LPF-25, LPF-30, LPF-40
Visit us at www.waltco.com
Installation Instructions
2500, 3000, 4000 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.
1-2010
GR02541
OHIO
GEORGIA
285 Northeast Avenue
Tallmadge, OH 44278
(330) 633-9191
FAX – (330) 633-1418
8960 Highway #5
Building A
Douglasville, GA 30134
(770) 949-5342
FAX – (770) 949-5344
E.O. 6348 Rev. 23
80122501
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
KIT, AUX BATTERY
80001066 --------------------------------------------------------------------------------------------- 80101387
KIT, TRAILER
80001069 --------------------------------------------------------------------------------------------- 80101387
WIRING KIT, TRACTOR
80000618 --------------------------------------------------------------------------------------------- 80100822
KIT, DUAL CONTROL SWITCH
80000435 --------------------------------------------------------------------------------------------- 80101488
KIT, LPF REAR IMPACT UNDER RIDE
22595010 & 22595011---------------------------------------------------------------------------- 80101523
KIT, COILED CHARGE LINE
80001087 --------------------------------------------------------------------------------------------- 80101426
RUBBER SNUBBER KIT
80000421 --------------------------------------------------------------------------------------------- 80100503
CAB SHUT-OFF SWITCH KIT
80000827 --------------------------------------------------------------------------------------------- 80101363
KIT, INTERFACE MOUNTING
80000878--------------------------------------------------------------------------------------------- 80101257
KIT, HAND HELD REMOTE
80000430 --------------------------------------------------------------------------------------------
80101485
KIT, WALK RAMP OPTION
22596000 --------------------------------------------------------------------------------------------
80101524
E.O. 6348 Rev. 23
80122501
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
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.
Refer to the Explanation of Specification Tag in the Liftgate Terminology chapter for liftgate capacity rating.
•
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.
•
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 03 EO 6156
Chapter 1
Safety Information
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.
WARNING
CAUTION
NOTICE
Page 1 - 2
80101253 Rev 03 EO 6156
Chapter 2
1.
2.
4.
5.
6.
7.
8.
9.
10.
11.
Hydraulic Cylinder
Hose Assembly
“Lower” Solenoid
“Raise” Solenoid
Access Cover Plate
Stud Terminal
Protective Sleeve
Power Cable Assembly
Control Cord Assembly
Pump and Motor Unit
Liftgate Terminology
12.
13.
14.
15.
16.
17.
18.
19.
20.
Breather
Pump Unit Starter Solenoid
Ground Cable Assembly
Slide Tray Assembly
Bulk Head Tee Fitting
Washer, Tooth Lock
Strain Relief
Power Down Module
Comp Valve
GR02530
Page 2-1
Chapter 2
21.
22.
23.
24.
25.
26.
Dock Bumper Assembly
Rubber Bumper
Bed Extension
Mount Plates
Mount Tube Assembly
Lift Arm Assembly
Liftgate Terminology
27.
28.
29.
30.
31.
32.
33.
Parallel Arm Assembly
Pivot Block Assembly
Deck Assembly
Deck Extension Assembly
Torsion Bar
Specification Tag
Latch Chain
GR02531
Page 2-2
Chapter 2
Liftgate Terminology
Explanation of Specification Tag
Model
LPF 25
LPF 30
LPF 40
LPF 25 A
LPF 30 A
LPF 40 A
Description
Steel Main Deck
Steel Main Deck
Steel Main Deck
Aluminum Main Deck
Aluminum Main Deck
Aluminum Main Deck
Capacity
2500 lb.
3000 lb.
4000 lb.
2500 lb.
3000 lb.
4000 lb.
RATED CAPACITY
Based on an evenly
distributed load on the
platform flat surface.
MODEL
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
GR02206
Page 2-3
Chapter 3
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
Bed Height
(Ground to Floor)
NOTE:
Tire clearance should be 6” minimum between tire
and mount frame.
GR00139
Bed extension
10” reference
6”
“A”
Dimension
Mount frame
clearance
Tire Clearance
GR01340
Bed Height
59”- 60”
56”- 58”
53”- 55”
49”- 52”
48”- 49”
46”- 48”
44”- 46” (Loaded)
GR02186
MOUNTING CHART
“A”
Mount Frame
Notch
Dimension
Clearance
Height Max.
28-3/8”
27-1/4”
25-5/8”
24”
22-1/2”
20-3/4”
20-3/4”
30-1/8”
31-3/8”
32-5/8”
33-5/8”
34-1/2”
35-1/2”
35-1/2”
Page 3-1
4-7/8”
4-3/4”
4-1/4”
4”
3-1/2”
3”
3”
Sill Height
Max.
Cut Out
Depth Min.
9”
8-3/4”
8-1/8”
7-3/4”
7-1/2”
7-1/4”
7-1/4”
12-5/8”
15”
17-3/4”
20-7/8”
24-3/4”
27”
27”
Chapter 4
Installation
PREPARATION OF BODY SILL
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.
Centerline of
Body and Sill
Max. Sill
Height
Body sill must have clearances indicated. Cut or notch
Rear Sill to obtain these clearances.
Max.
Notch
Height
Refer to chart p. 3-1
13”
45°
Typ.
64”
13”
GR01416
Max. Sill Height
Cut away chassis frame to obtain clearances indicated.
Refer to chart p. 3-1
18”
Minimum
Cut Out
Depth
GR00143
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
Page 4-1
Chapter 4
Installation
Hanger Tab
Gusset
INSTALLATION OF BED EXTENSION
Place two Support Gussets on rear sill as shown.
Tack weld Gussets to sill.
NOTE:
Do not weld hanger tabs to sill.
Break off Hanger Tabs.
32”
approx.
32”
approx.
GR00144
Place Bed Extension on Gussets and center Bed
Extension with sill.
(Two raised round spots on surface of diamond plate
indicate centerline.)
Weld Bed Extension to sill as shown.
NOTE:
Be certain centerline of body sill and centerline
of bed extension are in line.
GR02624
Weld the two Support Gussets to Bed Extension and
weld all bars to sill as shown.
NOTE:
When irregular sill exists, cut or shim bars to
maintain a level altitude of bed extension with
floor of body.
Weld 1/8” all around
three sides of each bar.
GR02534
Bolt Transit Chain to Bed Extension with 3/8-16 x 1-1/4
Grade 8 Bolt, Washer, and Locknut as shown.
GR02625
Page 4-2
Chapter 4
Installation
INSTALLATION OF MOUNT FRAME
Mark centerline of platform
Unfasten outboard ends of cylinders from lift
arms. Remove and discard tubes and wires.
Assemble counterweight as shown using
channels or angles as supports.
Position deck centrally and tight against bed extension,
making sure platform is level. Be sure that centerlines
of truck sill and liftgate deck are aligned and skin of
platform is tight against bed extension as shown at “B”.
Support Channels
WEIGHT
38”
Clamp main platform securely to supports.
“A” Dimension
Raise mount tube to required “A” dimension
(see “Mounting Requirements” chart)
When correctly positioned, parallel arms must be
fully extended (38” between pin centers). Top
surface of mount tube will be approximately
parallel with truck floor.
Bolts must remain tight
Other means may be used to support
Mount Frame in position. ALWAYS verify
the safety of your supporting method
before proceeding.
GR01326
MOUNT PLATE INSTALLATION
Locate mount plates on mount tube. Mount plates
should be approximately 90° to vehicle frame.
Check that mount plates extend a minimum of 5-1/4"
above bottom of vehicle frame. If dimension cannot be
held, refer to the optional installation.
1/4” Weld 100%
Vehicle
Frame
Shield all wires and hoses from heat and
weld splatter.
Mount Plate
Recheck “A” dimension. Weld three sides of mount
plates 100% to vehicle frame with ¼” weld.
Mount Tube
Weld mount tube to the mount plates. Weld all around,
both sides of the mount plates, and ends, with 1/4" weld.
5-1/4” Min
To avoid injury or property damage, do not
remove clamps from deck. Use forklift,
crane, or other safe means to support deck
and then remove clamps.
1/4” Weld 100%
GR01327
Page 4-3
Chapter 4
Installation
OPTIONAL INSTALLATION
If the 5-1/4” dimension cannot be met a 3/8” thick
plate must be added.
1/4” Weld
100%
Shield all wires and hoses from heat and
weld splatter.
5-1/4” Min.
Recheck “A” dimension. Weld three sides of mount
plates and three sides of 3/8” plate 100% with 1/4” weld.
Weld mount tube to mount plates. Weld all around, both
sides of mount plates, and ends, with 1/4" weld.
To avoid injury or property damage, do not
remove clamps from deck. Use forklift,
crane, or other safe means to support deck
and then remove clamps.
1/4” Weld 100%
5-1/4” Min
GR01328
NOTE:
If necessary, liftgate may be mounted to inside of
frame as shown.
One 8” to 12” channel or two
5” to 6” channels
Truck Frame
Weld channel
to Truck Frame
with 1/4“ weld.
Weld 100% all
around as
shown.
5-1/4” Min.
37” or wider
Weld Mount Plate to
channel with 1/4” weld
after channel is welded
to the Truck Frame.
GR01713
Page 4-4
Chapter 4
Installation
1.75
INSTALLATION OF CONTROLS
Locate Switch such that, when operating liftgate,
operator will have clear view of entire platform area
and will not be in area that liftgate will pass through.
2.80”
Install Switch Mounting Template Decal (or use this
diagram). Locate screw holes. Drill four (4) holes with
a #26 (0.147"dia.) drill bit.
Hole for
Control Cord
(optional)
0.147”
Dia. Hole
NOT ACTUAL SIZE
GR02181
If Control Cord will be run through a hole in side of body,
remove all sharp edges from hole and insert a grommet.
#8 SelfTapping
Screws
Use #8 Self-tapping Screws to secure switch.
GR02108
MOUNT TUBE WIRING
Loosen cover bolt and remove access cover from center
of mount tube.
Remove cap nuts and shipping plastic from strain relief
fittings. Slip one of the nuts over end of control cord.
Then, one at a time, slip wire connectors through strain
relief fitting furthest from pump and push cord through.
Switch Cord
Positive Battery Cable
White wire, ground to stud
Connect switch control wires to corresponding wires
from pump control cord.
Ground white wire, ring terminal to stud using nut
provided.
Cap Nuts
Pull cord up through fitting to minimize unsupported
length of wire inside Mount Tube.
NOTE:
All electrical connections are to be coated
with dielectric grease. This includes
ground wires/cables.
Insulated Stud
Switch Cord Connectors
GR01330
Page 4-5
Chapter 4
Installation
DRIP LOOPS
Control and
Battery Cables
To help insure that water does not get into the LPF
mount tube, route cables into a loop that extends below
top of mount tube.
This loop will allow water to drip off of cables rather than
following the cables into the mount tube.
Wire tie cables together for additional support.
Mount Tube
Wire Ties
Then secure cables to nearest cross member or other
structural member.
Loop
GR02091
TIGHTENING STRAIN RELIEFS
Strain Relief Nuts
Using a wrench to tighten the strain relief nuts, be sure
nuts are tight around cables.
If nuts are not tight water can seep into the mount tube.
NOTE:
Strain reliefs cannot be tightened sufficiently
by hand.
Plastic Plug
Verify plastic plug is securely capping the auxiliary hole
in mount tube.
If plug is missing it must be replaced.
GR02092
No Pressure
HOSE INSTALLATION
Avoid twisting of hoses.
High Pressure
Avoid sharp bends when routing hoses
Hoses will contract under pressure. Allow plenty of slack
between connecting points.
Do not clamp hoses at bends to allow for length
changes when hose is pressurized.
GR00717
INSTALLATION OF POWER CABLE
Remove cap nut and shipping plastic from strain relief
fitting closest to the pump. Slip nut over bare end of
battery cable. Then push cable through fitting.
Attach terminal to battery cable as follows:
Strip 7/8” to 1” of insulation from end of cable
Slide heat shrinkable tubing onto cable
Insert bare wire into compression nut until it seats
NOTE:
Copper wire should be flush with, or slightly past
nut
Heat shrinkable tubing
before installation
7/8” to 1”
GR00299
Page 4-6
Chapter 4
Installation
Grip nut with wrench and turn terminal until nut seats
GR00300
Position heat shrinkable tubing over terminal and end of
cable
Beads of Sealant
Shrink tubing using electric heat gun or torch.
NOTE:
To reduce chance of damaging tube and cable, a
heat gun is recommended
Apply sufficient heat to produce thin bead of sealant all
around tube edges
Heat Shrinkable
Tubing
GR00301
Connect cable end to insulated stud using nut provided.
NOTE:
All electrical connections are to be coated
with dielectric grease. This includes ground
wires/cables.
Insulated Stud
GR01330
Page 4-7
Chapter 4
Installation
Page 4-8
Chapter 4
Installation
INSTALLATION OF POWER CABLE
Locate and mount 150 Amp circuit breaker directly to
batteries using copper terminal link supplied.
Circuit breaker must be mounted to give good protection
against any objects coming into contact with circuit
breaker terminals and causing a short. Position must
also be readily accessible to reset breaker.
NOTE:
Circuit Breaker is to rest solidly on battery
to prevent vibration during transit.
Copper Terminal Link
If unable to connect circuit breaker direct to batteries, an
optional 24”, maximum length, 2 Ga. battery cable may
be used.
150 Amp Circuit Breaker
Connect end of battery cable from liftgate to Terminal
Link attached to circuit breaker.
Battery Cable
From Liftgate
Apply a generous amount of Dielectric Grease to all
Battery terminals and Circuit Breaker terminals.
Secure all battery cables to chassis frame with cable
ties provided.
NOTE:
Original equipment ground cable furnished on
vehicle should be at least a number 2 ga. to insure
proper operation of pump unit. An auxiliary ground
cable should be added between engine block and
chassis frame if engine is not adequately grounded
to chassis frame. When there are two or more
batteries, all cables connecting batteries together
must be 2 ga. or heavier. This includes all original
equipment batteries on vehicle.
Protect wires from any sharp edges or
holes that may abrade insulated covering
of wires.
Secure battery cable so it does not come
near, or in contact with, other vehicle
wiring, fuel lines, brake lines, air hoses,
exhaust system, etc.
GR00080
Page 4-9
Chapter 4
Installation
FASTENING CYLINDER RODS TO LIFT ARM
ASSEMBLY
Hex Bolt
NOTE:
Verify that raised platform is well supported before
proceeding. Keep head and body out from under
platform at all times.
Lock Washer
Flat Washer
Use a crane or forklift to lower platform to ground.
Use hydraulic pressure to align holes in cylinder rods
with holes in lift arm clevises.
Attach cylinder rods to lift arm using cylinder pivot pins.
Retain pivot pins with hex bolts, lock and flat washers
provided.
Cylinder
Pivot Pin
GR02510
CHECK AND FILL HYDRAULIC RESERVOIR
Breather Cap
Lower platform fully to ground.
Remove Breather Cap.
Oil level should be 1/2” from top of reservoir.
If low, fill as required. Use appropriate fluid per chart.
Replace Breather Cap.
GR01022
Recommended Fluids
Temperature Range
Acceptable Fluids
Mobil DTE 13M
-10 to 195 F
Shell Tellus 32T
Mobil DTE 11M
-25 to 140 F
Shell Tellus 15T
Mobil Aero HFA
-40 to 145 F
Exxon Univis HVI 13
Exxon Univis HVI 26
-45 to 200 F
A good quality SAE 10W motor oil may also be used
in temperatures above 32 F.
Page 4-10
Fill reservoir
Fill with recommended fluid or equivalent.
Fill the reservoir to within 1/2” from the top.
NOTE:
Do not use the following fluids:
Brake Fluid
Power steering fluid
Automatic Transmission Fluid (ATF)
Chapter 4
Installation
PIVOT BLOCK ACTIVATION
Remove bolts securing the bottom of each pivot block to
mount tube.
Power platform to ground level. The shims should then
fall out. In some cases a light tap of a hammer may be
needed to dislodge them.
Remove Bolts and Shims
GR01333
The platform will now pitch upward when raised so that
its tip will be 1” – 1-1/2” above the truck floor.
1” – 1-1/2”
GR01334
PLATFORM TILT ADJUSTMENT
Pitch of platform at bed level is set by installation.
Adjustment can be accomplished by adding or removing
material where pivot blocks rest on stop angles.
Lower liftgate until platform tilts fully toward ground.
Add or remove
material here
To lower platform tip, add material to pivot block.
To raise platform tip, remove material from pivot block
NOTE:
Adjust both pivot blocks equally.
NOTE:
Adjust in small increments. A 1/8” change on block
will result in a 7/8” change on the platform.
Do not weld
or grind on
this face
Weld shims to
or grind this
face only.
GR01301
Torsion
Spring
Page 4-11
Chapter 4
Installation
ANCHORING TORSION SPRINGS
Torsion
Spring
Lower platform to ground. Use crane to foldup platform
for storage.
1/2” Roll
Pin
Raise platform until hole in lower deck pin is inside of
spring hook.
Install the ½” roll pins through hole in deck pins as
shown.
Platform
GR01335
PREPARING THE LIFT GATE FOR STORAGE
To retain platform tight in transit position, bars are
welded to parallel arms.
Close platform and raise to 1-1/2" from bed extension.
Weld bars to parallel arms between sliding parts as
shown. Weld three sides 1/4”.
Raise the platform to transit position. Platform should
be held tight during transit. If not, move bars closer to
slide pin.
Attach eye bolts to S-hook and S-hook to closed ends of
extension springs. Bend both sides of the S-hook and
the eye of the eye bolt closed. Attach springs to both
parallel arms. Tighten down locknuts on both sides of
the attaching clip. Springs may be adjusted for amount
of folding assistance desired.
Bed
Extension
Bar, ¼” x 2” x 1 ¼”
1 ½”
¼” Weld (3)
Sides
Extension
Spring
Platform
Closed S
Hook
Eye Bolt
Parallel
Arm
If spring assist is too strong, platform may
unfold without assistance when lowering.
This is unsafe and MUST BE CORRECTED.
Reduce parallel arm spring tension. On
higher bed heights it may be necessary to
remove one lower spring.
NOTE:
Spring adjustment is easiest with platform
stored.
Slide Pin
GR02536
Assemble rubber pad to supplied angle.
ANGLE
Using supplied self-threading bolt and washer,
attach rubber pad to angle.
WASHER
RUBBER PAD
BOLT
Page 4-12
GR02542
Chapter 4
Installation
Raise liftgate in folded positon so that it is 1/2"
away from contacting bed extension or walk ramp
holder assembly if there is a walk ramp application.
Arrange upstop angles as shown with rubber pad
resting on platform shoe, on flat surface of 2x5
rectangular tube.
TYP
TYP
1/8
1/8
Upstop angle
3
3
TYP
1/8
Platform
Shoe
1/8
Weld in place.
Rubber Pad
Repeat for opposite side of liftgate.
GR02543
STORED CLEARANCES:
CHECK
When storing platform for first time, power it up slowly,
checking for clearance as it goes.
Correct any interferences of platform with truck body or
frame.
If platform hinge ears contact mount tube clevises, see
below.
CHECK
GR02710
If mount tube has not been fully rotated to its correct
position, mount tube clevises may interfere with
platform.
Spacers
Check platform pitch.
If satisfactory, the interference may be corrected without
remounting liftgate.
Spacers may be added to liftarm crosstube as shown.
Contact Waltco for spacers.
After adding spacers, recheck store clearances as
above.
GR02537
Page 4-13
Chapter 4
Installation
DOCK BUMPER INSTALLATION
Position bumper assemblies as shown. Weld into place
with 3/16" fillet weld as shown.
3/16” Weld
Weld support gussets or structural members to
bumper assembly and to cross members for
additional support as shown.
Steel structure of dock bumpers must extend out
past the liftgate when in stored position.
Optional
Support
Gusset
GR01339
LIGHT INSTALLATION
Install rubber bumpers to heavy duty dock
bumpers and lights as shown.
Hex Nut
Dock Bumper
Assembly
Machine Screw
Taillight Bracket
Harness, 2 Lamps
Light Grommet
Taillight,
white back-up
Taillight,
Red S, T&T
Rubber Bumper
Hex Nut
welded
inside dock
bumper
GR02089
Page 4-14
Chapter 4
Installation
Waltco offers three suggestions for the installation of the
vehicle taillights. We believe these suggested locations
meet D.O.T. regulations but do not warrant that they do.
Your installation of the vehicle taillights should meet all
applicable regulations and requirements. This is in no
way to infer that these suggestions are the only correct
method of installing taillights.
Location “B”
Location “A”
Location “A”: Mount lights beneath the bed extension
skin, if there is sufficient room.
Location “B”: Mount lights above bed extension or into
the body rear corner posts.
Location “C”: Waltco has dock bumpers available that
have lights included as part of the dock bumper.
NOTE:
Original equipment lights may not provide sufficient
clearance at this location so a narrower light may be
required.
Location “C”
All lights must be installed in accordance
with all applicable D.O.T. regulations.
GR02503
INSTALLATION OF TRANSIT HOOK AND CHAIN
All 14 links of chain will be used.
Attach chain based on truck width as shown. Make sure
nut and bolt are tight.
Make sure chain easily attaches to transit hook on lift
arm and is slack when platform is fully raised.
96” Wide
102” Wide GR02551
INSTALLATION OF TRANSIT HOOK AND CHAIN;
96” WIDE WITH DOCK BUMPER (ONLY)
Attach chain to bar inside dock bumper. Make sure bolt
and nut are tight.
Make sure chain easily attaches to transit hook on lift
arm and is slack when platform is fully raised.
Chain may be cut shorter but must have slack.
GR02571
Page 4-15
Chapter 5
Placement of Decals
All decals must be in place and legible or all warranties are void.
ITEM
1
DECAL
QTY
PART NO.
Safety Instructions
1
80100850
Operation
1
80101529
Warning Decal
1
80101370
Important Decal
1
80100828
Motor Thermal Switch
1
80101480
2500 lb Capacity
3000 lb Capacity
1
80100257
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.
80100260
Caution Decal
1
75089296
Caution Decal
1
75089295
Caution Decal
1
75089296
2500 lb Capacity
3000 lb Capacity
Locate in a conspicuous place near controls.
80100255
4000 lb Capacity
2
LOCATION
80100255
1
4000 lb Capacity
80100257
Locate near platform handle
(positioned under platform so as to be read when
platform is being unfolded into loading position)
80100260
3
Store Tight Decal
1
80101404
4
Warning Decal
1
80100829
5
Caution Decal
1
75089296
Locate on back of deck on curb side
(visible, and read, 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
Locate in a conspicuous place on driver side.
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
IMPORTANT
STORE
PLATFORM
TIGHT AGAINST
BED EXTENSION
IMPORTANT
DO NOT
REST BAIL
IN HOOK
AS SHOWN
GR02538
Page 5-1
Chapter 6
Lubrication Instructions
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.
#3 - Grease parallel arm slide with heavy chassis grease.
Oil Coils of Springs
GR02539
Page 6-1
Chapter 7
Final Inspection
IMPORTANT:
All of the following are to be checked and verified
before installation is complete.
A. Are all pivot pin retaining screws in place
and tightened?
R. Are all decals properly in place and legible
according to the decal placement drawings?
S. Is pump slide tray properly latched?
T. Is Owner’s Manual in the vehicle?
B. Are all roll pins securely in place?
C. Does liftgate fold and unfold properly?
D. Does the platform meet bed extension
properly?
E. Does chain engage with transit hook on lift
arm?
F. Do controls operate properly?
G. Are bed extension, mount frame, mount
plates, upstops, dock bumpers, bumper
braces, taillight guards and taillights all
finish welded?
H. Are hydraulic hoses and fittings properly
connected with no leaks?
I.
Is battery cable attached and clamped
tight?
J. Is 150 amp circuit breaker installed at
battery?
K. Are all electrical connections coated with
dielectric grease?
L. Has hydraulic system been properly bled
of all air?
M. Is pump reservoir full of oil?
N. Can lockout device be properly installed?
O. Are all parts properly lubricated according
to the lubrication instructions?
Do not use liftgate if any of the above are
not checked and verified. If you have any
questions not covered in this manual,
contact your nearest Waltco distributor, or
the nearest Waltco factory.
P. Do lights operate properly
(Note: Lights must be installed in
accordance with all applicable state
and federal D.O.T. regulations)
Q. Is license plate properly installed?
Page 7-1
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: 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.
________________________________________________
80101389
Page 8-1
EO 5534A
Rev 02
BATTERY KIT INSTALLATIONS
80101387
DETERMINE BATTERY AND PUMP LOCATION, AND
CABLE ROUTING
Determine where pump unit and battery box will be
located. Make certain hydraulic hoses supplied will
reach pump.
Your installation may use only one cable supplied with
liftgate, or, it may also use a cable supplied with the
trailer kit.
Truck with auxiliary batteries:
Cable supplied with liftgate will be cut into two lengths to
reach from pump to auxiliary batteries and to vehicle
batteries.
PUMP
AUXILIARY
BATTERY
VEHICLE
BATTERY
Trailer with auxiliary batteries:
Use cable supplied with liftgate from pump to auxiliary
batteries.
Use cable supplied with trailer kit from auxiliary batteries
to nose of trailer.
Note: Auxiliary batteries on trailers are to be
mounted “mid-ship” on the trailer.
GR01389
Page 1 of 5
EO6293 Rev 03
9-25-09
BATTERY KIT INSTALLATIONS
80101387
BATTERY AND PUMP BOX INSTALLATION
BODY CROSSMEMBERS
Locate battery box and pump box in a suitable location
under the vehicle body (refer to previous page.)
Weld hanger channels to body crossmembers.
PUMP BOX
HANGER
CHANNELS
BATTERY BOX
Hint:
To save space, hanger channels can be cut down and
boxes moved closer together as shown.
Install batteries.
GR01390
INSTALLATION OF BATTERY CABLE
Install battery cable supplied with liftgate to the pump
starter solenoid.
Cable runs to
vehicle batteries or
nose of trailer
For trucks:
Route cable to vehicle batteries, cut to desired length.
Cut cable to reach auxiliary batteries, and cut remaining
piece to reach from auxiliary batteries to vehicle
batteries.
For trailers:
Route cable to auxiliary batteries, cut to desired length.
Use cable supplied with trailer kit and route from
auxiliary batteries to nose of trailer.
NOTE: Do not connect cables to any batteries at this
time.
GR01391
Page 2 of 5
EO6293 Rev 03
9-25-09
BATTERY KIT INSTALLATIONS
INSTALLATION OF TERMINAL LUG
Strip 7/8” to 1” of insulation from end of cable.
Slide heat shrinkable tubing onto cable.
Insert bare wire into compression nut until it seats.
NOTE: Be sure to use correct compression nut, use
2 gauge nut for 2 gauge cable, use 0
gauge nut for 0 gauge cable.
Note: Copper wire should be flush with, or slightly
past nut
80101387
Heat shrinkable tubing
before installation
7/8” to 1”
Compression Nut
GR00299
Grip nut with wrench and turn terminal until nut seats
GR00300
Beads of Sealant
Position heat shrinkable tubing over terminal and end of
cable
Shrink tubing using electric heat gun or torch.
Note: To reduce chance of damaging tube and
cable, a heat gun is recommended
Apply sufficient heat to produce thin bead of sealant all
around tube edges
Heat Shrinkable
Tubing
GR00301
INSTALL OF TRAILER SOCKET
Rubber Boot
Drill 1-3/4” hole in nose of trailer for trailer socket.
Strip 3/4” to 7/8” of insulation from end of cable.
Slip rubber boot (supplied with socket) over cable.
Solder cable into socket.
After solder cools slip boot onto socket.
Mount socket to trailer.
Trailer Socket
GR01392
Page 3 of 5
EO6293 Rev 03
9-25-09
BATTERY KIT INSTALLATIONS
80101387
Ground trailer socket to main structure of trailer.
Trailer Socket
Use the 18” ground cable, supplied, and bolt it to the
trailer socket and suitable structure on the nose of the
trailer.
Angle
An angle has been provided, it can be used by welding
it to the crash plate, or other suitable structure.
Ground Cable
GR01414
Page 4 of 5
EO6293 Rev 03
9-25-09
BATTERY KIT INSTALLATIONS
INSTALLATION OF CIRCUIT BREAKER(S)
Auxiliary batteries on a truck will require circuit breakers
at both the auxiliary batteries and the vehicle batteries.
80101387
Cable supplied
with Liftgate
Locate and mount 150 Amp circuit breaker directly to
batteries using copper terminal link supplied.
See below
For detail
Circuit breaker must be mounted to give good protection
against any objects coming into contact with circuit
breaker terminals and causing a short. Position must
also be readily accessible to reset breaker.
Note: Circuit Breaker is to rest solidly on battery to
prevent vibration during transit.
If unable to connect circuit breaker direct to batteries, an
optional 24”, maximum length, 2 Ga. battery cable may
be used.
Connect end of battery cable from liftgate to Terminal
Link attached to circuit breaker.
Apply a generous amount of Dielectric Grease to all
Positive (Hot) Battery terminals and Circuit Breaker
terminals.
Secure all battery cables to chassis frame with cable
ties provided.
Ground
Cable
NOTE: Original equipment ground cable furnished
on vehicle should be at least a number 2 ga. to
insure proper operation of pump unit. An auxiliary
ground cable should be added between engine
block and chassis frame if engine is not adequately
grounded to chassis frame. When there are two or
more batteries, all cables connecting batteries
together must be 2 ga. or heavier. This includes all
original equipment batteries on vehicle.
Cable supplied with
Liftgate or with Trailer
Kit
Terminal Links
Cable from Liftgate
Protect wires from any sharp edges or
holes that may abrade insulated covering
of wires.
Secure battery cable so it does not come
near, or in contact with, other vehicle
wiring, fuel lines, brake lines, air hoses,
exhaust system, etc.
150 Amp
Circuit Breaker
Cable to Vehicle Batteries
or to Nose of Trailer
GR01413
Page 5 of 5
EO6293 Rev 03
9-25-09
LPF DUAL CONTROL SWITCH INSTALLATION
Dual Control Switch, Installation Instructions For Kit 80000434
NOTE: Kit may include additional parts not used in all installations
Locating and Mounting Switch
1.75"
Locate a position for Switch such that operator has a
clear view of entire Platform area and will not be in the
area that liftgate passes through.
IMPORTANT:
Verify that Control Cord is long enough to reach
pump unit before advancing to the next step.
2.80"
Using Switch Mounting Template or diagram to the
right, drill four fastener holes with a #26 (0.147”dia.)
drill bit.
GR00340
If Control Cord will be run through a hole in the side
of the truck, remove all sharp edges from center
hole and insert a grommet.
Mount Switch with #8 Self-tapping screws provided.
#8 SELF-TAPPING
SCREWS
GR02080
This step is for most liftgates, see next page for LPF
liftgate instructions.
Route Control Cord into pump enclosure.
CONTROL
CORD
First connect Pump wires to Dual Control
Adapter Harness as shown.
CONTROL
CORD
Connect both Control Cords to other ends
of Adapter Harness as shown.
ADAPTOR
HARNESS
NOTE:
Match wire connections male to female.
Color of wire may vary.
GR02081
80101488
Page 1 of 2
EO6007A Rev. 01
LPF DUAL CONTROL SWITCH INSTALLATION
STRAIN RELIEF
LPF Liftgate Instructions
PLUG
Loosen cover bolt and remove Access Cover
from center of Mount Tube.
MOUNTING
NUT
Remove Plastic Plug in top of Mount Tube
and insert Strain Relief Fitting through the
same hole. Tighten plastic Mounting Nut.
GR00335
Remove Strain Relief cap nut and slide cap
nut over Control Cord.
Insert Control Cord into Mount Tube through
Strain Relief, pushing one wire connector
through at a time.
GR00336
Route Control Cords behind Battery Cable, keeping
them close to back wall of Mount Tube and away
from battery cable stud (Contact between any
connectors and battery cable stud could result
in a short circuit).
BATTERY
CABLE
CONTROL
CORDS
Connect both Control Cords to three way
Dual Control Adapter Harness.
NOTE:
Match wire connections male to female.
Color of wire may vary
ADAPTER
HARNESS
GR00337
Pull unsupported lengths of Control Cord out of Mount
Tube and thread Strain Relief cap nuts on snuggly.
Using a wrench to tighten the strain relief nuts, be sure
nuts are tight around cables.
If nuts are not tight water can seep into the mount tube.
CABLE TIES
NOTE:
Strain reliefs cannot be tightened sufficiently by
hand.
Using 8” cable ties provided, secure Control
Cords to Hose Fittings as shown.
Secure Control Cords to vehicle with 16”
cable ties.
80101488
GR00338
Page 2 of 2
EO6007 Rev. 01
LPF REAR IMPACT GUARD INSTALLATION (80101523)
IMPORTANT
•
This rear impact guard has been designed to be compliant to Transport Canada’s Motor
Vehicle Safety Regulation Standard 223.
•
Installation of the liftgate and this guard is critical. The liftgate installation manual and
these instructions for the guard must be strictly followed to meet regulations.
•
The vehicle on which this guard is installed must be sufficient strength and design to
support this rear impact guard.
Mounting Requirements:
Bed Heights 46” – 60”
Fold platform and raise to the transit
position.
• Refer to Owner’s Manual and
Operation Decals.
IMPORTANT
Make certain chain is engaged to
transit latch hook.
GR02547
Nut
Mount brace plate to mount tube
angles as shown. Use supplied
bolts, nuts, and lock washers.
Mount Tube
Angle
Note: Mount brace plates go to
outside of angles.
Mount Brace
Plate
Bolt
Lock Washer
GR02548
80101523
Page 1 of 3
E.O. 6207 Rev. 01
LPF REAR IMPACT GUARD INSTALLATION (80101523)
Attach under ride bumper assembly
to mount brace plates with pins.
Fasten pins with bolts and lock
washers as shown.
Pin
Bolt
Lock
Washer
GR02544
Use the table to select which hole
on the bumper weldment needs to
be used.
IMPORTANT
If hole selection is not properly
met, rear impact guard will not
meet Transfer Canada’s Motor
Vehicle Safety Regulations
Standard 223.
HOLE SELECTION
BED HEIGHT RANGE
HOLE NUMBER
56” – 60”
HOLE 1
53” – 55”
HOLE 2
50” – 52”
HOLE 3
46” – 49”
HOLE 4
HOLE 1
HOLE 2
HOLE 3
HOLE 4
GR02546
Assemble support bars as shown
with pins, cotter pins, and washers.
Ensure proper hole selection from
previous step.
Cotter Pin
Support Bar
1” Pin
Washer
GR02545
80101523
Page 2 of 3
E.O. 6207 Rev. 01
LPF REAR IMPACT GUARD INSTALLATION (80101523)
NOTICE:
On lower bed height trucks, there
may be interference or pinch points
between bumper tube and dock
bumpers. If this does occur, trim
bumper tube for two (2) inch gap as
shown.
Dock Bumper
Bumper Tube
GRO2570
80101523
Page 3 of 3
E.O. 6207 Rev. 01
Support Spring Installation Instructions
80101426
Support Spring
The spring and associated hardware is for supporting
the charge line when connected between the tractor
and trailer.
Charge Line
GR01292
Support Spring
Use the nylon strap and spring hook that are provided
to secure the spring to the charge line.
Spring Hook
Nylon Strap
GR01291
Slide Bar
on Tractor
Spring Hook
Use the other spring hook to secure the spring to the
slide bar.
GR01290
EO5477 Rev 01
3/25/05
Snubber Kit Instructions
80100503
INSTALL RUBBER SNUBBERS
Raise Platform to fully closed position.
NOTE:
On F and FSL Series Liftgates only:
Pull up and rearward on Deck Extension to
make certain Platform is fully in stored
position.
GR00168
Measure distance “X” from tube at end of deck to a
selected spot on chassis frame.
Lower platform slowly until “X” increases by 3/8”.
GR00168
Position a Snubber Assembly approximately as shown
on each Mount Plate and tack weld in place.
Mount Plate
Snubber Assembly
Lower, open and re-store Platform a few times to check
operation of Snubbers.
Check that Snubber Assemblies do not interfere with
opening or storing away of deck.
Weld Snubbers 100% with 1/4” welds.
Pad to touch Platform
end tube.
IMPORTANT:
Shield all wiring and hoses from heat and weld
splatter.
Weld 100%, all around
GR00169
EO6091 Rev 03
8-08
Page 1-1
Installation of Cab Shut Off Switch
Install cab shut off switch and shut off switch decal in
convenient location in vehicle cab.
Decal
Cab Shut
Off Switch
GR00379
Remove
Remove fuse line from motor solenoid.
Unplug fuse line (or cut if required) from switch and
save for later installation.
Switch
To Battery
Connect green 16 ga. cab shut off wire to switch.
16 Ga. Cab
Shut Off Wire
Install supplied bullet connector onto switch wire,
if required.
Motor Solenoid
GR02087
Run green 16 ga. cab shut off wire to cab shut off
switch.
Cab Shut Off Switch
Cut off excess wire and connect to cab shut off switch
with supplied #10 ring terminal.
Re-using the fuse line, attach supplied bullet connector
if not already equipped. Connect to excess 16 ga. wire.
Fuse
To switch
green wire
Excess
Wire
Run excess 16 ga. wire from vehicle battery to cab shut
off switch. Fuse end to be toward battery.
NOTE:
Do not connect to battery at this time.
Connect 16 ga. wire to cab shut off switch with supplied
#10 ring terminal.
Connect fuse line to battery with attached 3/8” ring
terminal.
Battery
Cable
Bullet
Connector
NOTE: 150 Amp Circuit
Breaker to rest solidly
on battery to prevent
vibration during transit
IMPORTANT:
Heat shrink all connectors.
GR00716
80101363
Page1-1
REV 03
03-13-08
LIFTGATE INTERFACE INSTALLATION INSTRUCTIONS
(80101257)
This interface kit is for mounting most Waltco Flipaway,
Conventional, and Level Lift liftgates to trailers with
sliding rear suspensions.
IMPORTANT:
This kit is not to be used for any liftgates that have
a capacity rating over 4,000 pounds.
Slider rails must be fully welded to all
crossmembers for adequate support of liftgate.
1. Locate Interface Channels to inside of slider rails, at
41” from rear sill. Channels are to span a minimum
of three (3) body crossmembers as shown.
2. Tack weld channels in place with sufficient weld to
support liftgate.
3. Refer to liftgate installation manual to determine if
channels need to be trimmed for clearance. Trim
as required.
4. Cut two (2) angles (provided) to correct length
between channels.
5. Locate angles and tack weld in position.
NOTE:
Rear angle may have to be relocated after liftgate
is mounted to clear hydraulic cylinder or other
mechanism.
Continued:
6. Tack weld liftgate into position.
7. Verify all clearances to make sure angles will not
interfere with operation of liftgate.
8. Finish welding Interface Channels and angles as
shown at left.
9. Finish installation and welding of liftgate per the
liftgate installation manual.
Rev.04 – 2/16/07
Hand Held Remote Installation
DRILL SOCKET HOLES
Using dimension shown, drill mounting
holes in desired location for socket.
1-1/4” DIA.
7/32” DIA.
GR00036
INSTALL SOCKET
Assemble socket as shown.
Install wires according to colors:
W = White (Raise)
B or BK = Black (Lower)
G = Green (Power)
GR02241
CONNECT WIRES TO PUMP UNIT
This step is for most liftgates, see next
page for LPF liftgate instructions.
Route Control Cord into pump enclosure.
First connect Pump wires to Dual Control
Adapter Harness as shown.
CONTROL
CORD
Connect both Control Cords to other ends of
Adapter Harness as shown.
ADAPTOR
HARNESS
CONTROL
CORD
SOCKET
Note!
Match wire connections male to female. Color
of wire may vary.
GR02082
80101485
Page 1
EO6134 Rev.02
Hand Held Remote Installation
STRAIN RELIEF
LPF Liftgate Instructions
PLUG
Loosen cover bolt and remove Access Cover
from center of Mount Tube.
MOUNTING
NUT
Remove Plastic Plug in top of Mount Tube
and insert Strain Relief Fitting through the
same hole. Tighten plastic Mounting Nut.
GR00335
Remove Strain Relief cap nut and slide cap
nut over Control Cord.
Insert Control Cord into Mount Tube through
Strain Relief, pushing one wire connector
through at a time.
GR00336
Route Control Cords behind Battery Cable,
keeping them close to back wall of Mount
Tube and away from battery cable stud
(Contact between any connectors and battery
cable stud could result in a short circuit).
Connect both Control Cords to three way
Dual Control Adapter Harness.
BATTERY
CABLE
CONTROL
CORDS
ADAPTER
HARNESS
NOTE:
Match wire connections male to female.
Color of wire may vary
GR00337
Pull unsupported lengths of Control Cord out of
Mount Tube and thread Strain Relief cap nuts
on snuggly. Do not over-tighten cap nuts, as
this may damage the wires.
CABLE TIES
Using 8” cable ties provided, secure Control
Cords to Hose Fittings as shown.
Secure Control Cords to vehicle with 16”
cable ties.
GR00338
80101485
Page 2
EO6134 Rev.02
LPF Walk Ramp Option Installation Instructions
These instructions will install the liftgate walk ramp option.
After installation, operator will be able to access the walk ramp without operating liftgate.
Position walk ramp holder assembly and weld
in place to mounting plates (provided).
Weld mounting plates to body sill and bed
extension support gussets with 3/16" weld.
Note*: Weld to underside of bed extension
diamond floor plating if mount plates do not
lineup with bed extension gussets.
TYP
3/16
Weld to bed
extension gusset
(see Note*)
TY
3/16
Weld mount
plate to sill
Weld to walk
ramp holder
assembly
GR01881
Dock bumpers and rubber bumpers must be
installed with this option.
Rubber
Bumper
Steel structure of dock bumpers must extend
out past the liftgate when in stored position.
Dock
Bumper
GR01882
Check transit latch chain.
If chain does not attach to transit hook on lift
arm or does not have slack when platform is
fully raised, replace with longer supplied chain.
Make sure nut and bolt are tight.
Chain attaches
with slack.
(Minimum slack
shown)
GR02532
80101524
Rev 03
1-21-10
LPF Walk Ramp Option Installation Instructions
………………. Notching Instructions For Walk Ramp ……..………..
Measure walk ramp hook spacing.
Using this measurement, center it on the bed
extension, and mark where the walk ramp
hooks will rest.
WIDTH OF YOUR WALKRAMP HOOKS,
CENTERED ON BED EXTENSION
.750
Notch the bed extension and bed extension
reinforcement bar as shown.
1.500
1.500
GR02635
80101524
Rev 03
1-21-10
This page left blank intentionally
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
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
80101520
EO6156
Rev 01