, high bed 2205 X Steel platform, high bed 2206 X Steel platform, standard bed 2207 X Steel platform, standard bed 2208 X Steel platform, standard bed 2209 X Steel platform, standard bed Steel Deck (72 Wide) Steel Deck (84 Wide) Steel Deck (72 Wide) Steel Deck (84 Wide) Steel Deck Ext (72 Wide) Steel Deck Ext (84 Wide) Steel Deck Ext (72 Wide) Steel Deck Ext (84 Wide) Steel Deck Ext (72 Wedge) Steel Deck Ext (84 Wedge) Steel Deck Ext (72 Wedge) Steel Deck Ext (84 Wedge) Hinge Bar (Ramp Ext) Hinge Bar (Wedge Ext) Flat Washer, ¾ Transit Chain Lug Spring (Red Tip) Spring (green Tip) C-5 / C-20 REVISED: E.O REV 06 PM-876A STEEL PLATFORM ASSEMBLY C-5 / C-20 Page 8 REVISED: E.O REV 06 PM-876A

9 ITEM PART NUMBER 32x x x72 Wedge 36x84 Wedge 32x72+4 Galv 32x84+4 Galv 36x72 Wedge Galv 36x84 Wedge Galv DESCRIPTION X Aluminum Platform GV X Aluminum Platform, Galv X Aluminum Platform GV X Aluminum Platform, Galv X Aluminum Platform GV X Aluminum Platform, Galv X Aluminum Platform GV X Aluminum Platform, Galv Alum Deck (72 Wide) GV Alum Deck (84 Wide) Alum Deck (72 Wide) GV Alum Deck (84 Wide) GV Alum Deck Ext (72 Wide) 2 Alum Deck Ext ( GV Wide) Alum Deck Ext ( GV Wedge) 3 Alum Deck Ext ( GV Wedge) Pin Assembly Flat Washer, ¾ Hex bolt, 3/8-6x ¼ Grade * Locknut, 3/ Transit Chain Lug Spring (Red Tip) Spring (green Tip) REVISED: C-5 / C-20 E.O REV 06 PM-876B ALUMINUM PLATFORM ASSEMBLY C-5 / C-20 Page 9 REVISED: E.O REV 06 PM-876B

10 ITEM PART NUMBER QTY DESCRIPTION 2209 Steel Deck (72 Wide) High Bed Steel Deck Ext (72 Wide) High Bed St l Deck Ext (72 Wedge) High Bed Transit Chain Lug Hinge Bar Flat Washer, 3/ Alum Deck (72 Wide) GV Alum Galv Deck (72 Wide) GV Alum Deck Ext (72 Wide) GV Alum Deck Ext (72 Wedge) Pin Assembly Flat Washer, 3/ Hex Bolt, 3/8-6x¼ Grade Locknut, 3/8-6 (centerlock) PLATFORM ASSEMBLIES COMPLETE STEEL PLATFORMS 2209 Platform, 36 x High Bed Platform, 40 x 72 Wedge High Bed ALUMINUM PLATFORMS Platform, 36 x GV Platform, 36 x Galvanized Platform, 40 x 72 Wedge GV Platform, 40 x 72 Wedge Galvanized C-25 REVISED: E.O REV. 02 PM-878 C-25 PLATFORMS C-25 Page 0 REVISED: E.O REV. 02 PM-878

11 ITEM PART NUMBER QTY DESCRIPTION Mount Frame GV Mount Frame, Galvanized Mount Plate Mount Plate Bolt-On Galvanized Parallel Arm (32 CC) Steel Platforms Parallel Arm (32 CC) Alum Platforms GV 2 Parallel Arm (32 CC) Galvanized Parallel Arm (29 CC) Parallel Arm (29 CC) Alum Platforms GV Parallel Arm (29 CC) Galvanized Lift Arm (32 CC) GV Lift Arm (32 CC) Galvanized Lift Arm (29 CC) GV Lift Arm (29 CC) Galvanized Hinge Assembly (Half Dip) GV Hinge Assembly (Half Dip) Galvanized Hinge Assembly (Wedge) GV Hinge Assembly (Wedge) Galvanized Hinge Assembly (Level Ride) GV Hinge Assembly (Level Ride) Galvanized Parting Bar GV Parting Bar Galvanized Washer, ¼ Hex Nut, 5/6, Serrated Washer, 5/6 SAE Grommet for /4 hose stem fitting or 2 Grommet for 7/6 JIC fitting Pump Cover Latch or - Torsion Spring (See Platform Assembly) D Pin (Non-Greaseable) A C Pin (Geaseable) D Pin (Non-Greaseable) A Pin (Greaseable) Pump Cover C-5 / C-20 ITEM PART NUMBER QTY DESCRIPTION A D Lower Cylinder Pin D Lower Parallel Arm Pin (Non-Greaseable) A Lower Parallel Arm Pin (Greaseable) Gasket, Pump Cover B Bearing, -/4 I. D. x lg B 4 Bearing, I. D. 3/4 lg B Bearing, 7/8 I. D. x -3/4 lg B 2 Bearing, -/4 I. D. x 7/8 lg B 2 Bearing, I. D. x 7/8 lg Grommet, for Battery Cable Grommet, for Control Cord A B 2 Roll Pin, /2 x 2 lg A B C 8 /4-20 x 2-/2 lg. Bolt A B C 8 /4-20 Self-locking Nut /4-20 x lg. Bolt /4 Lock Washer GV Hardware Kit for Galvanized Liftgates (Nuts and bolts for bolting mount plates, parting bar and bed extension) A Included in Greaseable Pin Replacement Kit B Included in Bearing Replacement Kit C Included in Cylinder Replacement Kits and D Included in Non-Greaseable Pin Replacement Kit REVISED: E.O REV. 03 PM-57D C-5 / C-20 MOUNT FRAME ASSEMBLY C-5 / C-20 IMPORTANT: Grade 8 bolt to be installed through retaining collar and lower cylinder pin. Make certain that lock nut is screwed fully onto bolt until threads bottom out on bolt shank. Page REVISED: E.O REV. 03 PM-57D

12 ITEM PART NUMBER QTY DESCRIPTION Mount Frame GV Mount Frame, Galvanized Mount Plate Mount Plate Bolt-On Galvanized Parallel Arm (32 CC) Steel Platforms Parallel Arm (32 CC) Alum Platforms GV Parallel Arm (32 CC) Galvanized Lift Arm (32 CC) GV Lift Arm (32 CC) Galvanized Hinge Assembly (Half Dip) GV Hinge Assembly (Half Dip) Galvanized Hinge Assembly (Wedge) GV Hinge Assembly (Wedge) Galvanized Hinge Assembly (Level Ride) GV Hinge Assembly (Level Ride) Galvanized Parting Bar GV Parting Bar Galvanized Washer, ¼ Hex Nut, 5/6, Serrated Washer, 5/6 SAE Grommet for /4 hose stem fitting or 2 Grommet for 7/6 JIC fitting Pump Cover Latch Torsion Spring D Pin (Non-Greaseable) A C Pin (Greaseable) D Pin (Non-Greaseable) A Pin (Greaseable) Pump Cover A C Lower Cylinder Pin D Lower Parallel Arm Pin (N0n-Greaseable) A Lower Parallel Arm Pin (Greaseable) Gasket, Pump Cover B Bearing, -/4 I. D. x lg B 4 Bearing, I. D. 3/4 lg. C-25 ITEM PART NUMBER QTY DESCRIPTION B Bearing, 7/8 I. D. x -3/4 lg B 2 Bearing, -/4 I. D. x 7/8 lg B 2 Bearing, I. D. x 7/8 lg Grommet, for Battery Cable Grommet, for Control Cord A B 2 Roll Pin, /2 x 2 lg A B C 8 /4-20 x 2-/2 lg. Bolt A B C 8 /4-20 Self-locking Nut /4-20 x lg. Bolt /4 Lock Washer GV Hardware Kit for Galvanized Liftgates (Nuts and bolts for bolting mount plates, parting bar and bed extension) A Included in Greaseable Pin Replacement Kit B Included in Bearing Replacement Kit C Included in Cylinder Replacement Kits and D Included in Non-Greaseable Pin Replacement Kit REVISED: E.O REV. 02 PM-840A C-25 MOUNT FRAME ASSEMBLY C-25 IMPORTANT: Grade 8 bolt to be installed through retaining collar and lower cylinder pin. Make certain that lock nut is screwed fully onto bolt until threads bottom out on bolt shank. Page 2 REVISED: E.O REV. 02 PM-840A

13 ITEM PART NUMBER QTY DESCRIPTION A Bed Extension GV G Bed Ext 96, Galvanized Bolt-On A Bed Extension GV G Bed Ext 02, Galvanized Bolt-On Transit Chain Hex Bolt, 3/8-6 x -/4 long, Grade Washer, 3/8, x O.D FlexLoc Nut, 3/ Bed Extension Gauge/Gusset B 2 Dock Bumper Angle B 2 Support Channel B 2 Support Bar C Super Duty Dock Bumper (Driver s Side) GV G Dock Bumper, Galvanized w/ Rubber CS C Super Duty Dock Bumper (Curb Side) GV G Dock Bumper, Galvanized w/ Rubber DS D E Super Duty Dock Bumper w/lights (D.S.) D E Super Duty Dock Bumper w/lights (C.S.) F H 2 Rubber Bumper F H 8 Washer, 5/ F H 4 Hex Bolt, 5/8 - x 2 lg F H 4 Lock Washer, 5/ F 4 Hex Nut, 5/ D 2 Taillight Backup (Tractors only) (Clear) DE 2 Taillight S, T & T (Trailers only) (Red) DE Taillight S, T & T (Red) DE 2 Harness, 2 Lamp C-Series ITEM PART NUMBER QTY DESCRIPTION DE 4 Light Grommet DE 8 Hex Nut, # DE 8 Machine Screw, #0-32 x lg DE 4 Taillight Bracket A Kit, , Bed Extension Install, is required for mounting bed extensions B Heavy Duty dock Bumper Kit C Super Duty dock Bumper Kit (without lights) D Super Duty dock Bumper Kit With (4) Lights (Truck) E Super Duty dock Bumper Kit With (4) Lights (Trailer) F Rubber Bumper Kit (For Heavy Duty Dock Bumper Kit) G Kit, GV, Hardware, is required for mounting galvanized bed extension and dock bumpers H Rubber Bumper Kit (For Super Duty Dock Bumper Kit With Lights) REVISED: 2--6 E.O REV. 04 PM-777 BED EXTENSION C-Series Page 3 REVISED: 2--6 E.O REV. 04 PM-777

14 ITEM PART NUMBER QTY DESCRIPTION Pump Unit, w/thermal Switch Prior to optional after Standard after Pump Unit, Non-Thermal Switch Standard between and Pump Unit, 24 Volt w/thermal Switch A A Hydraulic Reservoir B A Breather A Motor, Non-Thermal Switch C A Motor, w/thermal Switch A Motor, 24 Volt, w/thermal Switch D A Starter Solenoid A Starter Solenoid, 24 Volt E A Valve Assembly, 2-way, 2 position w/ Coil A Valve Assembly, 24 Volt w/ Coil G A 5 amp Fuse H A Inline Fuse Assembly (Includes Fuse ) J A Bus Bar A Bus Bar for 24 Volt pumps K A Coil, 0V, 25A Coil, 8V, for 24 Volt pumps L A Elbow, Pressure M A Elbow, Return N B Adapter ( only) P A Steel Plug Hose Assy, /4 I.D. x /4 JIC º Elbow, /4 M NPT x 9/6 FM JIC for units with Pressure Compensated 3 Flow Valve, After º Elbow, /4 NPT x /4 JIC for units without Pressure Compensated Flow Valve Before Hydraulic Cylinder (C-5) Hydraulic Cylinder (C-20) ITEM PART NUMBER QTY DESCRIPTION Barbed Fitting, /4 NPTF x / Hose, /4 I.D /6 I.D. Grommet /4 I.D. Grommet Pressure Compensative Flow Valve A Included w/pump Assemblies if applicable. B Only used w/non-thermal Switch Pump Units. Warning: , and Pumps do not have a flow control valves, liftgate must be equipped with a Pressure Compensated Flow Control Valve as shown. C-Series REVISED: E.O REV. 08 PM-62A HYDRAULIC LAYOUT, GRAVITY DOWN C-Series Page 4 REVISED: E.O REV. 08 PM-62A

15 ITEM PART NUMBER QTY DESCRIPTION Hydraulic Pump, PD, w/thermal Switch Prior to Optional after Standard after Hydraulic Pump, PD, Non-Thermal Switch Standard between and -206 A A Hydraulic Reservoir B A Breather C A Motor, Non-Thermal Switch A Motor w/thermal Switch D A 2 Starter Solenoid E A Valve Assembly, 2-way, 2 position w/ Coil F A Valve assembly, 4-way, 2 position w/ Coil G A Steel Plug H A 5 amp Fuse J A Inline Fuse Assembly (Includes Fuse ) K A Bus Bar L A Coil, 0V, 25A M A 2 Elbow, Pressure N A 2 Solenoid Cable P B Adapter Hose Assembly, /4 I.D. x /4 JIC, º Elbow, /4 M NPT x 9/6 FM JIC Hydraulic Cylinder (C-20) º Elbow, /4 M NPT x 7/6 M JIC Pressure Compensative Flow Valve (C-20) A B Included w/pump Assemblies if applicable. Only used w/non-thermal Switch Pump Units. Warning: and Pumps do not have a flow control valves, liftgate must be equipped with a Pressure Compensated Flow Control Valve as shown. C- SERIES REVISED: E.O REV. 08 PM-622A HYDRAULIC LAYOUT, POWER DOWN C- SERIES Page 5 REVISED: E.O REV. 08 PM-622A

16 ITEM PART NUMBER QTY DESCRIPTION Switch Kit w/0ft Cord a Switch (Hand Held Remote) Trailer Socket Trailer Plug Amp Fuse Fuse Holder Dual Control Harness Amp Circuit Breaker (Manual Reset) Cycle Counter Kit a Included in Switch Hand Held Remote Kit ONE CYLINDER ON EM AND C-SERIES LIFTGATES TWO CYLINDERS ON EMTC HYDRAULIC CYLINDER LOWERING SPEED CONTROL VALVES LOWERING VALVE GR02700 GR0052 EM, EMTC and C-SERIES REVISED: E.O REV. 06 PM-786 ELECTRIC CONTROL OPTIONS Gravity Down EM, EMTC and C-SERIES Page 6 REVISED: E.O REV. 06 PM-786

17 ITEM PART NUMBER QTY DESCRIPTION a Switch w/0ft Cord (for curb side) b Switch w/5ft Cord (for Dual Control) c Switch (Hand Held Remote) Trailer Socket Trailer Plug Amp Fuse Fuse Holder Dual Control Harness Amp Circuit Breaker (Manual Reset) Cycle Counter Kit a Included in Switch Kit b Included in Switch Dual Control Kit c Included in Switch Hand Held Remote Kit ONE CYLINIDER ON EM AND C-SERIES LIFTGATES TWO CYLINDERS ON EMTC LIFTGATES LOWERING SPEED CONTROL VALVES LOWER VALVE PUMP UNIT RAISE VALVE GR0270 GR0053 EM, EMTC and C-SERIES REVISED: E.O REV. 05 PM-787 ELECTRIC CONTROL OPTIONS Power Down EM, EMTC and C-SERIES Page 7 REVISED: E.O REV. 05 PM-787

18 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 NOTE: When ordering, give model and serial number of the liftgate. Page 8

19 IMPORTANT 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 of this manual EO7820 Rev 02 Page 9