www.waltco.com Phone: 800..5685 parts@waltco.com Fax: 800..568 Parts Manual SERIES 3500, 500, 5500 & 6600 lb. Liftgates This manual identifies parts for Liftgates manufactured: /06 GEN Last Change Date Page(s) Description 0/06 7& 0 REVISED PM S PM-930 & PM-933 Waltco Lift Corp. Waltco Lift Corp. Waltco Lift Inc. Corporate Office United State United States Canada 85 Northeast Ave. 60 S Hambledon Ave. 90 North Queen St. Tallmadge, OH 78 City of Industry, CA 97 Etobicoke, ON M8Z C5 P: 330.633.99 P: 66.96.0990 P: 888.33.550 F: 330.633.8 F: 66.96.09 80703 REVISED: 0/06 EO: 808 REV.: 0
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.... Warranty.... 5 Model Information...... 6 H-Frame......... 7 Platform Steel....... 9 Platform Aluminum...0 Platform Flip Ramp... Platform BG...... 3 Platform Cart Stop..... Pump and Battery Box Components.... 5 Pump and Battery Box Accessories....... 6 Hydraulic Components and Harnesses... 7 Runner Assembly...... 8 Column Parts...... 9 Cylinders, Hoses, Fittings and Extensions.... 0 Decals... 80703 Page REVISED: 9/06 EO: 80 REV.: 0
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. 85 Northeast Avenue Tallmadge, OH 78 Phone: 800..5685 Fax: 800..568 E-mail: parts@waltco.com 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. 800668 EO77 REV 0 Page 3
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.)]. MODEL NUMBER - [Or capacity] 3. PLATFORM SIZE THEN INCLUDE THE FOLLOWING INFORMATION:. PART NUMBERS 5. DESCRIPTION 6. QUANTITY REQUIRED MAIL, E-MAIL OR PHONE YOUR REQUEST TO: Waltco Lift Corp 85 Northeast Avenue Tallmadge, OH 78-800--5685 FAX: -800--568 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. 800389 EO 553A Rev 0 Page
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 85 Northeast Ave, Box 35, Tallmadge, OH 78-800--307, 330-633-99 Please visit our websites: http://www.waltco.com or http://www.hiab.com We're behind you all the way! EO:77 Rev 0 5-05 800667 Page 5
Model Information EXPLANATION OF SPECIFICATION TAG MODEL No. DESCRIPTION CAPACITY BG35 BG-35 Series 3500 lb. BG5 BG-5 Series 500 lb. 35-35 Series 3500 lb. 5-5 Series 500 lb. 55-55 Series 5500 lb. 66-66 Series 6600 lb. Explanation of 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 GR00 Page 6
H-Frame PM-9 Page 7 REVISED: 9/8/06 EO: 80 REV.: 0
Bolt-On H-Frame ITEM # DESCRIPTION BLACK GALVANIZED 96" WIDE 0" WIDE 96" WIDE 0" WIDE PAINTED UNPAINTED PAINTED UNPAINTED UNPAINTED STAINLESS UNPAINTED STAINLESS COLUMN WELD, DS, BOLT ON 755 755GV COLUMN WELD, CS, BOLT ON 705 705GV 3 HOUSING WELD, BOLT ON 7905 79005 7905GV 79005GV HOUSING MOUNT WELD 700036 70003 70003 7000 70003 70006 7000 7000 5 MOUNT CHANNEL 70003 700035 70003 700035 700035 700038 700035 700038 6 BOLT / " X 5" 750000-37 8 7 BOLT / " X 3" 750000-3 8 NUT / " NYLOCK 750856 QTY PM-9 Page 8 REVISED: 9/8/06 EO: 80 REV.: 0
Platform-Steel Item 3,, and 5 are used on both sides of the platform to adjust deck extension angle. Platforms are available in many different sizes, material types, and special options. The chart below is given for general reference only. When ordering replacement platform sections, please provide the serial number ITEM # DESCRIPTION 60x8+ 60x8+ C/ S 7x8+6 7x8+ 7x8+ C/ S 8x8+6 60x88+ 60x88+ C/ S 7x88+6 7x88+ 7x88+ C/S 8x88+6 60x8+6 60x88+6 QTY PLATFORM ASSEMBLY 7003 70033 700 70030 7003 7000 700 7003 7000 7000 700 70000 700 7000 DECK 70 700 700 7000 70 700 DECK EXTENSION 7303 73033 730 73030 7303 6908 730 7303 7300 7300 730 73000 730 7300 3 LINKAGE ARM WELD, CS 7600 76000 7600 76000 7600 LINKAGE ARM WELD, DS 7605 76050 7605 76050 7605 5 NUT, / 750856 8 6 U-BOLT 750806 7 CHAIN 69550 695500 69550 695500 69550 8 PIN, RUNNER HINGE 668739 9 GREASE FITTING 75089306 5 0 BUSHING, /" ID x / 6689 PLATFORM STOP 6687 CHAIN HOLDER 76090 3 BOLT 5/6" x 3/8" 75086 LOCKNUT 5/ 6" 7508577 5 STORE BELOW HOOK 66879 6 SCREW SH, 3/8 x /" 7508599 7 PIN ASSY, FOLDING HINGE 75000 8 TRAVEL EAR, DS 7350 9 TRAVEL EAR, CS 7300 0 BOLT, 3/8" x /" 750000-3 BUSHING, ID x 700099 LOCKNUT, 3/ 8 75085 3 PLATFORM LEVELING BOLT 7508609 PLATFORM SHIM THICK 7508807 0-5 PLATFORM SHIM THIN 7508807 0-6 PLATFORM CAUTION LIGHT 63990 7 LOCK WASHER / " 75088079 8 SCREW BH, / x ", STAINLESS 7508670 PM-93 Page 9 REVISED: 3/3/05 EO: 7365E REV.: 0
Platform-Aluminum Platforms are available in many different sizes, material types, and special options. The chart below is given for general reference only. When ordering replacement platform sections, please provide the serial number Item 5, 6, and 7 are used on both sides of the platform to adjust deck extension angle. Aluminum Ext rusion Chart Part 96" Wide 0 Wide A 7000 70000 B 700 7000 C 700 7000 D 7003 70030 E 700 7000 F 7005 70050 G 70090 H 7006 70060 H w/ C/ S 7008 70080 J 7007 70070 ITEM# DESCRIPTION 60x8+ 60x8+ C/ S 7x8+6 7x8+ 7x8+ C/ S 8x8+6 60x88+ 60x88+ C/ S 7x88+6 60x8+6 60x88+6 7x88+ 7x88+ C/S 8x88+6 QTY DECK 70 700 700 70 700 7000 DECK EXTENSION 7033 70333 703 70330 7033 7030 703 7033 7030 703 7030 7030 703 70300 3 SIDEPLATE WELD, MAIN, DS 705 7050 705 705 7050 SIDEPLATE WELD, MIAN, CS 700 7000 700 700 7000 5 SIDEPLATE WELD, RAMP, DS 705 7050 705 705 7050 6 SIDEPLATE WELD, RAMP, CS 700 7000 700 700 7000 7 NUT, / " 750856 8 8 U-BOLT 750806 9 CHAIN 69550 695500 69550 695500 0 PIN, RUNNER HINGE 668739 GREASE FITTING 75089306 5 BOLT, 3/ 8, TAPTITE 750879 8/ /6 3 BUSHING, /" ID x /" 6689 PLATFORM STOP 6687 5 CHAIN HOLDER 76090 6 BOLT 5/6" X 3/8" 75086 7 LOCK NUT 5/ 6" 7508577 8 SCREW SH, 3/8" x /" 7508599 9 PIN ASSY, FOLDING HINGE 75000 0 LINKAGE ARM WELD, CS 7600 76000 7600 76000 LINKAGE ARM WELD, DS 7605 76050 7605 76050 BOLT, 3/8" x /" 750000-3 3 BUSHING, ID x " 655 LOCK NUT 3/ 8" 7508588 5 PLATFORM LEVELING BOLT 7508609 6 PLATFORM SHIM THICK 7508807 0-7 PLATFORM SHIM THIN 7508807 0-8 PLATFORM CAUTION LIGHT 63990 9 SCREW BH, /" x " STAINLESS 930990 30 LOCK WASHER / " 75088079 3 SCREW SHCS, 3/8" x " 750867 PM-95 Page 0 REVISED: 3/3/05 EO: 7365E REV.: 0
Platform-Flip Ramp FLIP RAMP ASSEMBLY STEEL PLATFORM GALVANIZED PLATFORM ALUMINUM PLATFORM PM-97 Page REVISED: 9/8/06 EO: 80 REV.: 0
BG PLATFORMS PM-937 Page REVISED: 09/07/06 EO: 80 REV.: 0
Parts Manual A Items are included in complete flip ramp kit, 700 PM-937 www.waltco.com Page 3
Platform-Cart Stop ALUMINUM PLATFORM STEEL PLATFORM ITEM# DESCRIPTION PART NUMBER 96" 0" QTY AL EXT CART STOP TOP CS 6690 AL EXT CART STOP TOP DS 6690 3 AL EXT CART STOP BOTTOM 7008 70080 AL EXT CART STOP CENTER 7009 7009 5 CART STOP PLASTIC BUSHING 66999 6 CART STOP SPRING 6680 7 CART STOP LATCH PIN 6690 8 CARTS STOP LATCH SPRING 7508868 9 COIL PIN, 3/6" x 7/8" 7508959 0 CART STOP SCREW SHIM 66986 6 SHOULDER SCREW, 3/8" DIA x 3/8" x 5/6-8 750009- CART STOP BASE PLATE (FOR STL AND GALV PLATFORMS ONLY) 738 7380 3 RIVET, / ", 3/8-/", STL (FOR STL AND GALV PLATFORMS ONLY) 7508975 AL EXT BOTTOM INSERT (FOR STL AND GALV PLATFORMS ONLY) 66890 GALVANIZED PLATFORM PM-96 Page REVISED: 3/3/05 EO: 7365E REV.: 0
Pump and Battery Box-Components PM-98 Page 5 REVISED: 3/3/05 EO: 7365E REV.: 0
Pump and Battery Box-Accessories ITEM# DESCRIPTION PART NUMBER SINGLE PUMP DUAL PUMP QTY BACKUP CONTROLS W/ 36 FT EXTENTION NOT INCL. 6900 AUX MOTOR USAGE ALARM NOT INCL. 7508977 3 SWITCH MOUNTING BRACKET 695 0/ TOGGLE SWITCH, ON-ON 75089809 0/ / 5 TOGGLE SWITCH SEAL 7508978 0/ / 6 50 AMP BREAKER, MANUAL RESET 750893 7 50 AMP BREAKER, AUTO RESET 7508970 8 MASTER DISCONNECT SWITCH 75089790 9 BATTERY HOLD DOWN BRACKET 669036 / 0 LOCK WASHER 3/ 8" 7508808 / NUT 3/ 8" 75085096 / GROMMET, 5/ 8" ID, 7/ 8" HOLE 750007-6 3 BOLT / " x " 75086006 LOCK NUT / " 750856 6/ 8 5 THREADED ROD 3/ 8" x " 669079 / 6 5 AMP CIRCUIT BREAKER 7508960 7 SCREW, 0-3 x 5/ 8" 75086707 5 8 NUT 0-3, SERRATED 75085000 5 9 BOLT / " x " 7508606 0 WING NUT 3/ 8" NOT INCL. 750858 0/ NUT 3/ 8"M SERRATED NOT INCL. 75085005 0/ TRUSS HEAD BOLT 3/ 8" x " NOT INCL. 7508589 0/ 3 HOLE PLUG 5/ 6" 7508006 9-3 PM-99 Page 6 REVISED: 3/3/05 EO: 7365E REV.: 0
Hydraulic Power Components and Harnesses PM-930 Page 7 REVISED: 0/7/06 EO: 808 REV.: 03
Runner Assembly PM-93 Page 8 REVISED: 9/8/06 EO: 80 REV.: 0
Column Parts ITEM # DESCRIPTION PART NUMBER QTY WEAR PAD, LOWER FRONT 7970 WEAR PAD, LOWER BACK 7970 3 DOCK BUMPER PAD 79700 TRAVEL LATCH CAM 668786 5 LOWER WEAR PAD STOP 79700 6 TRAVEL LATCH 7900 7 SCREW, FLAT HEAD, 5/ 6" X 5/ 8" W/ PATCH 75085993 8 SCREW, FLAT HEAD, 3/ 8" X -/ " 7508599 9 WASHER 3/ 8" 7508855 0 LOCK WASHER 3/ 8" 7508808 BOLT 3/ 8" X " 75086056 WASHER / " 75088067 3 BOLT / " X " 750000- PM-93 Page 9 REVISED: 0//05 EO: 7365E REV.: 0
Cylinders, Hoses, Fittings and Extension Cable *Cylinders have white cap with decal of part number. TRAILER LENGTH ITEM# DESCRIPTION PART NUMBER LESS THAN 33 FT 33-3 FT MORE THAN FT QTY QTY QTY 3 HOSE GUIDE 668380 HOSE, HP, /" x 3 FT 66933 - - 3 HOSE, HP, /" x 7 FT 7508337 - - HOSE, HP, /" x 6 FT 6693 - - HOSE, HP, /" x 3 FT 66980 - - 33 HOSE, HP, /" x 7 FT 7508336 - - HOSE, HP, /" x 6 FT 6698 - - EXTENSION 6 WIRE, 3 FT 66983 - - 3 EXTENSION 6 WIRE, 7 FT 693 - - EXTENSION 6 WIRE, 6 FT 66987 - - EXTENSION 3 WIRE, 3 FT 6698 - - 35 EXTENSION 3 WIRE, 7 FT 69 - - EXTENSION 3 WIRE, 6 FT 66986 - - Sleeve Replacement Kit * * Hoses and switch wire are pre-assembled in sleeve. # Kit 6690 includes: x 66906 Hose, 0 long x 66937 Switch, molded, up/dwn, 6 x 7508966 Hose, 3CT, 3/6 x 98 x 7508969 Hose 3CT, 3/6 x 90 *Cylinders may have white cap with decal of part number with -B at the end. PM-933 Page 0 REVISED: 0/7/06 EO: 808 REV.: 03
Chapter 5- Placement of Decals All decals must be in place and legible or all warranties are void. Properly placed warning decals are an essential part of your safety program. Check that all safety decals are in place and are legible. Any missing decals MUST be replaced immediately. Replacement decals may be obtained FREE of charge from your distributor or by phoning, writing, or faxing Waltco Part Sales. If your liftgate is equipped with dual controls, an additional Safety Instruction decal (8000850) is to be placed in a conspicuous place near the second set of controls. To maximize decal adhesion to surfaces: Surface must be dry and clean Firm pressure must be applied to decal Minimum surface temperature 65º ITEM# DESCRIPTION 35 5 55 66 WITH +6 FLIP RAMP QTY OPERATING INSTRUCTIONS 800538 WARNING, KEEP CLEAR 7508996 3 WARNING, MAX CAPACITY 8000586 80006 800308 800309 URGENT WARNING 8000850 5 DEANGER, LIFTGATE CAN CRUSH 800370 6 SAFETY, OPEN AND CLOSE 800537 7 OPEN AND CLOASE DECAL 800539 8 WARNING, KEEP CLEAR 7508696 9 FLIP RAMP STORAGE 80008 0 CONSPICUITY TAPE FOR 96" 80067 (73.5") CONSPICUITY TAPE FOR 0" 80067 (78.5") Page REVISED: 3/3/05 EO: 7365E REV.: 0
IMPORTANT WARNING Improper operation and maintenance of this liftgate could result in severe personal injury or death. Read and understand the contents of liftgate Owner s 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 Owner s manual 800666 EO77 Rev 0 Page