SERVICE & REPAIR | 47
Never disconnect a hydraulic hose or tube containing
pressure. Pressures in this hydraulic system are high enough
to cause serious injury or death. Hoses may whip or hydraulic oil may burn skin, or cause eye damage.
Use extreme caution when working with the hydraulic system.
TAILGATE REMOVAL
1) Park the unit on a level surface with the tailgate shut. Bring the swing and sweep panels to
the retracted position. Remove the keys from the ignition, use proper lock-out/ tag-out
procedures, and chock the tires. Finally, disconnect the negative battery cable.
2) Reduce the hydraulic pressure in the system by operating the hydraulic valve on the tailgate
and body until all the hoses are limp.
3) Disconnect the main pressure, return and tailgate lift cylinder hoses at the union located on
the tailgate hose bracket. Also, disconnect the tubes at the tailgate lift cylinders. Ensure caps
and plugs are installed on all hoses to prevent contamination.
4) Remove the tailgate lift cylinders by removing the bolts, locknuts and cylinder pins. Ensure
the tailgate lift cylinder is plugged to prevent contamination.
5) Remove the tailgate hinge pins by bending the pin head guards out of the way and removing
the snap rings.
6) Using an overhead crane, or other suitable lifting device, remove the tailgate from the body.
7) For installation, simply perform the above procedures in reverse order.
The tailgate assembly weighs between 7,000 and 9,000 pounds,
depending on optional equipment. Ensure the proper equipment
is used when removing or installing the tailgate.
The tailgate center of gravity will be di erent depending on
the optional equipment installed on the tailgate. Use
extreme caution when removing the tailgate from the body.
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