C-15RM, C-20RM

Transcription

C-15RM, C-20RM

RGL SERIES II
RBGL SERIES II
Owner’s Manual
Visit us at www.waltco.com
2000 – 6000 lb. Capacity Rail Lift
IMPORTANT
KEEP IN 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.
5-2009
GR02479
OHIO
GEORGIA
285 Northeast Avenue
Tallmadge, OH 44278
(330) 633-9191
FAX – (330) 633-1418
8960 Highway #5
Douglasville, GA 30134
(770) 949-5342
FAX – (770) 949-5344
EO231 Rev.10
80137602
Table of Contents
Chapter
INTRODUCTION ...............................................................................................................
SAFETY INFORMATION ................................................................................................... 1
WARRANTY POLICY ......................................................................................................... 1.3
LIFTGATE TERMINOLOGY ............................................................................................... 2
OPERATION INSTRUCTIONS ........................................................................................... 3
RBGL SERIES OPERATION INSTRUCTIONS.................................................................. 4
PREVENTIVE MAINTENANCE GUIDE ............................................................................. 5
PLACEMENT OF DECALS ................................................................................................ 6
LUBRICATION INSTRUCTIONS ....................................................................................... 7
PLATFORM BRAKE .......................................................................................................... 8
CABLE REPLACEMENT ................................................................................................... 9
PM DRAWINGS AND SCHEMATICS ...............................................................................10
HOW TO ORDER PARTS .................................................................................................11
EO231 Rev.10
80137602
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
avoided, may result in minor or moderate injury. May
also be used to alert against unsafe practices.
Black letters on a yellow background.
NOTICE
avoided, may result in property damage.
WARNING
CAUTION
NOTICE
Page 1 - 2
80101253 Rev 03 EO 6156
WALTCO Warranty Policy
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 Truck Equipment Co.
285 Northeast Ave, Box 354, Tallmadge, OH 44278
1-800-211-3074, 330-633-9191
Please visit our websites: http://www.waltco.com or http://www.hiab.com
We're behind you all the way!
Page 1-3
Chapter 2
1.
2.
3.
4.
5.
6.
Hydraulic Unit
Breather
Hydraulic Enclosure
Hydraulic Reservoir
Liftgate Wiring Harness
Opening Solenoid Valve
Liftgate Terminology
7.
8.
9.
10.
11.
12.
Lowering Solenoid Valve
Raise / Close Solenoid Valve
Toggle Switch (Dual Pump Only)
Relay
Motor Wiring Harness
Starter Solenoid
GR02015
Page 2-1
Chapter 2
13.
14.
15.
16.
Curb Side Rail
Control Switches
Safety Chain Assembly
Upstop Pin
17. Pulley Assembly
18. Pulley Guard Assembly
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Brake Assembly
Upper Roller / Tandem Assembly
Drivers Side Rail
H-Frame Hose Guide
Lift Cylinder
Flow Control Valve
Crossbeam Access Cover
Hydraulic Hose
Runner Hose Guide
Torsion Bar Anchor
Slide Bearing
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Curb Side Runner Assembly
Closure Cylinder
Chain Clip
Deck Assembly
Torsion Bar
Deck Extension Assembly
Drivers Side Runner Assembly
Upper Link Assembly
Connecting Bar Assembly
Lower Link Assembly
Curb Side Cable Assembly (Fixed)
Pulley Assembly
Drivers Side Cable Assembly (Adjustable)
Shoe Assembly
Specification Tag
GR02278
Page 2-2
Chapter 2
Explanation of Specification Tag
Model No.
363B
364B
372B
373B
374B
375B
376B
382B
383B
384B
385B
386B
Model Name
RBGL-30
RBGL-40
RGL-20
RGL-30
RGL-40
RGL-50
RGL-60
RGL-20
RGL-30
RGL-40
RGL-50
RGL-60
Description
Rail Lift, Bottle Gas
Rail Lift, Bottle Gas
Rail Lift (96" WIDE)
Capacity
3000 lbs.
4000 lbs.
2000 lbs.
3000 lbs.
4000 lbs.
5000 lbs.
6000 lbs.
2000 lbs.
3000 lbs.
4000 lbs.
5000 lbs.
6000 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
GR00241
Specification
Tag
NOTE: Tag located on
Curb Side Rail above
switches.
GR02279
Page 2-3
Chapter 3
Operation Instructions
OPERATION INSTRUCTIONS
Read and understand these instructions,
all warning and operation decals, and this
manual before operating this liftgate.
Raise / Lower
Switch
Platform and Runners are always to be powered up
against Upstop Pins when in transit.
Both safety chains must be used when liftgate is not
in use. A padlock may be used to prevent
unauthorized use of liftgate.
RAISE
LOWER
Never remove Safety Chains from Platform if chains
are in tension. Apply up power and closing power as
required to release tension on the chains.
OPEN
CLOSE
RAISE
LOWER
Open / Close
Switch
When in transit Platform must be in stored position
with Safety Chains hooked securely.
Do not allow anyone to stand in, or near area, in
which Platform will open and close before opening
or closing Platform.
Safety Chain
Inside Control
Switch
Do not allow anyone to stand near the Platform
where a falling load could land on them.
Platform Side Bar Linkage areas must be kept clear
for Platform opening and closing.
Certain conditions may cause Platform Brake(s) to
engage even if cable has not broken. In this case,
raise Platform first then lower Platform.
GR02469
Make sure all protective covers and guards are properly
in place at all times.
Pulley
Guards (2)
DO NOT operate liftgate unless Pulley
Guards and Access Cover are installed and
secured.
Access Cover
GR02479
Page 3-1
Chapter 3
LOADING OF PLATFORM
Load and unload from rear of platform and not side of
platform. Never remove side linkage to load or unload
platform.
Always load as close to center of platform and as close
to truck sill as possible.
Never operate lift trucks on or over any part of platform.
This unit is intended for loading and unloaded of cargo
only. Do not use for anything but its intended use.
TO RAISE AND LOWER PLATFORM IN DOCK
LOADING POSITION
Unhook Safety Chains from Platform
Press Lower Switch to lower Platform
Press Raise Switch to raise Platform
GR02470
TO OPEN PLATFORM TO LOADING POSITION
Unhook Safety Chains from Platform
Press and hold Open Switch then press Lower Switch to
open Platform
GR02471
TO RAISE/LOWER PLATFORM IN LOADING POSITION
Press Raise Switch to raise Platform
Press Lower Switch to lower Platform
GR02472
Page 3-2
Chapter 3
TO CLOSE PLATFORM TO TRANSIT POSITION
Press Raise Switch to raise Platform at least 12” from
ground
Press and hold Close Switch then press Raise Switch to
close Platform
Press Raise Switch to raise folded Platform
Hook both Latch Chains to Platform
GR02473
PROPER HOOKING OF SAFETY CHAIN
Correct hooking
of “S” Hook
Properly hook latch chain as shown.
Incorrect hooking
of “S” Hook
The safety chains provided with your
liftgate are an important safety device and
should always be in place when liftgate is
not in use.
To prevent unauthorized persons from
using liftgate, a padlock may be used in
place of “S” Hook.
Pad Lock
Always use chains on both sides of liftgate
when not in use.
GR02474
PROPER USE OF FOLDING RAMP
NOTE:
Folding ramps to be folded
and latched in place when
liftgate is closed in the transit
position.
RAISE
LOWER
OPEN
CLOSE
GR02483
Page 3-3
Chapter 3
FOLDING RAMP OPERATION INSTRUCTIONS
Ramp Latch
Unlatch ramp and unfold to loading position.
Use cables for retention ramp application.
Assure ramp is latched when in transit position.
GR01553
Stop Bar
CART STOP OPERATION INSTRUCTIONS
Push lever away from platform to release stop bar.
Rotate stop bar to lock in vertical position.
Rotate brace to engage stop bar.
Lever Lock
Lever
Stop Bar
Brace
GR01552
Page 3-4
Chapter 3
DUAL PUMP OPERATION INSTRUCTIONS
The purpose of an optional Dual Pump unit is to provide
a backup in the event of a malfunction of the Primary
Pump or the switches on the column of the liftgate.
Toggle Switch
The Auxiliary Pump is NOT INTENDED FOR NORMAL
OPERATION of the liftgate. Liftgate must be repaired as
soon as possible after a malfunction of the Primary
Pump unit occurs.
The Auxiliary Pump unit is operated with the Hand Held
Remote Control located in the Hydraulic Enclosure.
TO OPERATE THE PRIMARY PUMP:
Move toggle switch on the pump to the “Primary
Position”.
Operate liftgate with controls on columns as usual.
TO OPERATE THE AUXILIARY PUMP:
Move toggle switch on the pump to the “Auxiliary
Position”.
Operate liftgate with Hand Held Remote Control.
GR02135
AUXILIARY HAND HELD REMOTE CONTROL:
Auxiliary Pump Hand held remote operates in the same
manner as the outside Main Control Switches.
Use the center switch in conjunction with the Raise or
Lower switches to close or open platform.
Raise Button
Open / Close
Button
Lower Button
GR02043
Page 3-5
Chapter 3
OPERATION OF MANUAL OVERRIDE VALVES TO
LOWER AND UNFOLD PLATFORM IN EVENT PUMP
ISN’T FUNCTIONING:
A
Do not allow anyone to stand in, or near
area, in which Platform will open and/or
lower.
Use valve (A) to open platform. Then valve (B)
to lower platform to ground.
B
GR01987
HAND PUMP OPERATION INSTRUCTIONS:
Hand Pump option is to provide a backup in the event of
a malfunction of the batteries, pump unit or controls.
The Hand Pump is NOT INTENDED FOR NORMAL
OPERATION of the liftgate. Liftgate must be repaired as
soon as possible after a malfunction occurs.
A
B
Make certain Manual Override Valves (A & B) are
closed.
Raise platform to bed level with Hand Pump.
Make certain platform surface is clear of all objects.
Continue to pump until platform is closed.
Do not over pressurize hydraulic system.
Once platform is closed, stop pumping.
Install Safety Chains.
GR02484
Page 3-6
Chapter 4
RBGL Operation Instructions
RBGL SERIES OPERATION INSTRUCTIONS
The RBGL is specifically designed for handling tall loads
such as cylinder gas bottles.
Chain
Chain Hook
Securing loads can be accomplished by using the
chains.
After placing a load in position, fasten chain snugly
around load to Chain Hook on Runner.
Chain in transit position
After use, chains are hooked to Guard Rail and ramp is
folded onto the platform skin for transit.
GR02485 - 86
FOLDING RAMP USED AS CART STOP
Folding Ramp may be used as a retaining device to
prevent carts and similar devices from rolling off
platform.
Folding Ramp
Latch
GR02487
Page 4-1
Chapter 4
RBGL Operation Instructions
RBGL WITH FIXED RAILS IN DOCK LOADING
POSITION.
When dock loading, ramp is to be folded down onto
platform skin before raising platform to closed position.
GR02488
RBGL WITH FOLD DOWN RAILS (optional)
Fold Down Rails can be folded down out of the way to
increase available opening width when dock loading.
GR02489
Page 4-2
Chapter 5
Preventive Maintenance
Waltco recommends that the RGL-Series liftgate be inspected at recommended intervals listed below 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 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 RGL/RBGL-SERIES LIFTGATE
PREVENTIVE MAINTENANCE CHECKLIST
PM Interval: As listed below
Date: ______________
Vehicle No.__________
Mechanic:_________________
Liftgate S/N:____________
Model:______________
Check appropriate box below for each step:
Weekly PM Procedures
1
OK
Repair Required
Corrected
Check platform brake (weekly procedures).
Monthly PM Procedures
2
OK
Repair Required
Corrected
Check liftgate operates freely and smoothly throughout entire operation.
3
OK
Repair Required
Corrected
Check platform brake (monthly procedures).
4
OK
Repair Required
Corrected
Check for apparent damage to the lifting structure, such as bent or
distorted members or cracked welds.
5
OK
Repair Required
Corrected
Check that all pins, bolts and fasteners are tight and secure.
6
OK
Repair Required
Corrected
Check for worn or damaged bearings, pulleys, rollers, all pivot points.
7
OK
Repair Required
Corrected
Check safety chains and hooks.
8
OK
Repair Required
Corrected
Check that controls operate properly.
9
OK
Repair Required
Corrected
Check operating speeds.
10
OK
Repair Required
Corrected
Check for hydraulic leaks in hydraulic cylinder(s), hoses, fittings, and
valves.
11
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.
12
OK
Repair Required
Corrected
Check oil level in reservoir.
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”.
3 Month PM Procedures (Includes steps 2-14 above)
15
OK
Repair Required
Corrected
Check entire length of both lifting cables. Replace cables every 5 years
or 10,000 cycles whichever comes first.
Semi Annual PM Procedures (Includes steps 2-15 above)
16
OK
Repair Required
Corrected
Check motor brushes, clean motor housing and change oil.
Page 5-1
Chapter 5
WEEKLY INSPECTION
Platform Brake
Lower opened platform to within a few inches of the
ground. Place a 4 X 4 or similar block under the
Platform Side Tube at main Platform Pivot.
Runner
Lower opposite side of platform to the ground so that
platform is resting at an angle.
While raising platform with raise switch, listen for a
“click” near top of Runner. If no “click” is heard, try
again. If still no “click”, the “Monthly Inspection” must
be conducted.
Repeat above test for opposite Runner.
Main Pivot
Hinge
Do not use liftgate if Platform Brake is not
functioning properly. Have liftgate
serviced immediately.
Platform Side Tube
GR02490
MONTHLY INSPECTION
1. Check that liftgate operates freely and smoothly
throughout its entire operating cycle and there are
no unusual noises.
2. Check that platform is level when raised to bed
height.
3. Perform the following steps to test Platform Brake
mechanism:

Lower open platform to within a few inches of
ground. Place a suitable hydraulic or scissor
type jack under Platform Side Tube at main
Platform Hinge.

Jack Platform and Runner up approximately 3”
relative to Rail.

Lower jack. If Platform and Runner remain in the
raised position then Platform Brake is
operational.

Push Raise Switch to raise entire platform
several inches above test position and Platform
Brake should disengage.

Lower platform and repeat for
the opposite side Platform Brake.
Do not use liftgate if Platform Brake is not
functioning properly. Have liftgate
serviced immediately.
Runner
Main Platform
Hinge
Jack
Platform Side Tube
GR02491
Page 5-2
Chapter 5
4. Inspect entire length of both Cables. Replace if
necessary.
Pulley
Assembly
Adjustable
Cable
Entire length of both Cables must be
inspected a minimum of every three (3)
months or 750 cycles, whichever comes
first.
Cables must be replaced if they show any signs of wear,
kinking, corrosion, distortion, or if any broken cable
wires are visable.
Cables must be replaced every five (5)
years or 10,000 cycles, whichever comes
first.
Any time Cables are replaced, all Pulley
Bolts and lock washers must also be
replaced. Waltco provides kits for
Cable/Pulley Bolt replacement.
Pulley
Guard
Fixed
Cable
Pulley
Assembly
During Cable and Pulley Bolt replacement, also inspect
the Pulleys and Pulley Bearings. If any components are
worn or otherwise deteriorated they must be replaced. If
bearings do not rotate freely, they are to be replaced.
GR02492
5. Check for apparent damage to liftgate, such as bent
or distorted members and/or any cracked welds,
which may have resulted from overloading or abuse.
6. Check for any excessive wear in the Cable Pulleys,
Bearings and Rollers, Platform Linkage and Pins,
7. Closer Mechanism, Pulley Bolts, and all pivot points.
8. Check that all nuts and bolts are in place and
properly tightened.
9. Check that all Pivot and Stop Pins are in place and
retained by their proper fasteners.
10. Check that all control switches operate properly.
11. Check the Platform opening and closing speed. The
Platform must open and close smoothly and at a
safe and reasonable rate of speed subject to the
environment in which it will be operated.
12. On platforms with Side Linkage, inspect the Torsion
Bars with the platform in loading position at bed
level. If any Torsion Bars are broken they must be
replaced.
Torsion
Bars
Torsion
Springs
DO NOT get under Platform to inspect
Torsion Bars.
13. On platforms without side linkage, inspect Torsion
Springs visually with Platform in stored position. If
any Torsion Springs are broken they must be
replaced.
GR02497
Page 5-3
Chapter 5
14. Inspect entire length of Closer Cylinder Hose for
signs
15. of wear, abrasion, or leakage. Hose should flex
easily throughout operating cycle with no binding.
16. Check Hose Guides for bends or damage.
17. Check for oil leaks in hydraulic Lift Cylinder,
hydraulic Closer Cylinder, and all hydraulic hoses
and fittings. Replace any hose that show any sign of
excessive abrasion of the covering. Tighten or
replace any hydraulic component as required to stop
oil leakage.
18. Check level of oil in liftgate hydraulic Reservoir with
the Platform at ground level. The oil should be within
1/2" of top of Reservoir.
19. Lubricate the liftgate by following the “Lubrication
Instructions” chapter in this manual.
20. Check the electrolyte level of vehicle battery. Fill as
required per manufacturer recommendation.
21. Examine all Warning, Capacity, and Operation
decals.
H-Frame
Hose Guide
Curb Side Runner
Hose Guide
Closer
Hose
If any decals are illegible and need to be
replaced, decals can be obtained free of
charge from Waltco.
If liftgate is found to be in need of repair or
adjustment not covered in this manual,
contact your nearest Waltco distributor.
GR02493
CHECK BATTERIES
Check electrolyte level of batteries.
Check that all wiring and battery cable connections are
tight and free of corrosion.
All electrical connections are to be coated with dielectric
grease.
GR01471B
CHECK OIL LEVEL
Filler Plug
Lower platform to ground in open position.
Fill hydraulic reservoir to within 1/2" of top of reservoir.
GR02135
Page 5-4
Chapter 5
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.
SEMI ANNUAL INSPECTION
1. Perform procedures outlined in “Monthly Inspection”
2. Inspect pump unit motor:
 Disconnect battery cables.
 Remove motor end cover.
 Examine armature brushes for wear. Brushes
should be replaced if they are less than 1/8"
long.
 Clean out all residue from inside motor housing
 Apply several drops of light weight machine oil
to armature shaft bearing in motor end cover
and reassemble motor end cover.
If oil is dirty, drain oil from hydraulic system and
flush entire system. To replace Hydraulic Fluid:



Fill reservoir
 Fill with recommended fluid or equivalent.
 Fill the reservoir to within 1/2” from the top.
NOTICE:
Do not use the following fluids:
Brake Fluid
Power steering fluid
Automatic Transmission Fluid (ATF)
Reservoir
Open platform and lower to ground.
Drain oil from hydraulic system using drain port
located on bottom of reservoir and flush entire
system.
Fill reservoir to within 1/2” of top of reservoir
Motor
GR02135
Page 5-5
Chapter 5
PLATFORM ADJUSTMENT
If platform is not level with floor of vehicle check that
both up-stop pins are properly secured in place.
If not, up-stop pins must be re-installed properly.
Up-stop Pin
If platform is still not level proceed to next step.
GR02494
Unfold and raise platform to bed level and measure
how uneven platform is in relationship to vehicle floor.
This will be your “X” dimension.
Street
Side
Curb
Side
Vehicle Bed
“X”
Top of
Platform
Lower platform to ground. Remove access cover from
crossbeam box.
GR02495
Lock Washer
Loosen locknut. If curb side of platform is lower than
street side, adjust cable to the right by turning the
adjusting nut counterclockwise from cable end. If street
side of platform is lower than curb side, adjust cable to
the left by tuning the adjusting nut clockwise from cable
end. Adjust cable the same distance as “X” as
measured above. Tighten locknut.
Make certain adjusting nut is fully threaded
on cable end and tightened.
Adjustable Cable End
RIGHT
Cable End not to be
below surface of nut
Reinstall access cover.
WRONG
GR02496
Page 5-6
Chapter 6
Placement of Decals
All decals must be in place and legible or all warranties are void.
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
80101518
2000 lb Capacity Decal
80100253
80100257
1
80100260
80100263
80100265
LOCATION
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 the controls.
Circuit Breaker Decal
1
80100828
Hazard Decal
1
80101370
Caution Stand Clear
1
75089296
Locate one in a conspicuous place near controls.
2
Caution Stand Clear
1
75089296
Locate near liftgate on street side of vehicle.
3
Caution Decal
2
75089282
Locate near top of each rail, not on pulley covers themselves,
so can be read when removing pulley covers.
4
Important Decal
6
75089280
Locate one each in a conspicuous place near upper and
lower pulley bolts, main cylinder bolts, shoe assembly bolts,
and upper and lower cylinder bolts.
5
Caution Decal
2
75089282
Locate one on shoe assembly and one on bottom of
crossbeam box, under cylinder.
6
Caution Stand Clear
2
75089296
Locate on back (bottom) side of platform or ramp so as
to be visible when liftgate is in stored position. Used on
liftgates equipped with single section platform or with
folding ramp.
7
Safety Chain Decal
2
80100527
Locate at base of both runners.
8
Important Decal
1
80100482
Locate on lower curb side linkage. Used on liftgates
equipped with a folding ramp.
9
Warning Decal
1
80100829
Locate next to circuit breaker. If more than one circuit
breaker is used; decal must be in both locations.
10
Selector Switch Decal,
Single Pump Only
Selector Switch Decal,
Dual Pump Only
80101371
1
80101380
Dual Pump Decal
1
80101021
Hand Pump Decal
1
80101199
Single Pump Decal
1
80101372
Dual Pump Decal
1
80101373
11
12
Locate appropriate decal on pump unit selector switch
bracket.
Locate decal inside hydraulic enclosure cover for all dual
pumps.
Locate decal inside hydraulic enclosure cover for liftgates
with Auxiliary Hand Pump Option.
Locate decal inside hydraulic enclosure cover for all single
pumps.
Locate decal inside hydraulic enclosure cover for all dual
pumps.
Page 6-1
Chapter 6
Placement of Decals
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
GR02475
Page 6-2
Chapter 7
Lubrication Instructions
The liftgate should be lubricated every 120 days.
#1 – Grease with automotive type chassis grease with platform resting on ground.
#2 and #3– Oil with WD-40 or equivalent.
#1 Lubricate with chassis grease:
Under shoe assembly
Using a rag, lightly lubricate outside faces of
rails with light chassis grease if required for
smooth operation. Lubricate only areas where
bearings slide on rails.
Do not operate liftgate if any guards or
access covers are not in place and
properly secured.
#2 Lubricate with WD-40 or equivalent:
Platform Linkage which includes Torsion Bar
Anchors, and Springs on one-piece platforms.
NOTE:
Take care not to nick or scratch exposed cylinder
shaft as this could cause cylinder leakage.
GR02476
#3 With Platform at bed level, use WD-40 or equivalent
to lubricate two areas of both Platform Brake
Mechanisms.
A. Spray inside Lifting Cable Yoke end where it
attaches to Runner Assembly.
B. Spray generously with a circular motion inside
lubrication holes on both sides of each rail.
Use only WD-40 or equivalent light spray
lubricant to lubricate Platform Brakes. DO
NOT use grease
or heavy oil that may tend to build up and
become gummy.
Cable Yoke
End
A
Rail
Runner
NOTE:
Cables, Roller Bearings, and Pulley Bearings do not
require lubrication. While cables do not require
lubrication, if cables have ever been lubricated it is
recommend they continue to be lubricated.
Spray in
lubrication holes
on both sides of
each rail
B
Page 7-1
Pulley covers not shown
for clarity. Pulley covers
MUST be in place at all
times during operation
of liftgate.
GR02477
Chapter 8
Platform Brake
PLATFORM BRAKE
Lifting Cable
This liftgate is equipped with a platform brake system,
designed to prevent the platform from falling in the event
a lifting cable breaks. These platform brakes must never
be used as a substitute for timely inspection and
replacement of cables.
Connector
Plate
Certain conditions and/or circumstances
may prevent platform brakes from
functioning consistently. These platform
brakes are not intended to and must not
take the place of proper cable
maintenance. Lifting cables must always
be inspected and replaced as described in
this owner’s manual.
In the event a cable does break, do not
move vehicle with a load on platform.
Platform must be unloaded and secured for
transit before vehicle is moved.
Runner
Springs
Cam Pivot Pin
Toothed
Cam
GR02498
To Connector
Plate and Cable
DECSRIPTION AND FUNCTION OF PLATFORM
BRAKE
Cam Pivot Pin
The platform brake system consists of two independent
brake mechanisms located at the upper portion of the
runner assemblies (inside the rails).
Each platform brake assembly has a toothed cam. This
cam is joined by a spring and connector plate to lifting
cable. If cable is pulled taut, the cam pivots away from
the rail and runner is free to travel up and down the rail.
Locked
(braked)
position
Should a cable break, spring tension (lower spring)
pivots the cam so teeth contact the inside of rail,
causing runner to lock at that position.
Under certain conditions, one or both platform brakes
may engage (even if a cable has not broken), thus not
allowing platform to lower or allowing only one side to
lower.
If this happens and a cable has not broken, platform
brake(s) can be disengaged by raising platform to bed
level and slightly powering up against upstop pins.
Normal
operating
position
NOTE:
Never allow platform to lower unevenly.
Lower Spring
Rail
GR02499
Page 8-1
Chapter 9
Cable Replacement
CABLE REPLACEMENT
Upper Bearing
Assembly
Do not move vehicle with a load on
platform.
Platform must be unloaded and secured for
transit before vehicle is moved.
It is very important that both cables be
replaced at the same time.
Remove these bolts
Any time cables are replaced, remove
platform brake assembly for thorough
cleaning and inspection. In addition, all
pulley bolts and lock washers must also be
replaced.
Follow these procedures for replacing cables; if you are
performing a periodic replacement of cables then skip to
step 3.
1. If a cable is broken, carefully unload platform. Use a
forklift to support runner (side with broken cable).
Only then remove upper bearing assembly mount
bolts from runner (with broken cable).
Runner
Position Fork
under Runner
Be sure to use safety precautions to avoid
injuries.
GR02243
2. Lower platform slowly to ground by using one
person to push Lower Switch and another to lower
side of platform with forklift.
NOTE:
Be careful during this operation to prevent any
damage to liftgate.
Lock Washer
Flat Washer
Nut
Pulley
Upper Pulley
Cover Guard
Pulley Bolt
3. Make certain platform is on ground. If bolts have not
been removed from upper bearing assembly do so
at this time.
4. Remove pulley cover guards, upstop pins and upper
pulleys from top of both rails.
5. Lift upper bearing/brake assemblies out of rails
by the cable.
Upstop Pin
Cable may have broken wires sticking out –
using leather gloves is recommended.
Coiled
Pins
Insert a screwdriver or
similar tool and wedge
cable end up to
disengage brake
NOTE:
Bearing/Brake assembly should be pulled out by
the Cable. If unable to do so, insert a screwdriver
between Cable Anchor and Upper Bearing/Brake
Mount Plate. This will release Brake so Bearing
Assembly can be pulled out of Rail.
GR02244
Page 9-1
Chapter 9
Cable Replacement
6. Remove old cables from liftgate, making note of
how cables are routed. Install new cables.
NOTE:
Use proper cables. Cables used on liftgates with
Brakes must have 2-5/8” deep end slots as shown.
Lifting Cable
7. Platform brakes should be inspected cleaned and
lubricated at this time (see below).
8. Attach yoke end of new cable to brake
assemblies.
9. Use a screwdriver, if required, to lower
bearing/brake assembly down into rail
(see previous page).
3/8”-16 Locknut
NOTE:
Special care must be observed when attaching
Cable End to platform Brake Mechanism so use
proper parts as shown.
2-5/8” Deep slot
1-1/4” Shoulder
10. Reinstall upper pulleys, upstop pins and pulley
cover guards (ref previous page).
11. Line up holes in bearing/brake assembly with
mount holes in top of runner and install bolts, nuts
and lock washers.
12. Double check that all nuts, bolts, washers, and
coiled pins are in place and properly secured.
13. Adjust cables to level out platform per instructions
in this manual.
14. Test operation of each platform brake assembly
as outlined in the “Maintenance Guide” in this
manual.
Bearing / Brake
Assembly
1/2" X 1-1/4” w/3/8”-16
Socket Head Shoulder
Screw
GR02245
INSPECTION OF PLATFORM BRAKES
Connector Plate
Examine platform brake assembly for loose pins, bent
or damaged parts, etc. Replace any damaged
components.
Roller
Make certain all parts including cam moves freely
without binding which may be caused by corrosion,
bent pins, etc.
Cam Spring
Pin*
Be certain springs are not corroded, bent or broken.
Replace if necessary.
Examine toothed cam for chipped, broken or dulled
teeth. Replace if signs of damage. Clean any grease,
dirt, etc. from teeth of cam.
Lubricate areas shown with “WD-40” or similar light
spray lubricant.
Cam Pivot Pin
(welded in place)
Upper Spring
(larger)
Lower Spring
Pin (welded
place)
Lower Spring
(smaller)
Toothed Cam
GR02500
Page 9-2
Ch. 10
PARTS MANUAL SHEETS
PM Number
SINGLE PUMP ELECTRICAL SCHEMATIC .............................................................................
SINGLE PUMP HYDRAULIC SCHEMATIC ..............................................................................
SINGLE PUMP WITH HAND PUMP HYDRAULIC SCHEMATIC ..............................................
DUAL PUMP ELECTRICAL SCHEMATIC.................................................................................
DUAL PUMP HYDRAULIC SCHEMATIC ..................................................................................
RGL-30, 40, 50, 60 SERIES PLATFORM ASSY ........................................................ PM-439A
RGL SERIES PLATFORM ASSY (UNITS W/ 36”, 42” & 48” DECKS) ....................... PM-443A
RBGL SERIES PLATFORM ASSY ............................................................................. PM-444
RBGL SERIES FOLD DOWN RAIL PLATFORM ASSY ............................................. PM-445
RGL SERIES 16” ALUMINUM & 12” STEEL FOLDING RAMPS ............................... PM-243B
RGL-SERIES & RBGL SERIES MAIN FRAME ASSY ................................................ PM-225E
RGL SERIES RUNNER ASSEMBLIES ...................................................................... PM-446A
RGL SERIES UPPER ROLLER ASSEMBLY ............................................................. PM-448
RGL SERIES LIFTGATE HYDRAULIC AND ELECTRICAL LAYOUT ....................... PM-533A
RGL SERIES SINGLE PUMP AND SINGLE PUMP W/ HAND PUMP
HYDRAULIC AND ELECTRICAL LAYOUT ................................................................ PM-536C
RGL SERIES DUAL PUMP HYDRAULIC AND ELECTRICAL LAYOUT .................... PM-537B
Ch. 10
PARTS MANUAL SHEETS
SINGLE PUMP ELECTRICAL SCHEMATIC
GR02304
Page 10-1
Ch. 10
PARTS MANUAL SHEETS
SINGLE PUMP HYDRAULIC SCHEMATIC
GR02305
Page 10-2
Ch. 10
PARTS MANUAL SHEETS
SINGLE PUMP WITH HAND PUMP HYDRAULIC SCHEMATIC
GR02307
Page 10-3
Ch. 10
PARTS MANUAL SHEETS
DUAL PUMP ELECTRICAL SCHEMATIC
GR02308
Page 10-4
Ch. 10
PARTS MANUAL SHEETS
DUAL PUMP HYDRAULIC SCHEMATIC
GR02309
Page 10-5
ITEM
PART NUMBER
QTY
1
2
3
75089541*
35331601*
37412002
38412002
37612002
38612002
37418001
37418003
37418002
37418004
37418006
37418005
37618003
37618002
37618004
37618005
37618006
38418001
38418003
38418002
38418004
38418006
38418005
38618003
38618002
38618004
38618005
38618006
37618007
38618007
35455002
37455001
38455001
37456701*
35470201*
8
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
4
5
6
7
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
DESCRIPTION
1/4" x 1-7/8" Coiled Pin
Chain Clip
Platform Assy (RGL-30, 40 96" Wide)
60x90 Butt End Deck Ext. (RGL-30, 40)
60x90+12 CS Deck Ext. (RGL-30, 40)
60x90+12 Deck Ext. (RGL-30, 40)
72 x 90 Butt End Deck Ext. (RGL-30, 40)
72x90+12 CS Deck Ext. (RGL-30, 40)
72x90+12 Deck Ext. (RGL-30, 40)
60x90+12 CS Deck Ext. (RGL-50, 60)
60x90+12 Deck Ext. (RGL-50, 60)
72x90+12 CS Deck Ext. (RGL-50, 60)
72x90+12 Deck Ext. (RGL-50, 60)
60x96+12 CS Deck Ext. (RGL-30, 40)
60x96+12 Deck Ext. (RGL-30, 40)
72x96+12 CS Deck Ext. (RGL-30, 40)
72x96+12 Deck Ext. (RGL-30, 40)
60x96+12 CS Deck Ext. (RGL-50, 60)
60x96+12 Deck Ext. (RGL-50, 60)
72x96+12 CS Deck Ext. (RGL-50, 60)
72x96+12 Deck Ext. (RGL-50, 60)
Upper Link Assembly
Upper Link Assembly
Upper Link Assembly
Pin
Torsion Bar
ITEM
PART NUMBER
QTY
8
9
75088061*
35457001
37457001
38457001
35456002 *
37456001 *
38456001
35456052 *
37456051 *
38456051
75089548*
37417501*
35440002*
10
2
2
2
1
1
1
1
1
1
2
2
1
10
11
12
13
14
38440001*
1
22
23
24
25
26
27
28
29
30
35442501*
35442002*
75088056*
75089752*
75084052*
35440502*
35441502*
38441501*
75089547*
75088064*
37411102*
75089554*
85803391*
35456101*
20211200*
75088081*
75086055*
1
1
1
5
1
1
1
1
1
1
2
6
6
2
2
2
2
31
75088053*
2
15
16
17
18
19
20
21
DESCRIPTION
1" S.A.E. Washer
Lower Link Assembly
Lower Link Assembly
Lower Link Assembly
Connecting Bar Assembly (Curb Side)
Connecting Bar Assembly (Driver’s Side)
Pin Assembly
Cart Stop Ramp Assembly (96” Wide
Platforms) (Items 15 thru 25)
Cart Stop Ramp Assembly (102” Wide
Platforms) (Items 15 thru 25)
Cart Stop Brace Assembly
Lever Assembly
1/2" S.A.E. Washer
Extension Spring
5/32" x 1" Cotter Pin
Latch Pin Assembly
Cart Stop Assy (96” Wide Platforms)
Cart Stop Assy (102” Wide Platforms)
3/16" x 1" Coiled Pin
5/8" S.A.E. Washer
Pin
Fiber Bearing
Torsion Bar Anchor
Pin
3/8" Lock Washer
3/8"-16 x 3/4" Lg. Hex head Bolt
(Grade 5)
3/8” Flat Washer
* All RGL-30, 40, 50, 60 Units
 Used on 60” deep Butt End Platforms only.
 Used on 60+12” and 72” deep Butt End Platforms only.
 Used on 72+12” and 84” deep Butt End Platforms only.
REVISED:
E.O.
REV.
5-1-2009
6219
03
PM-439A
PLATFORM ASSEMBLIES
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
REVISED:
E.O.
REV.
5-1-2009
6219
03
PM-439A
ITEM
1
2
3
4
5
6
7
PART NUMBER
35631601
37211102
75089554
37270251
37270201
37410030
37410036
37410031
38410030
38410036
38410031
37410040
37410046
37410041
38410040
38410046
38410041
37410050
37410056
37410051
38410050
38410056
38410051
85803391
QTY
2
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
DESCRIPTION
Chain Clip
Pin
Torsion Spring (Driver Side)
Torsion Spring (Curb Side)
36" x 90" Butt End Platform
36" x 90" + 6" Platform
36" x 90" + 12" CS Platform
36" x 96" + 6" Platform
42" x 90" + 6" Platform
42" x 96" + 6" Platform
48" x 90" + 6" Platform
48" x 96" + 6" Platform
Fiber Bearing
REVISED:
E.O.
REV.
7-6-2001
4268
01
PM-443A
PLATFORM ASSEMBLY (Units w/ 36”, 42”, 48” Deep Platforms)
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
REVISED:
E.O.
REV.
7-6-2001
4268
01
PM-443A
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
PART NUMBER
36412001
36412003
36435004
36435054
36455001
36457001
36457002
31214001
75088061
75089541
10370800
75089361
75089349
36458336
36458342
37211102
75089554
35631601
36458236
36458242
36455051
37270201
37270251
31214701
75089324
85803391
QTY
DESCRIPTION
1
1
1
1
2
2
2
1
16
12
6
4
6
2
2
2
4
2
2
2
1
1
1
2
2
4
Platform Assembly (36" x 90")
Runner Assembly Complete (Curb Side)
Runner Assembly Complete (Street Side)
Guard Rail Sub-Assembly (Curb Side)
Side Rail Assembly (36" Platform)
Side Rail Assembly (42" Platform)
Ramp Assembly
1" Washer
Pin
Chain Hook
5/16” Cold Shut
Plated Chain (36" Platform)
Pin
Chain Clip
Guard Rail Sub-Assembly (Street Side)
Torsion Spring (Street Side)
Bar Ramp Pivot
Grommet
Fiber Bearing
WALTCO
TRUCK EQUIPMENT CO.
RBGL SERIES
REVISED:
E.O.
REV.
1-4-2002
4626
05
PM-444
PLATFORM ASSEMBLY
WALTCO
TRUCK EQUIPMENT CO.
RBGL SERIES
REVISED:
E.O.
REV.
1-4-2002
4626
05
PM-444
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
PART NUMBER
36412002
36412004
36435004
36435054
31214001
36457501
36457502
36459001
36459051
36455002
36455052
75088061
75089541
10370800
31214701
37211102
75089554
75089361
37270201
37270251
35631601
36458236
36458242
75089349
36458501
36459501
75089756
75089557
36458336
36458342
75089335
85803391
QTY
DESCRIPTION
1
1
1
1
1
2
2
1
1
1
1
20
16
8
2
2
4
4
1
1
2
2
2
6
2
2
2
2
2
2
2
4
Runner Assembly Complete (Curb Side)
Runner Assembly Complete (Street Side)
Ramp Assembly
Side Rail Assembly (36" Decks)
Side Rail Assembly (42" Decks)
Fixed Guard Rail Assembly (Curb Side)
Fixed Guard Rail Assembly (Street Side)
Guard Rail Assembly (Curb Side)
Guard Rail Assembly (Street Side)
1" S.A.E. Washer
Pin
Bar Ramp Pivot
Pin
Chain Hook
Torsion Spring (Street Side)
Chain Clip
Plated Chain (36" Decks)
5/16” Cold Shut
Lock Pin Assembly
Lock Pin Sub Assembly
Spring
Flexible Grommeting
Fiber Bearing
WALTCO
TRUCK EQUIPMENT CO.
RBGL SERIES
REVISED:
E.O.
REV.
1-4-2002
4626
05
PM-445
FOLD DOWN RAIL PLATFORM ASSEMBLY
WALTCO
TRUCK EQUIPMENT CO.
RBGL SERIES
REVISED:
E.O.
REV.
1-4-2002
4626
05
PM-445
ITEM
QTY
DESCRIPTION
37214101
1
37414101
1
38214101
1
37216500
1
37416500
1
38216500
1
2
37415551
1
3
37415501
1
4
5
37419502
37215202 *
37414501
2
1
1
6
7
8
37414801
75085193
75086057
9
75086001 *
2
37415401
75084053
27310303
2
2
2
16” Aluminum Ramp
(1 Piece 90" Wide Deck)
16” Aluminum Ramp
(2 Piece Folding 90" & 96" Wide Decks)
16” Aluminum Ramp
(1 Piece 96" Wide Deck)
12” Steel Folding Ramp (1 Piece 90"
Wide Deck)
12” Steel Folding Ramp (2 Piece Folding
90" & 96" Wide Decks)
12” Steel Folding Ramp (1 Piece 96"
Wide Deck)
Hinge Plate Assembly (Driver Side)
(Aluminum Ramp Only)
Hinge Plate Assembly (Curb Side)
(Aluminum Ramp Only)
Retention Cable Assembly
Ramp Latch (1 Piece Deck Only)
Ramp Latch Assembly (2 Piece Decks
Only)
Ramp Hinge Clevis
3/8"-16 Locknut (Aluminum Ramp Only)
3/8"-16 x 1-1/4" Hex Head Bolt (Aluminum
Ramp Only)
3/8"-16 x 1" Flat Head Screw (Aluminum
Ramp Only)
Ramp Brace
3/32” x 1” lg. Cotter Pin
1/2” Dia. Clevis Pin
1
10
11
12
PART NUMBER
2
12
10
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
REVISED:
E.O.
REV.
11-2-2001
4088
01
PM-243B
16” ALUMINUM & 12” STEEL FOLDING RAMPS
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
REVISED:
E.O.
REV.
11-2-2001
4088
01
PM-243B
ITEM
PART NUMBER
QTY
1
2
3
4
5
6
7
8
9
35693002
75089451
F
35470601 *
F
75086220 *
F
75088083
75085110 *
75089541
37427302
35428001
35628001
75088085
75088087
AB
37472502
2
1
2
2
6
3
4
2
7
7
3
3
1
38472502
AC
1
37672502
AD
1
38672502
AE
1
10
11
12
13
14
37420004
1
38420004
1
37620004
1
38620004
1
37472002
AB
1
38472002
AC
1
37672002
AD
1
38672002
AE
1
35427601 *
F
2
DESCRIPTION
A
NOTE:
Both Cables should be replaced at the same
time, when ordering replacement cables.
WALTCO
TRUCK EQUIPMENT CO.
RGL & RBGL SERIES
ITEM
Safety Chain Assembly
Waltco Nameplate
Short Pulley Bolt (Grade 8)
1/2"-20 x 3" Bolt (Grade 8)
1/2" Lock Washer
1/2"-20 Hex Nut (Grade 8)
Up Stop Pin
Pulley Assy Complete (RGL-20, 30, 40)
Pulley Assy Complete (RGL-50, 60)
5/8" Lock Washer (RGL-20, 30, 40)
3/4” Lock Washer (RGL-50, 60)
Adjustable Cable Assy (96" Wide)
(RGL-20, 30, 40)
(RGL-20, 30, 40)
(RGL-50, 60)
(RGL-50, 60)
Main Frame Assembly (96" Wide)
(RGL-20, 30, 40)
(RGL-20, 30, 40)
(RGL-50, 60)
(RGL-50, 60)
Fixed Cable Assembly (96" Wide)
(RGL-20, 30, 40)
(RGL-20, 30, 40)
(RGL-50, 60)
(RGL-50, 60)
Long Pulley Bolt (Grade 8)
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
PART NUMBER
QTY
DESCRIPTION
35426502
1
35626502
1
35427002
1
35627002
1
35470501 *
35670501 *
37471602
37671602
75089406
35427501
35627501
BCDE
75085184 *
GH
75087585
GH
75085165
75087588
35470901 *
35670901 *
G
37420101
H
38420101
75085183 *
75085192 *
BCDE
75089569
35426602
75085005
BCDE
75088085
BCDE
75085111 *
75088056
37471502
1
1
2
2
8
1
1
1
6
6
2
1
1
1
1
1
1
1
2
2
1
1
2
2
37671502
2
37471702
2
Shoe Sub-Assembly(with Items 19 & 30)
(RGL-20, 30, 40)
(RGL-50, 60)
(RGL-20, 30, 40)
(RGL-50, 60)
Long Cylinder Bolt (Grade 8)(RGL-20, 30, 40)
Long Cylinder Bolt (Grade 8)(RGL-50, 60)
Pulley Cover Guard (RGL-20,30,40)
Pulley Cover Guard (RGL-50,60)
1/4" Dia. x 5/16" Drive Rivet
Block Assembly (RGL-20, 30, 40)
Block Assembly (RGL-50, 60)
Special Lock Nut (AN365-1018A)
3/8"-16 x 1" Truss Head Screw
“J” Type Nut Retainer
3/8"-16 x 2-1/2" Nylon Hex Bolt
Short Cyl. Bolt (Grade 8) (RGL-20,30,40)
Short Cyl. Bolt (Grade 8) (RGL-50,60)
Access Door (96" Wide)
Access Door (102" Wide)
Self Locking Nut (RGL-20, 30, 40)
Self Locking Nut (RGL-50, 60)
Plastic Plug
Phenolic Bearing
3/8"-16 Serrated Hex Nut
5/8" Lock Washer
1/2” Flat Washer
Pulley Cover Guard Assembly(Includes Items
18, 19, 24, 31, 36)(RGL-20,30,40)
Pulley Cover Guard Assembly(Includes Items
18, 19, 24, 31, 36)(RGL-50,60)
Pulley Cover Shield
B
Included in Cable Replacement Kit 80000919.
D
E
F
Included in Pulley Bolt Replacement Kit 80000499.
G
Included in Access Door Replacement Kit 80000932.
H
Included in Access Door Replacement Kit 80000933.
C
REVISED:
E.O.
REV.
4-1-05
5221G
02
PM-225E
RGL & RBGL SERIES MAIN FRAME ASSEMBLY
WALTCO
TRUCK EQUIPMENT CO.
RGL & RBGL SERIES
REVISED:
E.O.
REV.
4-1-05
5221G
02
PM-225E
ITEM
QTY
DESCRIPTION
37235004
1
37435003
1
37535003
1
37235054
1
37435053
1
37535053
1
35635101 *
75088083
75085110 *
75089541
2
2
2
2
7
8
9
10
20211200
37432702
37435502
75088061
1
2
2
2
11
75089335
1
Runner Assembly (Curb Side)
(RGL-20,30,40 with One Piece Platforms)
(RGL-30, 40 with Two Piece Platforms)
Runner Assembly (Driver's Side)
(RGL-20,30,40 with One Piece Platforms)
1/2"-20 x 1-3/4" Bolt (Grade 8)
1/2" Lock Washer
1/4" x 1-7/8" Coiled Pin (Used only for
Two Piece Platforms)
Pin (Used only for Two Piece Platforms)
Retainer Clip
Outside Slide Bearing
1" S.A.E. Washer (Used only for Two
Piece Platforms)
Flexible Grommeting
1
2
3
4
5
6
PART NUMBER
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
* NOTE:
These are special high grade
nuts and bolts and must be
purchased from Waltco.
REVISED:
E.O.
REV.
7-6-2001
4268
01
PM-446A
RUNNER ASSEMBLIES
RUNNERS FOR SINGLE
PIECE PLATFORMS
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
* NOTE:
RUNNERS FOR TWO
PIECE PLATFORMS
REVISED:
E.O.
REV.
7-6-2001
4268
01
PM-446A
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
PART NUMBER
37437303
35436401
37436502
35436801
37436902
75085193
75087575
75087576
37439502
37438502
37438802
37437702
37437402
37437202
37437602
37438902
75089753
75089548
37437003
QTY
DESCRIPTION
1
2
4
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Upper Bearing Mount Plate (w/Brake)
Upper Bearing Pivot
Roller Assembly
Roller Pin (Upper)
Bearing Spacer
3/8"-16 Locknut
1/2" x 3/4" Socket Hd Shoulder Bolt
1/2" x 1-1/4" Socket Hd Shoulder Bolt
Connector Plate
Housing Assembly
Toothed Cam
Pin
Pin
Pin
Pin
Spring
Spring
3/16" Dia. x 1-1/4" Coiled Pin
Upper Bearing/Brake Assembly Complete
(Includes Items 1 thru 18)
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
REVISED:
E.O.
REV.
12-18-98
3760
04
PM-448
UPPER ROLLER ASSEMBLY
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
REVISED:
E.O.
REV.
12-18-98
3760
04
PM-448
ITEM
1
PART NUMBER
35480050
35680050
2
3
QTY
1
1
4
75083036
70110020
70110030
75082863
1
1
1
1
5
75083108
1
6
7
75089317
75082867
1
2
8
75083101
1
75083102
1
9
10
11
12
13
14
15
37480051
75086223
37470301
75088083
75085110
75085181
85803804
1
1
1
1
1
1
1
16
75083109
1
17
18
37474102
75083103
1
1




WALTCO
TRUCK EQUIPMENT CO.
RGL & RBGL SERIES
DESCRIPTION
Hydraulic Cylinder Assembly
(RGL-20, 30, 40)
Hydraulic Cylinder Assembly
(RGL-50, 60)
3/8" x 90° Elbow
Flow Control Valve (RGL-20, 30, 40)
Flow Control Valve (RGL-50, 60)
3/8”-18 NPT Male x 3/4”-16 37° Flare
Male Adapter
3/4”-16 37° Flare Male x 9/16”-18 37°
Flare Male x 3/8” I.D. x 24-1/2” Lg. Hose
Assembly
Cylinder Breather Cap
9/16”-18 37° Flare Male Bulkhead 45°
Elbow
9/16”-18 37° Flare Female x 9/16”-18 37°
Flare Female x 3/8” I.D. x 65” Lg. Hose
Assembly (Truck Kit Only)
9/16”-18 37° Flare Female x 9/16”-18 37°
Flare Female x 3/8” I.D. x 372" Lg. Hose
Assembly (Trailer Kit only)
Closer Cylinder
1/2"-20 x 5" Hex Head Bolt (Grade 8)
1/2”-20 x 2-1/4” Hex Head Bolt (Grade 8)
1/2" Lock Washer
1/2"-20 Hex Nut
Lock Nut (AN 364-820A)
1/4”-18 NPT Male x 9/16”-18 37° Flare
Male Adapter
9/16”-18 37° Flare Female x 9/16”-18 37°
Assembly
Control Wire Tube
9/16”-18 37° Flare Female x 9/16”-18 37°
Assembly (Truck Kit Only)
ITEM
19
20
21
22
23
24
25
26
PART NUMBER
75083104
75086860
80000425
80000844
75082033
37475506
31423101
37423101
37481751
QTY
1
12
2
1
9
1
1
2
1
DESCRIPTION
9/16”-18 37° Flare Female x 9/16”-18 37°
Flare Female x 1/4” I.D. x 372" Lg. Hose
Assembly (Trailer Kit Only)
#8-32 x 3/4" lg. Self Tapping Screw
Raise/Lower Switch Kit
Open/Close Switch Kit
16 Ga. Butt Connector
Control Wiring Harness
Outside Control Switch Guard
Inside Control Switch Guard
5/8” OD x 1/2" ID x 1” Lg. Bearing
 NOTE
These are special high grade nuts and bolts
and must be purchased from Waltco.
REVISED:
E.O.
REV.
3-17-08
6007
05
PM-533A
LIFTGATE HYDRAULIC AND ELECTRICAL LAYOUT
NOTE: DIRECTION OF ARROW
CAUTION
Do not run the
hydraulic hose
in or near the
vehicle exhaust
stream.
 NOTE
WALTCO
TRUCK EQUIPMENT CO.
RGL & RBGL SERIES
REVISED:
E.O.
REV.
3-17-08
6007
05
PM-533A
ITEM
1
2
3
4
5
6
7
8
9
10
PART NUMBER
31590102
75082867
QTY
1
2
1
1
1
1
2
2
1
1
11
75085093
31491803
75089309
75089312
75089578
75089569
10195518
80000557
80000555
80000549
70401651
12
13
14
15
16
75088081
70401650
31590902
75089853
75083094
4
1
1
1
2
17
18
19
75086055
75089572
37475506
31494601
31494602
75088056
10099500
75085003
75086007
85803921
70402075
4
1
1
20
21
22
23
24
25
1
2
1
3
2
1
1
70402050
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
DESCRIPTION
Hydraulic Enclosure Base
45° Bulkhead Elbow, 9/16”-18 37° Flare
Male
Hex jam nut, 5/16”-24
Grommet, Wiring Harness
Grommet, Battery Cable
Plug, Plastic, 3/8” Dia. Hole
Plug, Plastic, 7/8” Dia. Hole
Ground Cable, 2 Ga. X 18” Lg.
25 ft. Battery Cable Kit
Hand Pump Handle
(Included with Hand Pump Kit)
Lock Washer, 3/8”
Hand Pump Kit (Optional)
Hydraulic Enclosure Cover
Fuse, 5 Amp
Hose Assy, 3/8” ID x 18-1/2” x 9/16”-18
37° Flare Fem.
Hex Bolt, 3/8”-16 x ¾”, Grade 5
Plug, Plastic, 1-3/8” dia. Hole
Long Trailer Extension Harness
Short Trailer Extension Harness
Washer, ½” I.D. X 1-3/8” O.D.
Terminal Strip
Hex Nut, 5/16”-18, Serrated
Hex Bolt, 5/16”-18 x 1-1/4” lg.
Relay
Hydraulic Pump Unit – Single Pump
(RGL-20 & 30 Only)
Hydraulic Pump Unit – Single Pump
(RGL-40, 50, 60 Only)
ITEM
26
PART NUMBER
70092501
27
28
31491301
70092503
29
30
31
32
33
34
35
36
70092313
A
75089833
A
75089834
A
10099403
70401501
75086707
85803482
75085000
QTY
1
1
2
A
1
1
1
1
1
3
2
3
DESCRIPTION
Valve Assembly
3-Way/ 2-Position Solenoid Coil Valve
Wire, Control
Valve Assembly
Motor
Starter Solenoid
Bus Bar
Controller
Reservoir
Screw, #10-32 x 5/8” lg.
Holder, Spring Clip (Hand Pump Only)
Hex Nut, #10-32, Serrated
PUMP AND ENCLOSURE ASSEMBLIES COMPLETE
PART No.
DESCRIPTION
38296504 Direct Power & 21” Enclosure (RGL-20,30)
38496504 Direct Power & 21” Enclosure (RGL-40,50,60)
A
Included in Motor/Solenoid Assembly 70400858
REVISED:
E.O.
REV.
5/6/05
5535
02
PM-536C
SINGLE PUMP HYDRAULIC AND ELECTRICAL LAYOUT
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
REVISED:
E.O.
REV.
5/6/05
5535
02
PM-536C
ITEM
1
2
3
4
5
6
7
PART NUMBER
31590102
75088056
80000557
80000555
80000549
70400858
75089009
75082867
70402250
QTY
1
2
1
2
1
2
1
70402225
A
7A
7B
7C
7D
7E
7F
70092313
A
75089833
A
75089834
A
10099403
70401501
70092503
1
1
1
1
1
4
7G
70092501
1
8
1
9
10
11
12
13
14
37475506
31494601
31494602
75085000
75086707
31491601
75089832
75089569
75083094
15
16
17
18
31590902
10195524
75080062
85803921
1
1
1
2
1
1
1
1
2
2
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
DESCRIPTION
Hydraulic Enclosure Base
Washer, ½” I.D. X 1-3/8” O.D.
Motor/Solenoid Assy
Grommet, Wiring Harness
45° Bulkhead Elbow, 9/16”-18 37° Flare
Male
Hydraulic Pump Unit – Dual Pump
(RGL-20 & 30)
Hydraulic Pump Unit – Dual Pump
(RGL-40, 50, 60)
Motor
Starter Solenoid
Bus Bar
Controller
Reservoir
Valve Assembly
Valve Assembly
Long Trailer Extension Harness
Short Trailer Extension Harness
Hex Nut, #10-32, Serrated
Screw, #10-32 x 5/8” lg.
Toggle Switch
Plug, Plastic, 7/8” dia. Hole
Hose Assy, 3/8” ID x 18-1/2” x 9/16”-18
37° Flare Fem.
Hydraulic Enclosure Cover
Battery Cable Assy, 24”
Wire Clip
Relay
ITEM
19
20
21
22
23
24
25
26
27
28
29
30
31
32
PART NUMBER
75086055
75089578
10195518
75086007
75089853
75085003
10099500
31491501
75088081
75089572
31499001
31492201
75085093
75089312
QTY
4
2
1
2
2
3
1
2
4
1
1
2
1
1
DESCRIPTION
Hex Bolt, 3/8”-16 x ¾”, Grade 5
Plug, Plastic, 3/8” Hole
Ground Cable, 2 Ga. X 18” Lg.
Hex Bolt, 5/16”-18 x 1-1/4” lg.
Fuse, 5 Amp
Hex Nut, 5/16”-18, Serrated
Terminal Strip
Wire, Key Switch Control
Lock Washer, 3/8”
Plug, Plastic, 1-3/8” dia. Hole
Auxiliary Push Button Control
Wire, Control
Hex jam nut, 5/16”-24
Grommet, Battery Cable
PUMP AND ENCLOSURE ASSEMBLIES COMPLETE
PART NUMBER
DESCRIPTION
38298504
38498504
A
Dual Pump and 21” Enclosure Complete (RGL-20,30)
Dual Pump and 21” Enclosure Complete (RGL-40,50,60)
Included in Motor/Solenoid Assembly 70400858
REVISED:
E.O.
REV.
7/01/05
5507E
03
PM-537B
DUAL PUMP HYDRAULIC AND ELECTRICAL LAYOUT
WALTCO
TRUCK EQUIPMENT CO.
RGL SERIES
REVISED:
E.O.
REV.
7/01/05
5507E
03
PM-537B
Chapter 11 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.
________________________________________________
80101389
Page 11-1
EO 5534A
Rev 02
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

C-15RM, C-20RM

Transcription

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